Ford COUGAR 1968 Shop Manual page 372

GROUP 8
-
Engine
washers. Torque the retaining bolts
to specifications, working from the
center to the ends.
39. lnstall the spark plugs.
40. Use the hydraulic valve lifter
leakdown tester (Part 8-1) to f i l l the
lifters with test fluid. Coat the outside
of each valve lifter with engine o i l to
provide initial lubrication. Place each
lifter i n the bore from which i t was
removed.
41. lnstall the push rods i n their
original positions. Apply Lubriplate
over the valve stem tips. lnstall the
rocker arms over the push rods. Per-
form a valve clearance adjustment as
outlined i n Part 8-1. Section 2.
42. Clean the mating surfaces of
the intake manifold. cylinder heads
and cylinder block.
43. Coat the intake manifold and
cylinder block seal surfaces with
quick-setting adhesive.
44. Position new seals on the cyl-
inder block and new gaskets on the
cylinder heads with the gaskets in-
terlocked with the seal tabs. Apply
non-hardening sealer at the four
junction points of the seals and
gaskets. Be sure the holes i n the gas-
kets are aligned with the holes i n
the cylinder heads.
45. Carefully
lower the intake
manifold on the cylinder block and
cylinder heads.
After the intake mani-
fold is i n place, run a finger around
the seal area to make sure the seals
are in place. If the seals are not in
place, remove the intake manifold
and position the seals.
46. Be sure the holes i n the mani-
fold gaskets and manifold are i n
alignment.Using new sealing washers,
install the intake manifold retaining
nuts and bolts. Torque the intake
manifold nuts and bolts i n two steps
(Fig. 23).
Torque i n sequence t o specifications.
After completing the remaining
assembly steps, operate the engine
until it reaches normal operating
temperature, then retorque the mani-
fold nuts and bolts in sequence to
specifications.
47. Install the water
pump by-
pass hose on the coolant outlet hous-
ing. Slide the clarnp into position and
tighten the clamp.
48. Rotate the crankshaft until
the N o . I piston is on T D C after
the compression stroke, then position
the distributor i n the block with the
rotor at the N o . I firing position and
the points open. Install the hold down
clamp.
49. lnstall the ignition coil. Posi-
tion and install the alternator, shield
and mounting bracket.
O n Thermactor engines, install the
air pump and brackets. Connect the
air bypass valve t o the air pump. In-
stall the check valves. Connect the
air hoses to the check valves.
50. Clean the valve rocker arm
covers and the cylinder head gasket
surface. Apply oil-resistant sealer to
one side of new cover gaskets. Lay
the cemented side of the gaskets i n
place i n the covers.
51. Position the covers on the
cylinder heads. Make sure the gasket
seats evenly all around the head. I n -
stall the bolts. The cover is tightened
i n two steps. Torque the bolts to
specifications. T w o minutes later,
torque the bolts to the same specifi-
cations.
52. Install the crankcase ventila-
tion system.
53. Install the automatic choke
heat tube. lnstall the distributor cap.
Position the spark plug wires i n the
brackets on the valve rocker arm
covers. Connect the spark plug wires
and the coil wire.
54. Connect the carburetor fuel
inlet line and fuel pump inlet line.
55. Install the o i l filter adapter.
Clean the o i l filter gasket surface.
Coat the gasket on the filter with oil.
Place the filter i n position on the
adapter fitting. Hand tighten the
filter until the gasket contacts the
adapter face; then advance i t
112
turn.
56. lnstall the clutch pilot service
bearing (Fig. 55). Coat the threads
of the flywheel retaining bolts with
oil-resistant sealer. Position the rear
cover plate on the block and the fly-
wheel on the crankshaft flange. I n -
stall and torque the bolts to specifi-
cations.
O n a flywheel for a manual-shift
transmission, use tool T58P-7563-A
to locate the clutch disc. lnstall the
pressure plate.
57. Install the engine i n the ve-
hicle. F i l l and bleed the cooling sys-
tem. F i l l the crankcase with the prop-
er grade and quantity of engine oil.
58. Operate the engine and check
for o i l and coolant leaks. Check and
adjust the ignition timing. Connect
the distributor vacuum hose at the
distributor. Retorque intake manifold
bolts to specifications.
59. Adjust the engine idle speed,
fuel mixture and anti-stall dashpot
(if applicable). Adjust the transmis-
sion throttle linkage.