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Ford Thunderbird, Manual

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Ford Thunderbird Manual Download Page 104

03·01A·65 

SPECIAL SERVICE TOOLS/ EQUIPMENT 

(Continued) 

SPECIAL SERVICE TOOLS DESIRED 

Tool Number 

Description 

D81L-600-A 

Lb-ln Torque Wrench 

D81 L-600-B 

Lb-Ft Torque Wrench 

D81 L-4201-A 

Feeler Gauge 

TOOL-633 1 -E 

Main Bearing Insert Tool 

Engine, 3.8L 

03-01A·65 

ROTUNDA EQUIPMENT 

Model 

Description 

0 14-00792 

Engine Lifting Brackets (3.8L) 

0 14-00793 

Separator Bar 

1997 Thunderbird, Cougar July  1996 

Summary of Contents for Thunderbird

Page 1: ...ending Clearance 03 oo 26 Crankshaft 03 Go 21 Crankshaft End Play 03 oo 21 Crankshaft Main Journal and Connecting RodJournals 03 Go 22 Crankshaft Sprocket 03 Go 22 Crankshaft End Play 03 Go 15 Crankshaft Main and Connecting Rod Bearings 03 oo 20 Crankshaft Main or Connecting Rod Bearings Fitting 03 Go 20 SERVICE PROCEDURES Cont d Cylinder Block oa oo 11 CylinderBlock Distortion 03 Go 1 CylinderHea...

Page 2: ...This page intentionally left blank Get it ...

Page 3: ...uel system 1 Can be purchased as a separate item SERVICE PROCEDURES Cont d ValveSeatContactWidth 03 oo 34 Valve Stem Diameter 03 oo 35 SPECIFICATIONS 03 Go 37 SPECIAL SERVICE TOOLS EQUIPMENT 03 Go 37 ignition system emissions system exhaust system When performing tests adjustment or service to the engine fuel system or ignition system it is essential to follow the procedures and specifications in ...

Page 4: ... the following engine calibration number revision level These numbers are used to determine if parts are unique to specific engines Emission Calibration Label I ETALONNAGE CALl BRACI ON 7 25F ROO I CALlBAATION REVISION NUMBER ESAE 6E061 AAA AA0227 A 2 Can be purchased as a separate 1tem Always refer to this label when replacement partsare required checking engine calibrations Exhaust Emission Cont...

Page 5: ...alve seat contact Damaged cylinder head gasket REPLACE cylinder head gasket Leaking intake manifold gasket REPLACE intake manifold gasket Abnormal Combustion Damaged fuel system REFER to the Powertrain Restricted plugged induction Control Emissions Diagnosis system Manual3 Damaged ignition system REFER to the Powertrain Control Emissions Diagnosis Manual3 Damaged hydraulic valve tappet REPLACE hyd...

Page 6: ...REPLACE piston or piston pin Damaged piston ring s REPLACE piston ring s Bent connecting rod REPLACE connecting rod Damaged valve tappet REPLACE valve tappet Excessive hydraulic valve tappet ADJUST clearance or REPLACE clearance hydraulic valve tappet guide Broken valve spring REPLACE valve spring Excessive valve guide clearance SERVICE clearance or REPLACE valve guideI stem Loose timing chain REP...

Page 7: ...kcase 5 Can be purchased as a separate item 3 Run engine for 15 minutes Stop engine and inspect all seal and gasketareasfor leaks using Rotunda Oil Leak Detector 164 R0756 or equivalent A clear brightyellow or orangearea will identify leak For extremely small leaks several hours may be required for the leak to appear 4 If necessary pressurize main oil gallery system to locate leaks due to improper...

Page 8: ...witch in starting circuit With ignition switch in the OFF position and using auxiliary starter switch crank engine a minimum of five compression strokes and record highest reading Note the approximate number of compression strokes required to obtain the highest reading 4 Repeat test on each cylinder cranking the engine approximately the same number of compression strokes Test Results The indicated...

Page 9: ...rs cou d result from this condition Usethe Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading number is 75 percent of the highest reading Maximum Minimum Maximum Minimum PSI PSI PSI PSI 1448 kPa 1083 kPa 1655 kPa 1241 kPa 2 10 PSI 157 PSI 240 PSI 180 PSI 1462 kPa 1089 kPa 1669 kPa 1 248 kPa 212 PSI 158 PSI 242 PSI 181 PSI 1476 kPa 1 103 kPa 1682 kPa 1262...

Page 10: ...aces and bearing seals Look for bubbles or foam 4 Remove the spark plugs 12405 and rotate the crankshaft 6303 slowly with a wrench Check for large amounts of air escaping into the cylinders as each intake valve 6507 and exhaust valve 6505 opens 5 The spark plugs on the leaking cylinders will probably show deposits of burned oil Intake Manifold Vacuum Test Bring the engine to normal operating tempe...

Page 11: ...ng at idle could be relatively steady 10 LATE VALVE TIMING A steady but low reading could be caused by late valve timing 11 IGNITION TIMING RETARDING Retarded ignition timing will produce a steady but somewhat low reading 12 INSUFFICIENT SPARK PLUG GAP When spark plugs 12405 are gapped too close a regular small pulsation of the needle can occur 13 INTAKE LEAK A low steady reading which can be caus...

Page 12: ... of excessive internal oil consumption 1 NOTE Oil use is normally greater during the first 16 100 km 10 000 miles of service As mileage increases oil use generally decreases Vehicles in normal service should get at least 1 450 km 900miles per liter quart after 16 100 km 10 000 miles of service High speed driving towing high ambient temperature and other factors may result in greater oil use Define...

Page 13: ...on 03 D18 4 6L b Check piston ring clearance ring gap and ring orientation Service as required c Check for excessive bearing clearance Service as required 12 Perform oil consumption test as described to confirm oil consumption concern has been resolved Oil Pressure Test SPECIAL SERVICE TOOL S REQUIRED Description Tool Number Engine Oil Pressure Gauge T73L 6600 A 1 Disconnect and remove the oil pre...

Page 14: ...operation of positive rotator Valves and Cylinder Head Check for plugged oil drain back holes Check for missing or damaged valve stem seals 6571 or guide mounted valve stem seals Check for plugged oil metering orifice in cylinder head oil reservoir 4 6L engine only If insufficient oiling is suspected check oil passages for blockage then accelerate the engine to 1200 rpm with the transmission in NE...

Page 15: ...n into the system through a hole crack or leaking gasket on the oil pumpscreen cover and tube 6622 If the leakdown time is below the specified time for used valve tappets noisy operation may result If no other cause for noisy valve tappets can be found the leakdown rate should be checked and any valve tappets outside the specification should be replaced Assembled valve tappets can be tested with a...

Page 16: ...ylinder head 6049 I cylinder blocks 6010 for excessive wear 4 6L Engine 1 NOTE Dial indicator may also be installed on rear of engine with indicator point placed on flat area of camshaft end Push camshaft toward rear of engine Install Dial Indicator with Bracketry TOOL 4201 C or equivalent so indicator point is on camshaft sprocket bolt 2 Zero the dial indicator Pull camshaftforward and release it...

Page 17: ... openings with compressed air Make sure threads in the cylinder head bolt holes are clean Dirt in the threads may cause binding and result in a false torquereading Use a tap to true up threads and to remove all deposits Thoroughly clean the grooves in the crankshaft bearings and bearing retainers Check all machined surfaces for burrs nicks scratches and scores Remove minor imperfections with an oi...

Page 18: ...erviced area to blend with general contour of surrounding surface 6 Paint the surface to match the rest of the cylinder blocks Cylinder Walls Refinishing Cleaning 1 CAUTION If these procedures are not followed rusting of the cylinder bores may occur After any cylinder bore service operation such as honing or deglazing clean bores with soap or detergent and water 2 Thoroughly rinse the bores with c...

Page 19: ...e refinished Hone only the cylinder or cylinders that require refinishing All pistons are the same weight both standard and oversize therefore various sizes of pistons can be used without upsetting engine balance Refinish the cylinder with the most wear first to determine the maximum oversize If the cylinder will not clean up when refinished for the maximum oversize piston recommended replace the ...

Page 20: ... the surface by boring for the next specified oversize plug Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug Coat the plug andIor bore lightly with an oil resistant oil galley sealer such asStud and Bearing Mount EOAZ 19554 BA or equivalent meeting Ford specification WSK M2G349 A1 or Thread Lock 262 E2FZ 19554 B or equivalent meeting Ford specificatio...

Page 21: ...d air Inspection Inspect each bearing carefully Replace bearings that have scored chipped or worn surfaces Typical examples of unsatisfactory bearings and their causes are shown in the following illustration The copper lead bearing base may be visible through the bearing overlay If the base showing is less than 20 percent of thetotal area the bearing is not excessively worn It is not necessary to ...

Page 22: ...pply a lightcoat of clean engine oil meeting Ford specification WSS M2C153 F to journal and bearings Install bearing cap Tighten cap bolts to specification Referto Section 03 Q1A 3 8l or Section 03 01 8 4 6L under Specifications 8 Repeat procedurefor remaining bearings that require replacement Crankshaft Cleaning CAUTION Handle the crankshaft 6303 carefully to avoid damage to the finished surfaces...

Page 23: ...lean up to maximum undersize bearing available replace the crankshaft Always reproduce the same journal shoulder radius which existed originally Too small a radius will result in fatigue failure of the crankshaft Too large a radius will result in bearing failure due to radius ride of the bearing After refinishing thejournals chamfer the oil holes Polish thejournal with a No 500 grit polishing clot...

Page 24: ... clearance following the procedure under Piston Rings Fitting Replace pistonIrodIpin assembly the 3 8L engine uses powdered metalrods showing signs of fracture etching orwear Check the piston pin fit in the piston and connecting rod as described Cylinder Bore Diameter Gauge Pistons Fitting Coated Pistons SPECIAL SERVICE TOOL S REQUIRED Description Tool Number Engine Cylinder Hone Set T73L 601 1 A ...

Page 25: ...ance conditions of the cylinder bore are within specified limits newpiston rings will work well H installing newpiston rings in a used cylinder that has notbeen refinished remove the cylinder wall glaze only using spring loaded Engine Cylinder Hone Set T73L 601 1 A Remove only if there is no visible sign of cross hatch markings on the cylinder walls Refer to Cylinder Block Cylinder Walls Refinishi...

Page 26: ...essary periodically to use another piston within the same grade size that is either slightly larger or smaller to achieve the specified clearance Piston Rings CAUTION Piston rings should not be transferred from one piston to another regardless of mileage or piston ring failure may occur Replace all piston rings that are scored broken chipped or cracked Check the end gap and side clearance as descr...

Page 27: ... 0 0005 inch clearance light slip fit Assemble the piston piston pin and connecting rod as described The connecting rod and related parts should be carefully inspected and checked so they conform to specifications For Specifications referto Section 03 Q1A 3 8L or Section 03 018 4 6L Various forms of engine wear caused by thesepartscan be readily identified A shiny surface on either pin boss inside...

Page 28: ...ameters ofeach camshaft lobewith a Vernier caliper and record readings The difference in readings on each camshaft diameter is lobe lift 2 If readings do not meet specification replace camshaft For Specifications refer to Section 03 Q1A 6 35 mm 6 35 mm 0 25 INCH 0 25 INCH A NO PITTING ALLOWED IN THIS AREA DIMENSION A MINUS DIMENSION B EQUALS THE CAM LOBE LIFT A23322 B Camshaft Journal Oil Clearanc...

Page 29: ...engine Install Dial Indicatorwith Bracketry TOOL 4201 c or equivalent so indicator point is on camshaft sprocket bolt 2 Zero the dial indicator Pull camshaft forward and release it Compare dial indicator reading with specifications If end play is too tight check for binding or foreign material in camshaft thrust plate If end play is excessive check for worn camshaft thrust plate and replace cylind...

Page 30: ... 19 inches thick replace gear If gear thickness is within specification it may be necessary to replace the oil pump and filter body If thickness of gear is within specified limits go to Step 6 6 Measure depth of the gear pocket in the oil pump and filter body Depth should be 30 49 30 54 mm 1 200 1 202 inches If depth is more than 30 54 mm 1 202 inches replace oil pump and filter body 7 Measure sid...

