Major Repair Operations - Ford COUGAR 1968 Shop Manual

GROUP 8
-
Engine
FIG. 61
Engine Lifting Bracket
and Sling-Typical
sor as outlined in Group 16.
On a vehicle with power steering,
disconnect the power steering pump
bracket from the cylinder head. Re-
move the drive belt. Position the
power steering pump out of the way
and in a position that will prevent
the oil from draining out.
On a vehicle with power brakes,
disconnect the brake vacuum line at
the intake manifold.
9. Remove the heater hose from
the automatic choke housing. Dis-
connect the heater hoses at the
water pump and intake manifold.
Disconnect the water temperature
sending unit wire at the sending unit.
10. Remove the flywheel or con-
verter housing to engine upper bolts.
11.
Disconnect the primary wire
at the ignition coil and position the
wire out of the way.
12. Raise the front of the vehicle.
Disconnect the starter cable at the
starter. Remove the starter and dust
seal.
13. Disconnect the muffler inlet
pipes from the exhaust manifolds.
Disconnect the engine-support insu-
lators at the brackets on the frame
underbody.
On a vehicle with a manual shift
transmission, remove the remaining fly-
wheel housing to engine bolts.
On a vehicle with an automatic
transmission, remove the converter
housing inspection cover. Disconnect
the flywheel from the converter. Se-
cure the converter assembly in the
housing. Remove the remaining con-
verter housing to engine bolts.
14. Lower the vehicle, then sup-
port the transmission. Install the en-
gine left lifting bracket at the front
of the left cylinder head, and install
the engine right lifting bracket at
the rear of the right cylinder head;
then attach the engine lifting sling
(Fig. 63).
15.
Remove the air cleaner duct
stud from the exhaust manifold. Re-
move the battery.
16. Raise the engine slightly and
carefully pull it from the transmission.
Carefully lift the engine out of the
engine compartment so that the
rear cover plate is not bent or other
components damaged. Install the en-
gine on a work stand.
INSTALLATION
1. Position new gaskets on the
muffler inlet pipes.
2. Attach the engine lifting brack-
ets and sling (Fig. 61). Remove the en-
gine from the work stand.
3.
Lower the engine carefully into
the engine. compartment. Make sure
the exhaust manifolds are properly
aligned with the muffler inlet pipes
and the dowels in the block are
through the re'ar cover plate and en-
gage the holes in the flywheel hous-
ing.
On a vehicle with an automatic
transmission, start the converter pilot
into the crankshaft.
On a vehicle with a manual-shift
transmission, start the transmission
main drive gear into the clutch disc.
It may be necessary to adjust the
position of the transmission in rela-
tion to the engine if the input shaft
will not enter the clutch disc.
I f the
engine hangs up after the shaft enters.
turn the crankshaft slowly (transmis-
sion in gear) until the shaft splines
mesh with the clutch disc spline.
4. Install the flywheel or con-
verter housing upper bolts.
5. Install the engine support in-
sulator to bracket retaining nuts. Dis-
connect the engine lifting sling and
remove the lifting brackets.
6.
Raise the front of the vehicle.
Connect both exhaust manifolds to
the muffler inlet pipes. Torque the
nuts to specifications.
7. Position the dust seal and in-
stall the starter.
On a vehicle with a manual-shift
transmission, install the remaining
flywheel housing to engine bolts.
On a vehicle with an automatic
transmission, remove the retainer se-
curing the converter in the housing.
Attach the converter to the fly-
4
M A J O R REPAIR OPERATIONS
wheel.
Install the converter housing in
spection cover. Install the remaining
converter housing retaining bolts.
8. Remove the support from the
transmission and lower the vehicle.
9. Connect the engine ground
strap and coil primary wire.
10. Connect the water tempera-
ture sending unit wire. Install the
heater hose -on the automatic choke
housing and connect the hose at the
intake manifold.
11.
Connect the accelerator rod.
On a vehicle with an automatic
transmission, connect the transmission
filler tube bracket. Connect the man-
ual shift rod and install the retract-
ing spring. Connect the throttle valve
vacuum line.
On a vehicle with an air condi-
tioner, install the compressor as out-
lined in Group 16.
On a vehicle with power steering
install the drive belt and power steer-
ing pump bracket. Install the bracket
retaining bolts. Adjust the drive belt
tension to specifications.
On a vehicle with power brakes
connect the brake vacuum line.
12. Remove the plug from the
fuel tank line. Connect the flexible
fuel line and the oil pressure sending
unit wire.
13. Install the pulley, belt, spacer
and fan. Adjust the belt tension to
specifications.
14. Install the battery. Install the
air cleaner duct stud on the exhaust
manifold.
15.
Tighten the alternator adjust-
ing bolts. Connect the alternator wires
and the battery ground cable.
16. Install the radiator. Connect
the radiator upper and lower hoses.
On a vehicle with an automatic
transmission, connect the transmission
oil cooler lines.
17.
Install the oil filter. Fill and
bleed the cooling system. Connect
the heater hose at the water pump.
Fill the crankcase with the proper
grade and quantity of oil.
18. Adjust the transmission .throt-
tle linkage.
19. Operate the engine at fast idle
and check all gaskets and hose con-
nections for leaks.
20. Install the air cleaner and in-
take duct assembly. Connect the clos-
ed crankcase ventilation hose. Con-
nect the automatic choke heat chamber
air inlet hose.
21. Install and adjust the hood.
When installing nuts or bolts that must be torqued (refer to Part 8-5 for torque specifications), oil the threads