Ford Thunderbird Manual page 83

03-01A-44
REMOVAL AND INSTALLATION (Continued)
46. Partially lower vehicle.
47. Position floor jack under transmission.
48. Install Rotunda Engine Lifting Brackets (3.8L)
0 1 4-00792 and Separator Bar 0 1 4-Q0793 or
equivalent.
49. Position engine-lifting equipment.
50. Remove engine assembly from vehicle.
5 1 . Place engine on a workstand.
Installation
1 . NOTE: Lightly oil all bolt and stud threads before
installation except those specifying special
sealant.
Install engine-lifting equipment and remove engine
assembly from work stand.
2. Position engine assembly in vehicle.
3. Install two engine-to-transmission bolts.
4. NOTE: Seat LH side front engine support
insulator locating pin before RH side front engine
support insulator.
Lower engine onto front engine support insulators
and remove lifting equipment, Rotunda Engine
Lifting Brackets (3.8L) 0 1 4-Q0792 and Separator
Bar 0 1 4-Q0793 or equivalent.
5. Remove floor jack from under transmission.
6. Tighten two engine-to-transmission bolts.
7. Raise vehicle.
8. Install remaining engine-to-transmission bolts.
Tighten all bolts to 34-46 N-m (25-33 lb-ft).
9. Install torque converter bolts and tighten to 27-46
N-m (2Q-33 lb-ft). Install inspection plug to engine
rear plate.
10. Install and tighten front engine support insulator
through bolts. Tighten through bolts to 4 7-68 N-m
(35-50 lb-ft). Refer to Section 02-Q3.
1 1 . Install starter motor. Refer to Section 03-o6.
12. Install transmission oil coo l er line bracket.
13. Install dual converter Y pipe. Refer to Section
09-QO.
14. Connect heated oxygen sensor.
15. Install oil bypass filter as described.
16. Lower vehicle.
17. Install A I C compressor mounting bracket with
drive belt tensioner attached.
18. Connect evaporative emission hose.
19. Connect main vacuum source hose.
20. Connect fuel charging wiring to engine control
sensor wiring at 42-pin connector.
2 1 . Remove plugs from fuel supply and return lines
and connect lines as described in Section 1 o-o 1 .
22. Install accelerator cable bracket.
23. Connect accelerator cable and speed control
actuator cable to throttle body.
24. Install wiring shield.
Engine, 3.8L
25. Install A I C compressor and retaining bolts.
Tighten to 2 1 -29 N-m ( 1 6-2 1 1b-ft).
26. Remove caps or plugs on A I C compressor lines
and connect lines to A I C compressor.
27. Connect A I C clutch to fuel charging wiring.
28. Connect power steering pressure switch at wiring
connector.
29. Install power steering pump and bracket.
30. Connect power steering hoses.
3 1 . Install radiator as described in Section 03-Q3.
32. Connect lower radiator hose to water pump.
33. Install heater inlet and heater return tube hoses.
34. Install transmission cooler lines.
35. Install upper radiator hose.
36. Install cooling fan motor, fan blade and fan shroud
assembly. Refer to Section 03-Q3.
37. Connect engine control sensor wiring to cooling
fan motor.
38. Install radiator coolant recovery reservoir and
connect constant control relay module at wiring
connector. Refer to Section 03-03.
39. Install drive belt. Refer to Section 03-Q5.
40. Install radiator upper sight shield.
4 1 . Install air cleaner outlet tube to throttle body as
described in Section 03- 1 2.
42. Install hood to previously marked position.
43. Connect underhood lamp wiring.
44. Connect battery ground cable.
45. Refill crankcase to proper level with clean engine
oil meeting Ford specification WSS-M2C 1 53-F.
46. Refill engine cooling system. Refer to Section
03-03.
4 7. Evacuate and recharge A I C system. Refer to
Section 1 2-oo.
48. Start engine and check for leaks.
Camshaft Bearings
SPECIAL SERVICE TOOL(S) REQUIRED
Description
Camshaft Bearing Set
Removal
1 . Remove engine from vehicle as described.
2. Remove flywheel (6375) and engine rear plate
(7007).
3. Remove camshaft (6250) as described. Loosen
lower intake manifold bolts.
4. Remove crankshaft (6303) as described, and
push pistons (6 1 08) to top of cylinder bore.
03-01 A-44
Tool Number
T65L-6250-A
1997 Thunderbird, Cougar July 1 996