Page 31: ... the cylinder headsforcracks or excessively burned areas in the exhaust outlet ports Check the cylinder head for cracks and inspect the gasketsurfacefor burrs and nicks Small imperfections can be dressed down using an oil stone Replace the cylinder head if it is cracked The following inspection procedures are for a cylinder head that is to be completely overhauled For individual service operations...

Page 32: ... cylinder head gasket surface so it conforms to specification using Straight Edge D83L 4201 A or equivalent and Feeler Gauge 081L 4201 A or equivalent For Specifications refer to Section 03 Q1A If necessary to refinish the cylinder head gasket surface on the 3 8L plane or grind up to 0 254 mm 0 010 inch from original cylinder head gasket surface Remove all burrs or scratches with an oil stone If s...

Page 33: ...arded as having a practical working value and used to determine installation of the nextoversizevalve 3 8L Engine If the valve stem to valve guide clearance exceeds the service clearance ream the valve guide for the next oversizevalve stem Valves with oversize stem diameters of 0 38 mm and 0 76 mm 0 015 inch and 0 030 inch are available in diameters of 0 41 mm and 0 81 mm 0 016 inch and 0 032 inch...

Page 34: ...e the valve seat width Reface the valve seats if the width is not within specifications Refer to Section 03 Q1A 3 8L or Section 03 Q1B 4 6L for Specifications Refer to Engine Service Section in the Rotunda Tool catalog for a description of the various valve seat grinders and cutters available Refacing the valveseat should be closely coordinated with the refacing of the valve face so that the finis...

Page 35: ...ssed Refer to the illustration for critical valve dimensions VALVETYPICAL FOR DIMENSIONS REFER TOSPECIFICATIONS CHECK FOR THIN WORN LANDS BETWEEN KEEPER GROOVES OR BURRS MULTIPLE BEAD VALVES VALVE FACE ANGLE Valve Seat Contact Width CHECK FOR BENT STEM THIS LINE PARALLEL WITH VALVE HEAD A23526 B Use a seat width scale or a machinist scale to measure the seat width Narrow the seat if necessary to b...

Page 36: ...pecifications as described in Section 03 o1A 3 8L or Section 03 o 18 4 6L replace the valve spring Valve Spring Tension Inspectthe valve spring valve spring retainers and valve spring retainer keys for wear or damage Discard any damaged parts NOTE Make sure the valve springs are reassembled to their OWN ORIGINAL DAMPERS by pushing damper on the valve spring DO NOT OPEN damper with any kind of tool...

Page 37: ...uffs Replaceany damaged parts ROCKER 1 ARM BOLT 390385 I ROCKER ARM I SEAT 6A528 ROCKER ARM 6564 A5859 G CAUTION Do not attempt to true surfaces by grinding Check the rocker arm pad side ralls and seat for excessive wear cracks nicks or burrs Check the rocker arm seat bolt for stripped or broken threads Replace components as required or possible damage may occur Inspect the pad at the valve end of...

Page 38: ...ean the Exhaust Gas Recirculation EGR passages Exhaust Manifold Cleaning Remove all gasket or foreign material from all inlet and outlet sealing surfaces ofthe exhaust manifolds 9430 Inspection Inspect the cylinder headjoining flanges of the exhaust manifolds for evidence of exhaust gas leaks Inspect the exhaust manifolds for cracks damaged gasket surfaces or other damage that would make them unfi...

Page 39: ... SERVICE TOOLS DESIRED Cont d Tool Number Description D81L 6002 D Piston Ring Groove Cleaner D83L 4201 A Straight Edge D87C 77000 A Transmission Test Adapter TOOL 4201 C Dial indicator with Bracketry TOOL 6505 E Valve Stem Clearance Tool TOOL 6513 DD ValveI Clutch Spring Tester TOOL 6565 AB Cup Shaped Adapter ROTUNDA EQUIPMENT Model Description 014 00705 Pressurization Kit 014 R00707 Compression T...

Page 40: ...Cougar DESCRIPTION AND OPERATION Engine The 3 8L sequential multipartfuel injection SFI engine has V block construction with the following features overhead valves lightweight compact and similar to a V 8 engine in construction and components Engine Identification Engine codes and calibration number must be used when ordering parts or making inquiries about the engine IN VEHICLE SERVICE Cont d Oil...

Page 41: ...ne intake valves 6507 connected in parallelwith the fuel pressure regulator 9C968 Fuel is supplied fromthe vehicle fuel tank 9002 by a high pressureelectric fuel pump 9350 mounted in the fuel tank is filtered and sent to the fuel injection supply manifold 9F792 A fuel pressure regulator on the fuel injection supply manifold controls the fuel delivery pressure at a constant 269 kPa 39 psi Excessfue...

Page 42: ...sing shaft through an oil pump intermediate shaft 6A618 A full flow oil bypass filter 67 14 is externally mounted on the oil pump and filter body 6603 Normally all engine oil passes through the oil bypass filter element However if the oil bypass filter element should become restricted a spring loaded bypass valve will open which allows an uninterrupted flow of oil to the engine s moving parts Oil ...

Page 43: ...03 01A 4 Engine 3 8L 03 01A 4 IN VEHICLE SERVICE Engine Components 3 8L Engine Disassembled View 1997 Thunderbird CougarJuly 1996 ...

Page 44: ...03 01A 5 Engine 3 8L 03 01A 5 IN VEHICLE SERVICE Continued 3 8L Engine Disassembled View Continued 1997 Thunderbird Cougar July 1996 ...

Page 45: ...03 01A 6 Engine 3 8L 03 01A 6 IN VEHICLE SERVICE Continued 3 8L Engine Disassembled View Continued 1997 Thunderbird Cougar July 1996 ...

Page 46: ... ___ _ _ __ ___ _ T _ __ _ TT CD CD c Q I a 0 c IC c c CD CD Ls A24838 A o 0 1 r m I 10 CD I c i CD 3 0 c e 0 0 I c CD S m J z I m 1 0 r m en m u 0 m 0 0 c CD Q 0 1 I m I ca s w Co r 0 ...

Page 47: ...588 Bolt 5 Req d 63 6049 Cylinder Head LH 21 9424 Intake Manifold 64 6582 ValveCover LH 22 N390633 Bolt 4 Req d 65 6766 Oil Filler Cap 23 9A424 Intake Manifold Seal Rear 66 6853 Crankcase Ventilation Hose 24 9A424 Intake Manifold Seal Front 67 N807442 Stud Bolt 2 Req d 25 6010 CylinderBlocks 68 N807443 Bolt 3 Req d 26 6522 Push Rod Valley Baffle 69 12405 Spark Plug 3 Req d 27 W701607 Bolt 2 Req d ...

Page 48: ... Retainer 2 Req d 107 N800299 Fitting 150 6500 Valve Tappet 12 Req d 108 87744 Pipe Plug 151 6565 Push Rod 6 Req d 109 6701 Crankshaft Rear Oil Seal 152 6564 RockerArm 6 Req d 1 10 6C057 Engine Block Plug 2 Req d 153 6A528 Rocker Arm Seat 6 Req d 1 1 1 6397 Flywheel Housing to Block 154 N808305 Bolt 6 Req d Dowel 155 6514 Valve Spring Retainer 6 1 12 9F008 Oil Pump and Filter Body Req d 1 13 6714 ...

Page 49: ...t and stud threads before installation Using solvent clean cylinder head 6049 and valve cover sealing surfaces to remove all gasket material and dirt Position and install a newvalvecover gasket onto valve cover Part Item Number Description 187 6161 Piston Ring 6 Req d 188 6100 Piston and Connecting Rod Assy 6 Req d 189 6200 Connecting Rod Assy 6 Req d 190 6210 Connecting Rod Cap 6 Req d 191 621 1 ...

Page 50: ...g steps is an indication of valve andIor valve seat damage and requires removal of cylinder head 6049 Install an air line with an adapter in the spark plug hole and turn air supply on 5 Compress valve spring 6513 using a suitable valve spring compressor following tool manufacturer s instructions 6 CAUTION Ifair pressure has forced the piston to the bottom of the cylinder any loss of air pressure w...

Page 51: ...o aid removal When using a remover tool rotate valve tappet back and forth to loosen it from gum or varnish that may haveformed on the valve tappet Installation 1 Using solvent clean the cylinder head 6049 and valvesealing surfaces 2 NOTE Lightly oil all bolt and stud threads before installation except those specifying special sealant Lubricateeach valve tappet and bore with Engine Assembly Lubric...

Page 52: ...8 at the upper intake manifold and at positive crankcase ventilation valve PCV valve 6A666 7 Remove throttle body if necessary Refer to Section 03 04A 8 Remove the EGR valve EGR valve 9D475 from the upper intake manifold Refer to Section 03 QS 9 Remove the nutand bolt retaining engine support and wiring retainer bracket located at the LH front of the intake manifold and set aside with ignition wir...

Page 53: ...b ft A20849 C Part Item Number Description 1 9424 Intake Manifold Upper 2 Stud Part of 9424 Continued 2 Can be purchased as a separate item Part Item Number Description 3 9E936 ThrottleBody Gasket 4 9E926 Throttle Body 5 N807610 Stud Bolt 6 N805328 Nut 3Req d A Tighten to 20 30 N m 15 22 Lb Ft 6 Connect crankcase ventilation tube to positive crankcase ventilation valve on the upper intake manifold...

Page 54: ...VIEW A NOTE LUBRICATE FUEL INJECTOR BORES OR 0 RINGS WITH MOTOROIL PRIORTO INSTALLATION SIX PLACES FRONT OF ENGINE Description Bolt 4 Req d Fuel Injection Supply Manifold Intake Manifold Bolt Item 5 A B 03 01A 15 AA1006 A Part Number Description 6049 CylinderHead Tighten to 8 1 1 N m 71 97 Lb ln Tighten to 20 30 N m 15 22 Lb Ft 1997 Thunderbird Cougar July 1996 ...

Page 55: ...FACTANT PRIOR TO INSTALLATION Part Item Number Description 1 N807609 Nut A24823 A 2 18663 HeaterWaterOutletTube 3 Lower Intake Manifold Stud 4 8A530 Water Bypass Tube 5 8501 Water Pump 6 Clamp 7 N606676 Bolt A Tighten to 8 1 1 N m 71 97 Lb ln 5 Remove heater water outlet hose 6 Remove lower intake manifold retaining bolts studs 7 CAUTION The lower intake manifold is sealed at each end with silicon...

Page 56: ...ture sensor all vacuum fittings heater elbows and electricalfittings if equipped Refer to Specifications b Install water hose connection notedirection and water thermostat Install water hose connection Tighten retaining bolts to 8 1 1 N m 7 1 97 lb in 3 NOTE Priorto applying sealer clean sealing surfaces of cylinder heads 6049 and lower intake manifold with Metal Surface Cleaner F4AZ 19A536 RA or ...

Page 57: ...Head Gasket 6 Carefully lower intake manifold into position on cylinder blocks and cylinder head Use locating pins as necessary to guide intake manifold 7 Install bolts and stud bolt in their original locations FRONT OF ENGINE INSTALL BOLTSISTUDS AS SHOWN Part Item Number 1 W701589 2 W701588 3 9424 4 9439 5 A20850 B Description Stud Bolt 2 Req d Bolt 10 Req d IntakeManifold Lower Intake Manifold G...

Page 58: ...generator bracket retaining bolts Leaving hoses connected place pump Ibracket assembly aside in a position to prevent fluid from leaking out 6 If RH cylinderhead is being removed perform the following a Removedrive belt b If equipped with AIC remove mounting bracket retaining bolts Leave hoses connected and position AIC compressor 19703 aside If not equipped with AIC remove A IC belt idler pulley ...

Page 59: ...ed using the following procedure it is not necessary to retighten bolts after extended engine operation However bolts can be checked for tightness if desired Tighten cylinder head retaining bolts in numerical sequence in three steps as follows a 20 N m 15 1b ft b 40 N m 30 lb ft c 50 N m 37 lb ft AA0866 A d CAUTION Do not loosen all ofthe bolts at the same time only work on one bolt at a time or d...

Page 60: ...nstall upper intake manifold 13 Install spark plugs 12405 if removed Refer to Section 03 Q7A 14 Connect ignition wiresto the spark plugs Refer to Section 03 Q7A 15 If LH cylinder head is being installed perform the following a Install oil filler cap b Install generatorIpower steering pump mounting bracket c Install generator d Install accessory drive belt tensioner e Install power steering pump 3A...

Page 61: ...nts as necessary 2 Lubricate the crankshaft front seal lip with clean engine oil and install the crankshaft front seal using Damper I Front Cover Seal Replacer T82L 6316 A and Front Cover Seal Replacer T70P 68070 8 3 Lubricate crankshaft front seal surface on the crankshaft pulley and vibration damper with clean engine oil Install crankshaft pulley and vibration damper using DamperI Front Cover Se...

Page 62: ...ater pump retaining bolt must be coated with Pipe Sealant with Teflon D8AZ 19554 A or equivalent meeting Ford specifications WSK M2G35D A2 before installing Position water pump on the engine front cover Install retaining bolts stud bolts and nuts Tighten retaining bolts and studs to 2D 30 N m 15 22 lb ft Tighten retaining nuts to 8 12 N m 7 1 106 1b in 4 Inspect 0 ring replace as necessary and ins...

Page 63: ... Refer to Section 03 Q3_ 5 Remove drive belt 8620 and water pump pulley 8509 A24826 A Part Item Number Description 4 8501 Water Pump 5 N808217 Bolt 6 N804852 Stud Bolt 7 6010 Cylinder Blocks 6 Remove power steering pump bracket retaining bolts Refer to Section 1 1 02_ Leaving hoses connected place powersteering pump 3A674 and bracket aside in a position to prevent fluid from leaking out 7_ If equi...

Page 64: ... Remove engine front cover retaining bolts It is not necessary to remove water pump 19 Remove engine front cover and water pump as an assembly 20 If necessary remove engine front cover gasket 6020 and discard 2 1 If necessary removecrankshaft position sensor shield and crankshaft position sensor CKP sensor 6C315 22 If necessary remove oil pumpand filter body Installation 1 NOTE Lightly oil all bol...

Page 65: ...7 N804852 Stud Bolt 8 N804839 Bolt 9 6049 CylinderHead 10 N804841 Socket Head Cap Bolt 1 1 NOTE Priorto applying sealer clean sealing surfaces with Metal Surface cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B392 A to remove all residues that may interfere with the sealer s ability to adhere NOTE When using silicone sealer assembly must occur within 15 minutesafter sealer a...

Page 66: ...ankcase to proper level with engine oil meeting Ford specification WSS M2C153 F 28 CAUTION The engine has aluminum cylinder heads 6049 and requires a special corrosion inhibited coolant formulation to avoid cooling system damage Refer to Section 03 03 for coolant specifications Fill engine cooling system with specified coolant Refer to Section 03 Q3 29 Install engine air cleaner and air cleaner ou...

Page 67: ...TION WSS M2C153 F Part Item Number 7 6303 Retaining Bolt and Washer 8 388907 2 6255 Distributor Drive Gear 9 6284 3 6256 Camshaft Sprocket 4 6306 Crankshaft Sprocket 10 N805256 S 5 6268 Timing Chain Belt 1 1 6250 6 6K305 Engine Balance Shaft Gear 12 6265 Spacer A Continued 03 01A 28 Description Crankshaft Crankshaft Key Timing Chain Vibration Damper Camshaft SprocketKey Camshaft Camshaft Sprocket ...

Page 68: ...t position sensor CMP sensor 12126 and housing asdescribed in Section 03 14 5 Remove upperintake manifold 9424 and lower intake manifold as described 6 Remove valvetappet 6500 valvetappet guide plate 6K512 and tappet guide plate and retainer 6K564 as described 7 Remove engine front cover 6019 timing chain and camshaftsprocketspacer 6265 as described 8 Remove oil pan 6675 as described 9 Remove cams...

Page 69: ... plugs 12405 Refer to Section 03 Q7A 2 Disconnect EGRvalveto exhaust manifold tube 9D477 from exhaust manifold 9430 1 1 Install radiator Refer to Section 03 Q3 Part Item Number 4 6269 5 N804621 6 N805256 7 376958 THOROUGHLY COAT CAM BEARINGS IN BLOCK WITH MOTOR OIL PRIOR TO INSTALLATION FRONT OF ENGINE NOTE APPLY WSK M2G349 A10 SEALER PRIOR TO INSTALLATION A24829 A Description Camshaft Thrust Plat...

Page 70: ...ly 5 Connect EGR valve to exhaust manifold tube loosely 6 Tighten exhaust manifold retaining bolts and studs to 30 36 N m 22 27 lb ft 7 Raise vehicle Referto Section OQ 02 8 NOTE If a new exhaust manifold is being installed or a new dual converter Y pipe to exhaust manifold retaining stud is required install stud until seated securely on exhaust manifold Connect dual converter Y pipe to exhaust ma...

Page 71: ...the sequence shown in the illustration 4 Raise vehicle 5 Connect dual converter Y pipe to exhaust manifold Tighten retaining nuts to 21 32 N m 16 23 1b ft 6 Lower vehicle 7 Connect ignition wires to spark plugs Refer to Section 03 07A 8 Install oil level indicator tube support bracket retaining nut Tighten to 20 30 N m 15 22 lb ft 9 Start engine and check forexhaust leaks FRONT OF ENGINE _ FRONT O...

Page 72: ...ll oil pump screen cover and tube using a new oil pump inlet tube gasket Tighten retainer bolts to 20 30 N m 15 22 1b ft and support bracket nut to 4Q 55 N m 30 40 lb ft FRONT OF ENGINE Part Item Number 1 6622 2 N81 1 1 15 3 N81 1461 4 6010 5 6626 6 N801689 A B A24831 A Description Oil Pump Screen Cover and Tube Nut Stud Bolt Cylinder Blocks Oil Pump InletTubeGasket Bolt Tighten to40 55 N m 30 40 ...

Page 73: ...stall crankshaft position sensorlower shield lighten in two steps in sequence to 4 5 N m 36 44 lb in then in sequence to 9 12 N m 8Q 106 1b in NOTE FRONT OF ENGINE SEALER MUST FILL SEAL GROOVE AS SHOWN TWO PLACES VIEW A APPLY A ZIG ZAG BEAD OR EXTRA SEALER ON JOINT OF FRONTCOVER AND CYLINDER BLOCK TWO PLACES A20805 B Part Item Number Description 6 N605892 Bolt 16 Req d 7 Rear Crankshaft Main Beari...

Page 74: ...3 F 26 Start engine and check for leaks Oil Pump Removal 1 If necessary remove oil bypass filter 67 14 2 Remove oil pump and filter body to engine front cover retaining bolts and remove oil pump and filter body 6603 from engine frontcover 6019 3 Inspect Q ring for distortion and wear Replace if necessary Installation 1 Position oil pump and filter body on engine front cover and install retaining b...

Page 75: ...l bolt and stud threads before installation Lubricate and position the upper crankshaft main bearing on crankshaftjournal with plain end started into the side of cylinder blocks with locking tang slot Line up crankshaft main bearing tang with slot in cylinder blocks 2 Install Main Bearing Insert Tool TOOL 6331 E or equivalent in crankshaftjournal oil hole 3 With crankshaft main bearing and tool in...

Page 76: ...n Tool Number Cylinder Ridge Reamer T64L 601 1 EA Removal 1 Drain engine cooling system Refer to Section 03 Q3 2 Remove upper intake manifold 9424 and lower intake manifold as described 3 Remove cylinder heads 6049 as described 4 Remove oil pan 6675 as described 5 Before removing piston 6108 inspect top of each cylinder bore If a ridge has formed at the top of the cylinder it must be removed befor...

Page 77: ...s as follows Tighten oil pump screen cover and tube cylinder block bolts to 2Q 30 N m 15 22 1b ft Tighten oil pump screencoverand tube support bracket retaining nut to 4Q 55 N m 3Q 40 lb ft 9 Install oil pan as described 10 Check piston deck clearance and bore clearance as shown NOTE PISTON TO DECK CLEARANCE NOTE LETTERS FOR CAP ORIENTATION IN THIS AREA PISTON CYLINDER BLOCK TO BE 0 27 mm 0 011 IN...

Page 78: ...pull connecting rod down until connecting rod seats on crankshaft When installing connecting rod bearings make sure tab on connecting rod bearings engages slot in connecting rod and that connecting rod bearing is fully seated in connecting rod 4 Install lower connecting rod bearing in connecting rod cap and lubricate bearing surface with Engine Assembly Lubricant 09AZ 19579 D or equivalent meeting...

Page 79: ...77L 9533 B Rear Main Seal Replacer T82L 6701 A Removal 1 Remove transmission Refer to Section 07 o1 2 CAUTION Avoid scratching or damaging oil seal surface or possible engine oil leakage may occur Using a sharp awl punch one hole into the crankshaft rear oil seal metal surface between lip and cylinder blocks 6010 3 Screw in the threaded end of Jet Plug Remover T77L 9533 B Use thejet plug remover t...

Page 80: ...3 Remove oil pandrain plug and drain 4 Remove oil bypassfilter 67 14 Installation 1 Install oil pan drain plug lighten to 20 34 N m 15 25 1b ft 2 lubricateoil bypass filter gasket with Engine Assembly lubricant D9AZ 19579 D or equivalent meeting Ford specification ESR M99C80 3 Thread oil bypass filter onto adapter until gasket contacts cylinder blocks 6010 and then advance oil bypass filter an add...

Page 81: ...nto 20 30 N m 15 22 Lb Ft 1 Disconnect wiring connector from oil pressure sensor 9278 2 Remove oil pressure sensorfrom the oil pressure fitting Installation 1 Follow removal procedure in reverse order 2 Tighten to 1 1 16 N m 98 141 1b in FRONT OF ENGINE NOTE ADVANCE CLOCKWISE TO POSmON SHOWN IN VIEW A NOT MORE THAN ONE FULL TURN NO BACK UP ALLOWED VIEW A FRONT OF ENGINE 40 DEGREES 50 DEGREES Part ...

Page 82: ...C compressor retaining bolts and remove AIC compressor 19703 24 Remove wiring shield 25 Disconnect accelerator cable 9A758 and speed control actuator cable 9A825 from throttle body 9E926 26 Remove accelerator cable bracket 9723 and moveasidewith cables 27 Release fuel system pressure and disconnect fuel supply hose as described in Section 10 01 28 Disconnect fuel return hose as described in Sectio...

Page 83: ...ector 21 Remove plugs from fuel supply and return lines and connect lines as described in Section 1o o1 22 Install accelerator cable bracket 23 Connect accelerator cable and speed control actuator cable to throttle body 24 Install wiring shield 25 Install AIC compressor and retaining bolts Tighten to 21 29 N m 16 2 1 1b ft 26 Remove caps or plugs on AIC compressor lines and connect lines to AIC co...

Page 84: ... Part of T65L 6250 A 2 Back Up Nut Part of T65L 6250 A 3 626 1 Camshaft Bearing Continued Installation 1 CAUTION Failure to use correct expanding collet can cause severe camshaft bearing damage Make sure front camshaft bearing is installed at specified distance below front face of cylinder blocks NOTE Camshaft bearings are available refinished to size for standard and 0 38 mm 0 0 15 inch undersize...

Page 85: ...nal position during assembly 1 1 Remove crankshaft main bearing caps 12 NOTE Handle crankshaft withcare to prevent possible damage to finished bearing surfaces Carefully liftcrankshaftout of cylinder blocks 6010 to prevent damage to bearing surfaces 13 Remove crankshaft rearoil seal 670 1 and discard 14 CAUTION Because the crankshaft incorporates deep rolling of the main journal fillets journal re...

Page 86: ...cation After this time the sealer may start to set up and its sealing effectiveness may be reduced Apply a 3 mm 0 125 inch bead of Silicone Rubber D6AZ 19562 AA or equivalent meeting Ford specifications ESB M4G92 A and ESE M4G195 A to rear main bearing cap to cylinder block parting line 7 Lubricate bearing surfaces with Engine Assembly 8 9 10 1 1 12 Lubricant D9AZ 19579 D or equivalent meeting For...

Page 87: ...ark plug Do not pull on ignition wire directly or it may become separated from connector inside boot Disconnect ignition wires from spark plugs Refer to Section 03 07A 7 Remove the following components throttle body 9E926 and throttle body gasket TB gasket 9E936 EGR valve EGR valve 9D475 upper intake manifold and intake manifold upper gasket 9H486 fuel injectors 9F593 and fuel injection supply man...

Page 88: ...6256 crankshaft sprocket and timing chain at the same time IF NECESS rv RY PRY SPROCKET OFF CRANKSHAFT PRY DOWNWARD TO REMOVE SPROCKET A6677 E 2 1 Remove timing chain vibration damper 6284 fromfront of cylinder blocks This requires pulling back on ratcheting mechanism and then installing pin through hole in bracketto relieve tension 22 Remove camshaftthrust plate 6269 23 CAUTION Do notdamage camsh...

Page 89: ...llation When the sealant is applied the component should be installed within 15 minutes After this time the sealant begins to set upand its sealing effectiveness can be reduced NOTE lightly oil all retaining bolt and stud threads before installation except those specifying special sealant If removed install oil gallery and coolingjacket plugs Tighten plugs to specification Before installation coat...

Page 90: ...crankshaft main bearing g Tighten main bearing cap retaining bolts in two steps tighten to 50 N m 37 lb ft tighten AA0192 B an additional 1 15 125 degrees 3 Check crankshaft end play Refer to Section 03 QO 4 Install pistons as follows a Install connecting rod bearings in connecting rods 6200 and connecting rod caps b NOTE Lubricate piston and cylinder walls with Engine Assembly Lubricant D9AZ 1957...

Page 91: ...d in Section 03 QO Part Item Number 4 6269 5 N804621 6 N805256 7 376958 THOROUGHLY COAT CAM BEARINGS IN BLOCK WITH MOTOR OIL PRIOR TO INSTALLATION FRONT OF ENGINE NOTE APPLY WSK M2G349 A10 SEALER PRIOR TO INSTALLATION A24829 A Description Camshaft Thrust Plate Bolt Woodruff Key Cup Plug 6 NOTE Coat sealing edge of camshaft rear bearing cover with Perfect Seal Sealing Compound B5A 19554 A or equiva...

Page 92: ...olts to 2Q 30 N m 15 22 lb ft and supportbracket retaining nut to 4Q 55 N m 3Q 40 lb ft 20 Install oil pan as follows a NOTE Prior to applying sealer clean oil pan and cylinder block sealing surfaces with Metal Surface Cleaner F4AZ 19A536 RH or equivalent meeting Ford specification WSE M5B392 A to remove all residues that may interfere with the sealers ability to adhere Using a small blade screwdr...

Page 93: ...29 NOTE Using solvent clean valve cover and cylinderhead sealing surfaces to remove all gasket material and dirt Install valve covers as follows a Install a newvalvecovergasket 6584 onto cylinder head b Install valve cover and retaining bolts Note location ofstudIbolts c Tighten retaining bolts to 8 12 N m 71 106 Ib in 30 Install camshaft position sensor housing and hold down clamp as described in...

Page 94: ...LH Shown RH Similar FRONT OF ENGINE _ FRONT OF_ ENGINE VIEW A Part Item Number Description 1 6049 CylinderHead A24300 A 2 9448 Exhaust Manifold Gasket Continued Item art N mber Description 3 9430 Exhaust Manifold LH 4 N801tr 48 Stud 3 Req d 5 N8o1647 Bolt 3 Req d A Tighten to 30 36 N m 23 26 Lb Ft 4 1 NOTE Apply a thin coatof Pipe Sealant with Teflon DBAZ 19554 A or equivalent meeting Ford specifi...

Page 95: ...4 Install lowervalve spring retainer 5 Install valve spring over valve and then install upper valve spring retainer Compress valve spring and install valve spring retainer keys 6 CAUTION Do not install the spacers unless necessary Use of spacers in excess of recommendations will result in over stressing valve springs and overloading camshaft lobes which could lead to valve spring breakage and or w...

Page 96: ...cting rod bearings will distort connecting rod bearings and cause a failure Install connecting rod bearings in connecting rod and cap with tangs fitting in slots provided Oil Pump Disassembly 1 If necessary remove oil bypass filter 67 14 2 Remove oil pump and filter body 6603 to engine front cover retaining bolts and remove oil pump and filter bod from engine front cover 6019 3 Lift pump gear out ...

Page 97: ...ump intermediate shaft and camshaft position sensor as described in Section 03 14 3 Install hold down clamp 12270 lighten to 20 30 N m 15 22 lb ft Cylinder Block Assembly Disassembly 1 Mount the engine in a workstand and remove all parts notfurnished with the new cylinder blocks 6010 following the procedures in Removal and Installation 2 Remove the cylinder head to block dowels 6A008 and the cylin...

Page 98: ...ormal operating position The leak down rate can be accelerated by using a valve tappet bleed down wrench on rocker arm and applying pressure in a direction to collapse valve tappet ROCKER ARM SEAT AND BOLT MUST BE FULLYSEATED AFTER FINAL TORQUE SPECIFICATIONS A13129 C SPECIFICATIONS Description Specification GENERAL SPECIFICATIONS Displacement 3 8L Number of Cylinders 6 Bore 96 8 mm 3 81 in Stroke...

Page 99: ...ear Face Runout Specified Height Crankshaft 0 10 mm 0 004 in RockerArm Camshaft 0 25 mm 0 010 in Ratio 1 73 Timing Chain Deflection 12 7 mm 0 5 in Valve Tappet Hydraulic CYLINDER BLOCK Diameter Std 22 200 22 212 mm 0 8740 8745 in Head Gasket Surface Flatness 0 08 mm 0 003 in in 152 0 mm 6 00 in Clearance to Bore 0 018 0 068 mm 0 0007 0 0027 in Service Limit 127 mm 0 005 in Hydraulic Leakdown Rate ...

Page 100: ... mm measure the cylinder bore as 0 001 0 0014 in outlined in Section 03 oo Allowable 0 022 0 069 Install the service piston 0 00086 0 0027 in matched to the piston bore diameter above Bearing Wall Thickness Std 1 453 1 466 mm 0 0572 0 0577 in Pin Bore Diameter 23 170 23 185 mm 0 9122 0 9128 in Main Bearings Clearance to Crankshaft I Desired 0 025 0 035 mm 0 001 0 0014 in Allowable 0 013 0 058 mm 0...

Page 101: ...otated b Used belt is any belt that has been rotated on an engine c Cold belt i e 3 hour soak 0 warm up LUBRICANTIADHESIVE CLEANER SPECIFICATIONS Ford Description Part Number Specification Engine Assembly D9AZ 19579 D ESR M99C80 A Lubricant Pipe Sealant with DBAZ 19544 A WSK M2G350 A2 Teflon Metal Surface F4AZ 19A536 RH WSE M5392 A Cleaner Gasket and Trim D7AZ 19B508 B ESR M 1 1 P 1 7 A Adhesive G...

Page 102: ...aterHose Clamps 2 5 3 5 23 30 1 Advance half turn after gasket contacts sealing surface 2 Tighten in sequenceas follows a 20 N m 15 1b ft b 40 N m 30 lb ft c 50N m 37 lb ft 3 CAUTION Do not loosen all ofthe bolts at the same time only work on one bolt at a time or damage to the engine may occur Back off all bolts one at a time two to three revolutions and retighten as follows Long bolts a Tighten ...

Page 103: ...d Size Aluminum TIII413S A 1 4 18 Pipe 24 N m M6 1 4 N m 18 Lb Ft 1 1 Lb Ft 3 8 18 Pipe 38 N m M8 28 N m 28 Lb Ft 21 Lb Ft T70P 6B070 B Front Cover Seal Replacer u M10 53 N m 11070 11 39 Lb Ft T74P 6666 A M 1 2 96 N m 71 Lb Ft M14 158 N m 1 1 7 Lb Ft Spark Plug Wire Remover T7 A T77L 9533 B SPECIAL SERVICE TOOLS EQUIPMENT Jet Plug Remover T77L t533 ll SPECIAL SERVICE TOOLS REQUIRED T81P 6513 A Too...

Page 104: ...r Description D81L 600 A Lb ln Torque Wrench D81L 600 B Lb Ft Torque Wrench D81L 4201 A Feeler Gauge TOOL 6331 E Main Bearing Insert Tool Engine 3 8L 03 01A 65 ROTUNDA EQUIPMENT Model Description 0 14 00792 Engine Lifting Brackets 3 8L 014 00793 Separator Bar 1997 Thunderbird Cougar July 1996 ...

Page 105: ...h the following single overhead camshafts 6250 OHC twovalves per cylinder Engine Identification It is imperative that the engine codes and the calibration number be used when ordering partsor making inquiriesaboutthe engine IN VEHICLE SERVICE Cont d Oil Bypass FilterIAdapter 03 o1B 61 Oil Level Indicator Tube 03 o1B 81 Oil Pan Oil Pump Screen Cover and Tube 03 o1B 50 Oil Pump 03 o1B 54 Pistons and...

Page 106: ...Calibration Label 49 States I FOIIIIIOtORCOII NIY VEHICLE E111SS10NCONrROLINFORMA110N _ _Willi _____ IIUICK_ _ __TIC __ AI L WIIII AT _IIAL ____ ___ TIII WITII TIC CCIIfTIICIL 1 _ _10u PA Ll _ _AM ICMUTOI A ocvl CATALYST 1 1 11CIHOal l_ A14873 D 1 Can be purchased as a separate item Emission Calibration Label California FOIIIIIOTOIICOII NIY I VEtiCLEEMISSIONeotmiOLIIFORIIA110N vaa a WRMILIC I IIOI...

Page 107: ...ive steel backed over plated aluminum crankshaft main bearings 6333 connects with the camshafts 6250 by two sprockets and two timing chains The crankshaft thrust main bearing 6337 and crankshaft thrust washer 6334 limits crankshaft end playand absorbs thrust loads applied to the crankshaft ends Camshaft The camshafts 6250 are individually chain driven There is an automatic hydraulic timing chain t...

Page 108: ...Oil entersthe main oil gallery where it is distributed to the crankshaft main journals and to both cylinder heads 6049 Part Item Number 9 10 1 1 12 6714 13 9278 14 6881 15 16 17 6600 18 19 METERED OILTRAVELS THROUGH VALVE TAPPET AND ROCKER ARM AND IS SPLASHED ONTO CAM LOBE ROLLER BEARINGS IN ROLLER FOLLOWER ANDVALVETIP VALVESTEM IS LUBRICATED BY METERED LEAKAGE PAST LIP OFVALVESTEM SEAL A14937 D D...

Page 109: ...rotor is piloted on the crankshaft post and is driven through flats on the crankshaft System pressure is limited by an integral internally vented relief valve which directs the bypass oil back to the inlet side of the oil pump Oil pump displacement has been selected to provide adequate volume to ensure proper oil pressure both at hot idle and maximum speed Relief valvecalibration protects the syst...

Page 110: ... the same type as originally installed Engines are equipped with an automatic drive belt tensioner 68209 that will not require any drive belt tension adjustment for the life of the drive belt A loose drivebeltwill result in slippage which may cause a noise complaint or improper accessory operation Part Item Number Description 7 6881 Oil FilterAdapter 8 8260 Upper RadiatorHose 9 8005 Radiator 10 85...

Page 111: ...03 018 7 IN VEHICLE SERVICE Engine Components Disassembled View Engine 4 6L 2V 03 018 7 A24843 A 1997 Thunderbird Cougar July 1996 ...

Page 112: ... U ID 1 c 1 c ID a 0 0 c fC c c i c ii Ill CD a c r i Q i 0 0 I c CD S A24844 A z I m t 0 r m f m u 0 m c CD Q n m I ca j c r 1 P 00 ...

Page 113: ...03 018 9 Engine 4 6L 2V 03 G1B 9 IN VEHICLE SERVICE Continued Disassembled View Continued 1997 Thunderbird CougarJuly 1996 ...

Page 114: ...ture 4 9E936 Throttle Body Gasket Sensor 5 9A589 Throttle Body Adapter 6 N806154 Bolt 5 Req d 7 90476 EGR Valve Gasket 16 8575 WaterThermostat 17 9424 Intake Manifold 18 9439 Intake Manifold Gasket 2 Req d 8 90475 EGR Valve 19 6010 Cylinder Blocks 9 90477 EGRValveto Exhaust Manifold Tube 20 6345 Crankshaft Main Bearing Cap Stud 10 Req d 10 9L437 Intake Manifold Water Connection Gasket 21 6C070 Tor...

Page 115: ...Hose 83 274161 Bolt 2 Req d 42 N808801 Stud Bolt 84 18198A Engine Lifting Eye 43 9J434 EGA Backpressure 85 9430 Exhaust Manifold RH Transducer 86 9448 Exhaust Manifold Gasket RH 44 N807959 Bolt 87 6049 Cylinder Head RH 45 N805320 Nut 88 N806139 Bolt 46 6051 Head Gasket LH 89 N806164 Washer 47 6505 Exhaust Valve 8 Req d 90 6256 Camshaft Sprocket 48 6507 IntakeValve 8 Req d 91 6265 Camshaft Sprocket...

Page 116: ...007 Dowel 129 N806155 Bolt 2 Req d 169 N87836 Dowel 2 Req d 130 6345 Crankshaft Main Bearing 170 N806435 Pipe Plug CapStud 9 Req d 171 6K301 Crankshaft Rear Oil Seal and 131 6C360 Crankshaft Main Bearing Retainer Cap Adjusting Screw 10 Req d 132 6333 Crankshaft Main Bearing 4 Req d 172 N806155 Bolt 173 6701 Crankshaft Rear Oil Seal 174 6310 Crankshaft Oil Slinger 133 N806201 Woodruff Key 175 6375 ...

Page 117: ...ly applied sealant from the sealing surfaces Clean all sealing surfaces with Metal Surface Cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE MSB392 A Sealing surfaces must be clean and dry before applying sealant NOTE Install valve covers and retainers no more than four minutes after applying sealer Apply Silicone Gasket and Sealer F6AZ 1 9562 AA or equivalent meeting Ford specif...

Page 118: ...ainers no more than four minutes after applying sealer Apply Silicone Gasket and Sealer F6AZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 in both places where engine front cover meets cylinder head 4 Install valve cover gaskets valve covers bolts and studs bolts Tighten stud bolts and bolts to 8 1 2 N m 7 1 106 lb in no later than four minutes after applying sealer 5 Install ign...

Page 119: ...linder heads 6049 3 Clean and inspect valve tappetsas described in Section 03 0Q Installation 1 Apply clean engine oil to valve stem and tip rocker arm roller contact surfaces and valve tappets and cylinder head valvetappet bore 2 NOTE Valve tappets must have no more than 1 5 mm 0 059 inch of plunger travel prior to installation Install valvetappets into cylinder heads 3 Install rocker arms as des...

Page 120: ...OTE Piston must be at top dead center TDC of cylinder being serviced Remove air pressure from spark plug adapter Inspect the valve stem for damage Rotate the valve and check the valve stem tip for eccentric movement during rotation Move the valve up and down through normal travel in the valve guide and check the stem for binds 2 CAUTION If the valve has been damaged It will be necessary to remove ...

Page 121: ...6303 5 Install Crankshaft Damper Remover T58P 6316 D on crankshaft pulley 6312 and pull crankshaft pulleyfrom crankshaft A13668 B 6 Using FrontCoverSeal RemoverT74P 670Q A remove crankshaft front seal 6700 Installation 1 Lubricate seal bore in engine front cover 6019 and seal lip with clean engine oil 2 Using Crankshaft Seal Replacer Cover Aligner TBBT 6701 A install crankshaftfront seal CRANKSHAF...

Page 122: ...ill not come all the way out Remove bolts retaining power steering pump to cylinder blocks 6010 and engine front cover 7 Wire power steering pump out ofway 8 Remove oil pan and oil pan gasket as described 9 Remove crankshaft pulley bolt 6A340 and crankshaft pulley retaining washer 6378 from crankshaft 6303 10 Install Crankshaft Damper Remover TSSP 6316 0 on crankshaft pulley 631 2 and pull cranksh...

Page 123: ...t seal 6700 and engine front cover gasket threeeach Part Item Number Description 3 N806300 Stud Bolt 5 Req d 4 6019 Engine Front Cover 3 NOTE Prior toapplying sealer clean sealing surfaces with Metal Surface Cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B392 A to remove all residuesthat may interferewith the sealer s ability to adhere NOTE Install engine front cover and ret...

Page 124: ...enginefront cover on engine no morethan four minutes after applying sealant Item 5 6 7 8 VIEW B TYPICAL TWO PLACES A25166 A Part Number Description 12A227 CrankshaftPositionSensor Pulse Wheel 60081 EngineFrontCoverGasket 6010 Cylinder Blocks 6710 Oil Pan Gasket 5 Install studs and bolts retaining engine front cover to engine in location as shown in illustration lighten to 2Q 30 N m 15 22 lb ft in ...

Page 125: ... coil bracket and ignition wires as an assembly Tighten nuts to 2Q 30 N m 15 22 1b ft 8 Install LH ignition coil bracket Tighten nuts to 2Q 30 N m 15 22 1b ft 9 Install LH ignition coil and ignition wires as an assembly 2 Part Item Number Description 3 N806300 Stud Bolt 5 Req d 4 6019 Engine Front Cover 10 Position and install powersteering oil reservoir 1 1 Connect fuel charging wiring to both ig...

Page 126: ... four retaining bolts Tighten to 2D 30 N m 15 22 1b ft 20 Lower vehicle 2 1 Install water pump pulley withfourbolts Tighten to 2Q 30 N m 15 22 1b ft 22 Install drive belt Refer to Section 03 05 23 Install cooling fan motor fan blade and fanshroud assembly Refer to Section 03 03 24 Start engineand check for leaks Camshaft Timing Chains and Tensioners SPECIAL SERVICE TOOL S REQUIRED Description Tool...

Page 127: ...r 10 Remove LH timing chain tensioner arm 1 1 Remove twobolts retaining LH timingchain guide to cylinder head and removetiming chain guide 1 2 Remove LH timing chain from camshaft sprocket and crankshaft sprocket 13 If necessary removecamshaft sprockets and crankshaft sprockets as described 14 CAUTION Do not rotate crankshaft and or camshafts Engine damage may occur Inspect the plastic running fac...

Page 128: ...procket installation NOTE Make suretapered part of crankshaft sprocketfacesaway from cylinder blocks 6010 If removed install LH crankshaft sprocket frviEW A CORRECT INCORRECT INCORRECT INSTALLATION 7 NOTE If copper links of timing chain are not visible split both timing chains in half and mark the two opposing links as shown Install LH timing chain on camshaft sprocket Make sure copper link of tim...

Page 129: ...t surfaces with clean engine oil and install RH and LH timing chain tensioner arms on their dowels FRONT OF ENGINE Part Item Number 1 6049 2 6049 3 N806040 S 4 6L253 5 6L266 6 N606543 S2 7 8 6L266 9 6L253 A NOTE DO NOT REMOVE TENSIONER LOCK PINS UNTIL CHAIN GUIDES HAVE BEEN INSTALLED NOTE LUBRICATE TENSIONER ARM CONTACTSURFACES WITH ENGINE OIL PRIOR TO ASSY A14822 C Description Cylinder Head RH Cy...

Page 130: ... 6256 A Removal 1 Remove camshaft timing chains and timing chain tensioners 6L266 as described 2 Remove crankshaft sprockets 6306 from crankshaft 6303 3 NOTE Cam Positioning Tool Adapters T92P 6256 A and Cam Positioning Tool T91P 6256 A must be installed on camshafts 6250 to prevent camshafts from rotating Remove camshaft sprocket retaining bolts washers camshaft sprockets 6256 and camshaft sprock...

Page 131: ...d remove from vehicle as an assembly with the ignition wires 13 Remove three nuts retaining LH ignition coil bracket to engine front coverand remove 14 Remove water pump pulley 8509 15 Remove positive crankcaseventilation valve PCV valve 6A666 from valve cover 6582 and position outofthe way 16 Disconnectfuel charging wiring at the 42 pin engine harness connector and 8 pin connector leading to the ...

Page 132: ...LER RH SIDE SIMILAR Part Item Number Description 1 6582 Valve Cover RH AA0636 A 2 6584 Valve Cover Gasket Continued Part Item Number Description 3 N806356 S309 Stud LH 4 Req d RH 2 Req d 4 6766 Oil FillerCap 5 N806183 S309 Bolt LH 7 Req d RH 9 Req d 6 6582 ValveCover LH 7 6049 Cylinder Head LH 8 N807441 Stud Bolt A Tighten to 8 12 N m 71 106 Lb ln 32 Remove engine front cover as described 1997 Thu...

Page 133: ... rotating camshafts 6250 or damage to pistons and or valve train will result Rotate crankshaft counterclockwise 45 degrees from toe CRANKSHAFT KEYWAY A13655 B Part Item Number Description 3 N806300 Stud Bolt 5 Req d 4 6019 Engine Front Cover 35 NOTE This ensures that all pistons 6108 are below the top of the cylinder block deck face Install Valve Spring Compressor T91P 6565 A under camshaft and on...

Page 134: ...6B280 4 6250 5 6564 6 6500 7 6049 8 N806070 A NOTE VALVETAPPETMUST BE PUMPED UP BEFORE INSTALLATION NOTE LH SHOWN RH SIMILAR Description A14818 C FrontCamshaft Bearing Cap Bolt 2 Req d RearCamshaft Bearing Cap Camshaft LH RockerArm 8 Req d Valve Tappet 8 Req d CylinderHead LH Bolt 12 Req d Tighten to 8 12 N m 71 106 Lb ln 4 1 If both camshafts are being serviced repeat Steps 35 through 40 to remov...

Page 135: ...stalled Install Valve Spring Compressor T91P 6565 A undercamshaftand on top of valve spring retainer Install valve tappet 6500 10 Compress valve spring far enough to install rocker arm 1 1 Repeat Steps 8 through 10 until all rockerarms are installed RemoveValveSpring Spacerfrom valve spring 12 CAUTION Crankshaft must only be rotated in the clockwise direction and only as far as top dead center TDC...

Page 136: ...ption 6019 Engine Front Cover 6049 CylinderHead N806040 S Dowel 2 Req d 6303 Crankshaft Continued Engine 4 6L 2V Item 5 6 7 8 03 018 32 VIEW B TYPICALTWO PLACES A25166 A Part Number Description 12A227 Crankshaft Position Sensor Pulse Wheel 6020 Engine FrontCoverGasket 6010 Cylinder Blocks 6710 Oil Pan Gasket 1997 Thunderbird Cougar July 1996 ...

Page 137: ...aling surfaces with Metal Surface Cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M58392 A to remove all residues that may interfere with the sealer s ability to adhere NOTE Install valve covers and retainers no more than four minutes after applying sealer Apply SiliconeGasketand Sealant FBAZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 at both places engine ...

Page 138: ...Stud Bolt A Tighten to 8 12 N m 71 106 Lb ln 2 1 Raise vehicle 22 Connect the fuel charging wiring to the electronic variable orifice sensor and oil pressure sensor 23 NOTE Prior to applying sealer clean sealing surfaces with Metal Surface Cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B392 A to removeall residuesthat may interfere with the sealer s ability to adhere Apply S...

Page 139: ...Refer to Section 1o o1 45 Install cooling fan motor fan blade and fan shroud assembly Fill cooling system Referto Section 03 Q3 46 Install air cleaner outlet tube Refer to Section 03 12 47 Connect battery ground cable 48 Start engine and check forleaks 49 Check and add oil as needed Cylinder Heads SPECIAL SERVICE TOOL S REQUIRED Description Tool Number Crankshaft Damper Remover T58P 6316 D Cranksh...

Page 140: ...tall Crankshaft Damper Remover T58P 6316 D on crankshaft pulley 6312 and pull crankshaft pulley from crankshaft A13668 B 30 Disconnect the fuel charging wiring from the electronicvariable orifice sensor and oil pressure sensor 9278 31 Positionfuelcharging wiring out of the way 32 Disconnect EGR valve to exhaust manifold tube 9D477 from RH exhaust manifold 9430 33 Disconnect three way catalytjc con...

Page 141: ...onnection 3 N81 101 1 S309 Bolt 2 Req d Continued 46 Remove intake manifold gaskets 9461 Engine 4 6L 2V Part Item Number 4 9424 5 6049 6 6049 03 018 37 FRONT OF ENGINE A24999 A Description Intake Manifold CylinderHead LH Cylinder Head RH 47 Removeeightstud bolts and seven bolts retaining enginefrontcover to engine Removeengine front cover 1997 Thunderbird Cougar July 1996 ...

Page 142: ...e to interference with the power brake booster 2005 Use a rubber band or similar item to hold bolt awayfrom cylinder blocks as shown in the following illustration Remove 10 bolts retaining LH cylinder head to cylinder blocks Part Item Number Description 3 N806300 Stud Bolt 5 Req d 4 6019 Engine Front Cover A1383 a 50 NOTE Cylinder head mustnot be set on head face If valves are open damage may occu...

Page 143: ...aced or serviced refer to Cylinder Head Disassembly and Assembly in this Section Installation 1 Clean cylinder head intake manifold valve cover and cylinder block sealing surfaces as described under Disassembly and Assembly lf necessary check cylinder head and cylinder block flatness Referto Section 03 00 2 NOTE This step makes sure that all pistons 6108 are below top of cylinder block deck face R...

Page 144: ...uence 85 95 degrees c Loosen head bolts a minimum of one full turn 360 degrees d Retighten head bolts in sequence to 37 43 N m 28 31 lb ft e Rotate head bolts in sequence 85 95 degrees f Rotate head bolts in sequence an additional 85 95 degrees 15 Position heater water hose on cylinder head and install two bolts Tighten retaining bolts to 2Q 30 N m 15 22 1b ft 16 Rotate camshafts 6250 usingflats m...

Page 145: ...ption 6019 Engine Front Cover 6049 Cylinder Head N806040 S Dowel 2 Req d 6303 Crankshaft Continued Engine 4 6L 2V Item 5 6 7 8 03 018 41 VIEW B TYPICAL TWO PLACES A25166 A Part Number Description 12A227 CrankshaftPosition Sensor Pulse Wheel 60081 EngineFrontCoverGasket 6010 Cylinder Blocks 6710 Oil Pan Gasket 1997 Thunderbird Cougar July 1996 ...

Page 146: ...Replace intake manifold as required NOTE Make sure alignment tabs on intake manifoldgaskets are aligned with holes in cylinder heads Position new intake manifold gaskets on cylinder heads 2 Part Item Number Description 3 N806300 Stud Bolt 5 Req d 4 6019 Engine Front Cover 24 Position intake manifold on cylinder heads 25 Install and tighten intake manifold retaining bolts one through nine in sequen...

Page 147: ...rHose Connection 3 N81 101 1 S309 Bolt 2 Req d 4 9424 Intake Manifold Continued 27 Connect heater water hose 28 Connectfuel charging wiring to heated oxygen sensors FRONT OF ENGINE A24301 A Part Item Number Description 5 6049 CylinderHead LH 6 6049 CylinderHead RH A Tighten to 20 30 N m 15 22 Lb Ft 29 Connectvacuum hose to throttle body adapter vacuum port 1997 Thunderbird Cougar July 1996 ...

Page 148: ...ts into RH valve cover lighten all boltsand stud bolts to 8 12 N m 7 1 106 1b in 33 Install boltsand stud bolts into LH valve cover lighten all bolts and stud bolts to 8 12 N m 71 106 1b in FRONT OF ENGINE APPL SILICONE LH SIDE SHOWN GASKET SEALER RH SIDE SIMILAR AA0636 A Part Item Number Description 1 6582 Valve Cover RH 2 6584 Valve Cover Gasket 3 N806356 S Stud LH 4 Req d RH 2 Req d 4 6766 Oil ...

Page 149: ...tall oil pan with new oil pan gasket as described 46 Position powersteering pump on engine and installfour retaining bolts Tightento 2Q 30 N m 15 22 1b ft 47 Lower vehicle 48 Connectfuel charging wiring to the A C clutch crankshaft positionsensorand evaporative emission canister purge valve 49 Position and connect 42 pin engine harness connector and 8 pin connector 50 Position A C line and install...

Page 150: ...system Refer to Section 03 Q3 7 Check tor leaks Intake Manifold Removal 1 Disconnect battery ground cable 14301 Refer to Section 14 Q1 2 Drain engine cooling system 3 Relieve fuel system pressureand disconnect fuel lines Refer to Section 10 Q1 4 Remove air cleaner outlet tube 98659 Refer to Section 03 12 5 Release drive belt tensioner 68209 and remove drive belt 8620 Refer to Section 03 Q5 6 CAUTI...

Page 151: ...y Intake Manifold e 22 Remove the remaining nine bolts retaining intake manifold to cylinder heads 6049 and remove intake manifold I I FRONTOF ENGINE 0REFERTO LEGEND eREMOVE BOLTS IN SEQUENCE A24999 A Part Part Item Number Description Item Number Description 1 N808130 S309 Bolt 8 Req d 4 9424 Intake Manifold 2 8592 WaterHose Connection 5 6049 CylinderHead LH 3 N81 101 1 S309 Bolt 2 Req d 6 6049 Cy...

Page 152: ...iption 1 N808130 S309 Bolt 8 Req d 2 8592 Water Hose Connection 3 N81 101 1 S309 Bolt 2 Req d Continued 4 NOTE Make sure alignmenttabs on intake manifold gasket are aligned with holes in cylinder heads Install and tighten intake manifold retaining bolts one through nine in sequence shown to 2Q 30 N m 15 22 1b ft 5 Replace D ring seal on water hose connection Position water hose connection and uppe...

Page 153: ...Connect ignition wire separators on valve cover studs 19 Connect the fuel charging wiring to both ignition coils and camshaft position sensor 20 Install drive belt Refer toSection 03 Q5 21 Install air cleaner outlet tube Refer to Section 03 12 22 Connectfuel lines Refer to Section 10 Q1 23 Connect battery ground cable 24 Fill and bleed engine cooling system Refer to Section 03 Q3 25 Check and fill...

Page 154: ... and connect EGR valve to exhaust manifold tube to exhaust manifold Tighten line nut to 35 45 N m 26 33 1b ft 7 NOTE Two through bolts required on LH front engine support insulator 6038 and one through bolt required on RH front engine support insulator NOTE Makesure exhaust system clears No 3 crossmember Adjust as necessary Remove wire and position three way catalytic converter Install four nuts a...

Page 155: ... front engine support insulator and one through bolt required for RH front engine support insulator Remove front engine support insulator through bolts 20 Remove EGR valve to manifold tube nut from RH exhaust manifold 9430 and remove EGR valve to exhaust manifold tube 2 1 Disconnect threeway catalytic converter TWCX5E21 2 from RH and LH exhaust manifolds Refer to Section 09 00 22 Lowerexhaustand s...

Page 156: ...uired 2 Clean sealing surfaces of engine front cover 6019 crankshaft rear oil seal and retainer 6K301 and cylinder blocks 6010 3 Inspect oil pump screen coverandtubeand replace if necessary 4 If removed position oil pump screencoverand tube on oil pump and hand starttwo bolts 5 Install bolt retainingoilpumpscreen cover and tube to main bearing stud spacer hand tight 6 Tighten oil pump screen cover...

Page 157: ...f wood under oil pan rearward of oil pan drain hole 10 Raiseengine enough to remove wood blocks WOODEN BLOCKS A13647 B 1 1 Lower engine onto fro engine support insulator and removejack 12 NOTE Two through bolts required on LH front engine support insulator and one through bolt required on RH front engine support insulator Install front engine support insulator through bolts and tighten to 2Q 30 N ...

Page 158: ... Install upper radiator hose 28 Connectfuel lines Refer to Section 10 Q 1 29 Install windshield wiper governor and retaining bracket Refer to Section 01 16 30 Fill crankcase to specified level on oil level dipstick 6750 with engine oil meeting Ford specification WS8 M2C153 F 31 Evacuate and recharge air conditioning Refer to Section 12 oo 32 Install cooling fan motor fan bladeand fan shroud assemb...

Page 159: ... Assembly Remove oil pan 6675 and oil pan gasket 67 10 as described Part FRONT OF ENGINE A13653 B Item Number Description 1 W701240 S309 Bolt 16 Req d 2 6730 Oil Pan Drain Plug 3 6675 Oil Pan 4 6710 OilPanGasket 5 6010 Cylinder Blocks A Tighten to 20 N m 15 Lb Ft B Tighten to 1 1 16 N m 9 1 1 Lb Ft 5 Remove oil pump andoil pump screen cover and tube 6622 Part Item Number 1 N806180 S 2 N605904 S 3 ...

Page 160: ...connecting rod together DRIVE BOLTS OUT USING HAMMER AND PUNCH SUPPORT BEARING CAP WHILE REMOVING BOLTS A15051 B 8 Using a new connecting rod bolt attach capand lower connecting rod bearing to connecting rod and upper bearing to prevent mixing parts and damaging the fractured jointface surfaces 9 Clean and inspect piston connecting rod connecting rod bearings and cylinder block bores as described ...

Page 161: ...e using Dial Indicator with Bracketry TOOL 4201 c or equivalent Clearanceshould be 0 15 Q 45 mm 0 006 Q O177 inch If side clearance is greater than maximum service limit of 0 50 mm 0 020 inch replace connecting rods andIor crankshaft DIAL INDICATOR WITH BRACKETRY TOOL 4201 C 5 NOTE Install new 0 ring on oil pump screen coverand tube and then start all bolts on oil pump 6600 and oil pump screen cov...

Page 162: ...TE RH and LH head gaskets are not interchangeable Position new head gaskets on cylinder head 10 CAUTION Failure to position crankshaftas shown will cause damage to pistons and or valve train components NOTE With crankshaft in this position no piston will be at top dead center TDC Rotate crankshaft to position as shown CRANKSHAFT KEYWAY A13655 B 1 1 CAUTION Use care when positioning cylinder heads ...

Page 163: ...g rod bearing with notch in connecting rod 4 NOTE Due to the use ofa cracked connecting rodjointfacesurface the connecting rod cap must be properly aligned to the connecting rod The connecting rod and connecting rod cap bearing tangsshould be located on the same side ofthe connecting rod Install lower connecting rod bearings in the connecting rodcap s Align retaining tang of connecting rodbearingw...

Page 164: ...EH and Slide Hammer T50T 10Q A 5 If required remove crankshaft rear oil seal retainer 6335 Installation 1 Clean and inspect crankshaft rear oil seal retainer and retainer to cylinder block mating surfaces 2 NOTE Priorto applying sealer clean sealing surfaces with Metal Surface Cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B392 A to remove all residues that may interfere wit...

Page 165: ...d inspect the sealing surfaces of the oil filter adapter gasket and cylinder blocks 6010 Installation 1 If only the oil bypass filter was removed go to Step 2 If removal of the oil filter adapter was required proceed with the following a Install new oil filter adapter gasket oil filter adapter and retaining bolts Tighten bolts to 2Q 30 N m 15 22 1b ft b Install the lower radiator hoseonto the oil ...

Page 166: ...QUIRED Description ToolNumber Spring Lock Coupling Disconnect Tool T81P 19623 G1 3 S inch Spring Lock Coupling DisconnectTool T81P 19623 G2 112 1nch Removal 1 Disconnect battery ground cable 14301 Refer to Section 14 Q1 2 Drain engine cooling system Referto Section 03 Q3 3 Remove air cleaner outlet tube 98659 and engine air cleaner ACLX9600 Refer to Section 03 12 4 Recover air conditioning system ...

Page 167: ...entering socketyoke 4782 to rear axle universal joint flange 4851 28 Remove four bolts connecting driveshaft centering socket yoke to rear axle universal joint flange Support rearaxle assembly 4200 with jackstand 29 Remove two nut and boltassemblies retaining the front of the rearaxleassembly to the rear sub frame 30 Loosen rear differential bracket to body bolts and lower 31 Slide driveshaft 4A37...

Page 168: ...from cylinder blocks to gain access to torque converter retaining nuts Rotate crankshaft 6303 until each nut four required is accessible and remove nuts 50 Lower engine and transmission assembly to a level stationary surface 51 Disconnect transmission wire harness connectors at transmission 52 Remove six bolts retaining transmission to engine Separate engine from transmission 53 Position engine on...

Page 169: ...e universal joint flange and install four retaining bolts lighten to 95 130 N m 7Q 95 lb ft 29 Connect transmission shift linkage Referto Section 07 Q1 30 Position front suspension lower arms to front spring and shock and install retaining bolt lighten to 16Q 220 N m 1 18 162 1b ft 31 Install lower radiator hose 32 Connect power steering hoses to power steering oil cooler Refer to Section 1 1 Q2 3...

Page 170: ...wires as described in Section 03 Q78 2 Remove six flywheel retaining bolts and remove flywheel 6375 from crankshaft 3 Remove accessory drive belt 8620 Refer to Section 03 Q5 4 Remove water pump pulley 8509 5 Remove drive belt idler pulley 8679 and drive belttensioner 68209 with ignition coils 12029 6 Remove oil bypass filter 6714 as described NOTE LUBRICATE SEAL WITH CLEAN ENGINE OIL MEETING FORD ...

Page 171: ...N806155 S2 5 N806155 S2 A Continued I FRONT OF ENGINE 00 A24307 A Description Crankshaft Position Sensor Bolt 4 Req d Camshaft Position Sensor Bolt Bolt Tightento 20 N m 14 Lb Ft Then an Additional 60 Degrees Part Item Number Description B Tightento 8 12 N m 71 106 Lb ln 12 Remove oil pan 6675 and oil pan gasket 6710 Part Item Number 1 W701240 S309 2 6730 3 6675 4 6710 5 6010 A B FRONT OF ENGINE D...

Page 172: ...7 Bolt 7 Req d Continued 14 NOTE This will position all pistons 6108 below top of cylinder block deck face Position crankshaft on TDC No 1 CRANKSHAFT KEYWAY A13658 B Part Item Number Description 3 N806300 Stud Bolt 5 Req d 4 6019 Engine Front Cover 15 Remove timing chains as described 16 Remove camshafts 6250 as described 1997 Thunderbird Cougar July 1996 ...

Page 173: ...scription 1 6010 Cylinder Blocks 2 6303 Crankshaft 3 6335 Crankshaft Rear Oil Seal Retainer 4 6701 Crankshaft Rear Oil Seal 5 N806155 2 Bolt 6 Req d 6 6310 CrankshaftOil Slinger A Tighten to 8 12 N m 71 106 Lb ln 19 NOTE Connecting rods 6200 connecting rod caps and connecting rod bearings 621 1 should be numbered to make sure they are assembled in their original positions Turn crankshaft until con...

Page 174: ...ain bearing caps and the crankshaft main bearings 6333 should be identified When the engine is assembled crankshaft main bearings which are to be reused should be installed in their original positions Remove each main bearing cap and lower crankshaft main bearing and crankshaft thrust main bearing 6337 Keepeach cap lower crankshaft main bearings and crankshaft thrust main bearing together A13637 D...

Page 175: ...te and install upper crankshaft thrust washer by rolling the crankshaft thrust washer onto machined shelf between rear side of No 5 bulkhead and thrust surfaceof crankshaft Make sure coated side of crankshaftthrust washer with three 5 mm wide oil groovesfacesthe crankshaft thrust surface Item 1 2 3 4 5 6 7 8 9 10 1 1 03 018 71 A13637 D Part Number Description 6C360 Crankshaft Main Bearing Cap Adju...

Page 176: ... cap rearward and position the lowercrankshaft thrust main bearing rearfaceproperly against the thrust faceof the crankshaft 7 CAUTION Main bearing bolts must be replaced with new bolts They are torque to yield designed and cannot be reused Tighten new main bearing cap bolts one through ten in twosteps as follows a Tighten bolts in sequence to 37 43 N m 28 31 lb ft b Rotate bolts in sequence an ad...

Page 177: ... 106 1b in 13 Using RearCrankshaft Seal Adapter T95P 670 1 DH and Rear Crankshaft Seal Replacer T95P 6701 BH install crankshaft rear oil seal 6701 if removed REAR CRANKSHAFT SEAL ADAPTER T95P 6701 DH CRANKSHAFT REAR MAIN SEAL 6701 REAR CRANKSHAFT SEAL REPLACER T95P 6701 BH AA0243 A 14 Using RearCrankshaft Slinger Replacer T95P 6701 CH replace crankshaft oil slinger 6310 if removed 15 Tum crankshaf...

Page 178: ...NOTE Install new 0 ring on oil pump screen cover and tube and start all bolts on oil pump and oil pumpscreen cover and tube before tightening Install oil pumpand oil pump screen cover and tube Item 1 2 3 4 5 6 7 8 9 A B Part Number N806180 S N605904 S 6622 6K258 6010 N806183 S2 6600 3Z728 N806155 S2 03 018 74 FRONT OF ENGINE Description Stud Spacer Bolt A24303 A Oil Pump Screen Cover and Tube Cran...

Page 179: ...osition as shown CRANKSHAFT KEYWAY A13655 B 20 CAUTION Crankshaft must only be rotated in theclockwise direction and only as far as top dead center TDC No 1 Rotate crankshaft clockwise 45 degrees This will position crankshaft attopdead center TDC No 1 A13858 B 2 1 Install camshafts as described 22 Install timing chains as described 23 Replace crankshaft front seal 6700 in engine front cover if req...

Page 180: ...mber Description 6019 Engine Front Cover 6049 Cylinder Head N806040 S Dowel 2 Req d 6303 Crankshaft Continued Item 5 6 7 8 03 018 76 VIEW B TYPICAL TWO PLACES A25166 A Part Number Description 12A227 CrankshaftPosition Sensor Pulse Wheel 60081 Engine FrontCoverGasket 6010 Cylinder Blocks 6710 OilPan Gasket 1997 Thunderbird Cougar July 1996 ...

Page 181: ...Item Number Description 1 N808586 Stud Bolt 3 Req d 2 N806177 Bolt 7 Req d Continued 25 Install crankshaft positionsensorand camshaft position sensors into engine front cover and tighten retaining bolts to 8 12 N m 71 106 lb in Item 3 4 03 018 77 2 Part Number Description N806300 Stud Bolt 5 Req d 6019 Engine Front Cover 1997 Thunderbird Cougar July 1996 ...

Page 182: ... to 20 N m 14 Lb Ft Then Rotate Bolt an Additional 60 Degrees Tighten to 8 12 N m 71 106 Lb ln 27 Install oil pan with new oil pan gasket as described Tighten bolts to 25 35 N m 19 25 lb ft in no more than four minutes after applying sealer Item 1 2 3 4 5 A B Part Number W701240 S309 6730 6675 6710 6010 FRONT OF ENGINE Description Bolt 16 Req d Oil PanDrainPlug Oil Pan Oil Pan Gasket Cylinder Bloc...

Page 183: ...6 B CRANKSHAFT DAMPER REPLACER T74P 6316 B 29 Install crankshaft pulley bolt and crankshaft pulley retaining washer Tighten in four steps a Tighten to 90 N m 67 1b ft b Loosen one full turn c Tighten to 50 N m 37 lb ft d Tighten an additional 90 degrees 30 Install RH and LH valvecovergaskets 6584 Tighten studsand boltsto 8 12 N m 7 1 106 Ib in Item 1 2 3 4 5 6 7 8 A 03 01 8 79 FRONT OF ENGINE LH S...

Page 184: ...Fit crankshaft main bearings as described in Section 03 QO 2 Install upper crankshaft main bearing and crankshaft thrust washer into cylinder blocks Install lower crankshaft main bearings and crankshaft thrust main bearing into main bearing caps 3 Install crankshaft as described 4 Install engine into vehicle as described DISASSEMBLY AND ASSEMBLY Engine SPECIAL SERVICE TOOL S REQUIRED Description T...

Page 185: ...10 To 14290 Harness Part of 90930 4 To EGR Backpressure Transducer Part of90930 1 1 To Camshaft Position CMP Sensor Part of90930 5 To LH H02S Part of 90930 12 To LH Ignition Coil Part of 90930 6 To Fuel Injectors 8 Places Part of90930 13 To LH Radio Ignition Interference Capacitor Part 7 To 14290 Harness Part of of 90930 90930 14 To Crankshaft Position 8 To Electronic Variable CKP Sensor Partof Or...

Page 186: ... belt tensioner 68209 with ignition coils 9 Remove RH and LH exhaust manifolds 9430 10 Remove oil bypassfilter 6714 and oil filter adapter 6881 Part Item Number Description 20 To Generator Part of 90930 21 To Engine Coolant Temperature ECT Sensor Part of90930 22 To Fuel Injection Supply ManifoldGround Part of 90930 23 To Idle Air Control lAC Valve Part of90930 24 To Throttle Position TP Sensor Par...

Page 187: ...on 6582 Valve Cover RH 6584 Valve CoverGasket N806356 S2 Stud LH 4 Req d RH 2 Req d 6766 Oil Filler Cap N806183 S2 Bolt LH 7 Req d RH 9 Req d 6582 Valve Cover LH Continued Part Item Number Description 7 6049 Cylinder Head LH 8 N807441 Stud Bolt A Tighten to 8 12 N m 71 106 Lb ln 15 Remove crankshaft pulley bolt 6A340 and crankshaft pulley retaining washer 6378 16 Using Crankshaft Damper Remover T5...

Page 188: ...B Tightento 20N m 14 Lb Ft Then Rotatean Additional 60 Degrees Tighten to 1 1 16 N m 9 11 Lb Ft 19 Remove EGR backpressure transducer bracket and heater water hose 18472 from rear of RH cylinder head 20 Remove water pump 8501 NOTE LUBRICATE 0 RING WITH CLEAN ANTIFREEZE Item 1 2 3 4 5 6 7 8 A FRONT OF ENGINE Part Number 6049 18472 N807381 6010 N806177 8309 8501 3Z728 A24309 A Description CylinderHe...

Page 189: ...t at top dead center TDC of No 1 cylinder A13658 B 23 Remove timing chains as described 24 Rotate crankshaft counterclockwise 45 degrees Item 3 4 Part Number N806300 6019 CRANKSHAFT KEYWAY Description Stud Bolt 5 Req d Engine Front Cover A13855 B 25 Remove RH and LH cylinder heads Discard all head bolts 26 Remove and discard head gaskets 6051 27 If cylinder heads are to be serviced refer to Subass...

Page 190: ...n to8 12 N m 71 106 Lb ln 30 NOTE Pistons connecting rods 6200 and connecting rod bearings 621 1 should be numbered to make sure they are assembled in their original positions NOTE Before removing pistons inspect thetop ofthe cylinder bores If necessary remove the ridgeandIorcarbon depositsfrom each cylinder using Cylinder Ridge Reamer T64L 601 1 EA or equivalentasdescribed in Section 03 00 Turn c...

Page 191: ...g rods and connecting rod bearings together in proper cylinder order Using Piston Pin Tool D81L 6135 A or equivalent press piston pin from piston and connecting rod REMOVAL PISTON PIN 6135 RECEIVING TUBE PRESS PLATES A8121 C 36 Remove horizontal main bearing cap side bolts from cylinder blocks 37 loosen crankshaft main bearing cap adjusting screws 6C360 38 Remove bearing main cap retaining bolts T...

Page 192: ...umber Description 4 10 6333 Crankshaft MainCBearing Upper 1 1 N806201 S Woodruff Key NOTE Crankshaft main bearing cap adjusting screws must be bottomed on main bearing cap prior to installation of main bearing cap Install main bearing caps Tap main bearing caps with a brass hammer to seat caps properly NOTE ALL MAIN BEARING CAPS MUST BE TAPPED INTO POSITION PRIOR TO TIGHTENING FAILURE TO DO SO MAY...

Page 193: ...ertwomain bearing cap Checkcrankshaft end play in both directions as shown CRANKSHAFT END PLAY 3 0 130 0 301 mm 0 005 0 010 INCH DIAL INDICATOR WITH BRACKETRY TOOL 4201 C NOTE PRY CRANKSHAFT IN DIRECTION OF ARROWS AND NOTE TOTAL END PLAY A13643 E 1 1 NOTE Prior to applying sealer clean sealing surfaces with Metal Surface Cleaner F4AZ 19A536 RA or equivalent meeting Ford specification WSE M5B392 A ...

Page 194: ...h cylinder wall or crankshaftjournal with connecting rod Push piston down until connecting rod bearing seats on crankshaft FRONT OF ENGINE NOTCHTOWARD IIZY FRONT OF ENGINE AA0633 A Part Item Number Description 1 6214 Connecting Rod Bolt 16 Req d 2 6200 Cap 8 Req d Part of6200 3 621 1 Connecting Rod Bearing Lower 8 Req d 4 6303 Crankshaft 5 621 1 Connecting Rod Bearing Upper 8 Req d 6 6108 Piston 8...

Page 195: ...n oil pump and oil pumpscreen cover and tube before tightening Install oil pump and oil pump screen cover and tube Part Item Number 1 N806180 S 2 N605904 S 3 6622 4 6345 5 6010 6 N806183 S2 7 6600 8 3Z728 9 N806155 S2 A B FRONT ENGINE A24303 A Description Stud Spacer Bolt Oil Pump Screen Coverand Tube Crankshaft Main Bearing Cap Stud Cylinder Blocks Bolt 4 Req d Oil Pump 0 Ring Bolt 2 Req d Tighte...

Page 196: ...age to cylinder blocks and or cylinder heads may result Position cylinder heads on cylinder blocks Use Cam Positioning Tool Adapters T92P 6256 A and Cam Positioning Tool T91 P 6256 A to prevent crankshafts from rotating 24 RH CYLINDER HEAD 6049 CRANKSHAFT KEYWAY LH CYUNDER HEAD 6049 A1365 B CAUTION Cylinder head bolts must be replaced with new bolts They are torque to yield designed and cannot be ...

Page 197: ...r Rotate crankshaft clockwise 45 degrees This will position crankshaft at top deadcenter TDC No 1 cylinder Retainer Locations lillij11111QI1111IIIII 0REFERTO LEGEND 1 A TIGHTEN IN SEQUENCE W SHOWN A13658 B 26 Install timing chains as described 27 Replace crankshaft front seal 6700 in engine frontcover if required 28 Install engine front coveras described 2 1997 Thunderbird Cougar July 1996 ...

Page 198: ...en to 1 1 16 N m 9 1 1 Lb Ft Part Item Number Description 3 N806300 Stud Bolt 5 Req d 4 6019 Engine Front Cover 30 lubricate water pump housing gasket 8507 with Ford Premium Cooling System Fluid E2FZ 19549 AA in Canada Motorcraft exe s B or equivalent meeting Ford specification ESE M97B44 A and install water pump and tighten retaining bolts to 2Q 30 N m 15 22 1b ft 31 Install heaterwater hose NOTE...

Page 199: ...all residues that may interfere with the sealer s ability to adhere NOTE Silicone Gasket and Sealant F6AZ 19562 AA or equivalent meeting Ford specification WSE M4G323 A6 must be applied to crankshaft keyway prior to installing crankshaft pulley Install crankshaft pulley using Crankshaft Damper Replacer T74P 6316 B CRANKSHAFT DAMPER REPLACER T74P 6316 B 34 Install crankshaft pulley bolt and cranksh...

Page 200: ...ads 38 Install intake manifold as described lighten retaining bolts in sequence to 2Q 30 N m 15 22 lb ft 39 NOTE Water outlet connection bolts are also intake manifold retaining bolts Install water outlet connection D ring and water hose connection lighten bolts to 2Q 30 N m 15 22 1b ft 40 Install oil filter adapter and tighten bolts to 2Q 30 N m 15 22 1b ft 41 Install oil bypass filter FRONT OF E...

Page 201: ...ription 1 To 12A581 Harness Part of 90930 2 90930 Fuel Charging Wiring 3 To RH H02S Part of 90930 4 To EGR Backpressure Transducer Part of90930 Continued 49 Install positivecrankcase ventilation valve and frontvapor hose 50 Install flywheel to crankshaft and tighten six bolts to 73 87 N m 56 64 1b ft 5 1 Install fuel charging wiring and connect all applicable wiring connectors A24308 A Part Item N...

Page 202: ...571 A Driver Handle TSOT 4000 W Disassembly 1 NOTE Camshaft 6250 must be at base circle before compressing valve spring 6513 Rotate camshaft as required unt all rocker arms 6564 are removed Install Valve Spring Compressor T91P 6565 A under camshaft and on top of valve spring retainer 6514 2 Install Valve Spring Spacer T91P 6565 AH between valve spring coils Item 17 18 19 20 21 22 23 24 Part Number...

Page 203: ...bearingcapsto gradually lift camshaft bearing capsfrom cylinder head Removecamshaft Part Item Number 1 6B280 2 N807352 3 6B280 4 6250 5 6564 6 6500 7 6049 8 N806070 A Assembly NOTE VALVETAPPET MUST BE PUMPED UP BEFORE INSTALLAOON NOTE LH SHOWN RH SIMILAR Description A14818 C Front Camshaft Bearing Cap Bolt 2 Req d Rear Camshaft Bearing Cap Camshaft Rocker Arm 8 Req d Valve Tappet 8Req d CylinderHe...

Page 204: ...basecircle priorto compressing valve spring Rotate camshaft as necessary until all rocker arms are installed Compress valve spring using Valve Spring Compressor T91 P 6565 A far enough to install rocker arm Pistons and Piston Pins Disassembly 1 Using Piston Pin Tool 081L 6135 A or equivalent press piston pin 6135 through piston 6108 and connecting rod 6200 2 Clean and inspect piston and connecting...

Page 205: ... ofthe check valve disc or ball check 3 Position the check valve retainer over the check valve and spring and push the retainer down into place on the plunger 4 Place the plunger spring and thenthe plunger open end up into the valvetappet body 5 Position the metering valve disc in the plunger and then place the push rod cup in the plunger 6 Depressthe plunger and position the closed end of the loc...

Page 206: ...Valve Head Diameter Intake 44 5 mm 1 752 in Exhaust 34 0 mm 1 339 in Gauge Diameters 42 5 mm and 32 0 mm 1 6732 in and 1 2598 in Continued ENGINE SPECIFICATIONS Cont d Description Specification Valve Face Runout Limit 0 05 mm 0 00197 in ValveFace Angle 45 5 degrees Valve Stem Diameter Std Intake 6 995 6 975 mm 0 2754 0 2746 in Exhaust 6 970 6 949 mm 0 27441 Q 27358 in Valve Springs Compresalon Pre...

Page 207: ...op 1 530 1 550 mm 0 06024 0 061024 in Compression Bottom 1 520 1 540 mm BearingWall Thickness Std 2 444 2 452 mm 0 05984 0 060630 in 0 0962 0 0965 in e Oii Ring 3 030 3 055 mm Main Bearings 0 1 1929 0 12028 in Clearance to Crankshaft Piston Pin Desired 0 027 0 065 mm Length 61 93 62 05 mm 0 00106 0 00256 in 2 43818 2 44291 in Allowable 0 027 0 065 mm Diameter 2 1 994 21 999 mm 0 00106 0 00256 in 0...

Page 208: ...ion Silicone Gasket F6AZ 19562 AA WSE M4G323 A6 and Sealant Gasket and Trim D7AZ 19B508 B ESR M 1 1P17 A Adhesive Metal Surface F4AZ 19A536 RA WSE M5B392 A Cleaner Engine Oil X0 5W30 QSP WSS M2C153 F Premium Cooling E2F2 19549 AA ESE M97B44 A System Fluid Premium Cooling CXC 8 B Canada ESE M97B44 A System Fluid Anaerobic Gasket WSK M2G348 A9 Compound Sealer TORQUE SPECIFICATIONS Description N m Lb...

Page 209: ...18 162 76 93 7Q 95 51 67 2 lighten to 9 1 1 N m 80 97 Lb ln b lighten in 2 steps Lb ln 71 106 71 106 71 106 7 1 106 71 106 1 lighten bolts in sequence to 10 N m 7 Lb Ft 2 lighten bolts in sequence 19 23 N m 14 16 Lb Ft c lighten in 2 steps 1 lighten bolts to 4Q 45 N m 3Q 33 Lb Ft 2 Rotate bolts 9Q 120 degrees d lighten in 6 steps 1 lighten bolts in sequence to 37 43 N m 27 32 Lb Ft 2 Rotate bolts ...

Page 210: ...ng Spacer Tl1P 115115 AH T91P 657 1 A o J Valve Stem Seal Replacer Tt1P e571 A Continued SPECIAL SERVICE TOOLS REQUIRED Cont d ToolNumberI Description Illustration T92P 6256 A QTmP a A Cam Positioning Tool Adapters T93P 6303 A Crankshaft Holding Tool T64L 601 1 EA Cylinder Ridge Reamer lMI 1111 0 SPECIAL SERVICE TOOLS DESIRED ToolNumber Description 081L 6002 D Piston Ring Compressor D81 L 6135 A P...

Page 211: ...s then circulatedfrom the radiator outlet tank through the water pump 8501 and into the cylinder blocks 6010 to completethe circuit REMOVAL AND INSTALLATION Cont d Radiator Draincock 03 o3 17 Radiator Hoses 03 o3 13 Thermostat Water 03 o3 13 Water Pump o3 o3 13 Water Temperature Indicator Sender Unit o3 o3 18 SERVICE PROCEDURES Radiator Core 03 o3 19 Transmission Fluid Cooler Connection Leaks o3 o...

Page 212: ...Lower Intake Manifold Water CrossoverIOutlet Coolant SystemAir Bleed WaterThermostat Water Bypass Hose WaterHose Connection To Radiator Inlet Cylinder Blocks LHBank The constant control relay module CCRM 128581 activates the cooling fan motor when coolant or engine reach a specified temperature On vehicles equippedwith air conditioning the cooling fan motor is activated wheneverthe A C clutch 2884...

Page 213: ...h a pressure relief cap WARNING ON VEHICLES EQUIPPED WITH THE 4 6L ENGINES NEVER REMOVE THE PRESSURE RELIEF CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND OR PERSONAL INJURY TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE COOLING SYSTEM USE EXTREME CARE WHEN REMOVING THE PRESSURE R...

Page 214: ... Crossflow The crossflow radiators used in base 3 8L and 4 6L 2V model Thunderbird Cougar vehicles are an aluminum tube and louvered fin core design with tubes arranged horizontally for crossflow of the engine coolant havetwotanks one on each sideofthe radiator that provide uniform coolant distribution to the crossflow tubes have an integral transmission oil cooler in the tank on the left side of ...

Page 215: ...Control Relay Module INLET TANK 03279 8 WARNING DISCONNECT THE COOLING FAN MOTOR PRIOR TO PERFORMING ANY UNDERHOOD SERVICE SINCE THE COOLING FAN MOTOR COULD CYCLE IF THE IGNITION SWITCH IS LEFT IN THE ON POSITION EVEN THOUGH THE ENGINE IS NOT RUNNING NOTE Cooling fan motor will not cycle with AIC clutch 2884 The cooling fan motor will come on when AIC switch is turned ON The cooling fan motor is c...

Page 216: ...d powertrain Damaged water pump control module PCM Damaged radiator Damaged radiator coolant recovery reservoir or degas bottle Damaged heater core If coolant condition is satisfactory check coolant concentration for proper protection level as described under Coolant Condition Check If concentration level is low partially drain the cooling system by opening the radiator draincock 81 15 or partiall...

Page 217: ...Powertrain control module Cooling tan motor Pinpoint Tests PINPOINT TEST A LOSS OF COOLANT Test Step Result A1 I CHECK ENGINE COOLANT LEVEL NOTE If engine is hot allow engine to cool down before Yes proceeding No Check engine coolant level at radiator coolant recovery reservoir or degas bottle Is engine coolant level OK A2 I CHECK FOR VISIBLE LEAKAGE Engine coolant has an added dye color that make...

Page 218: ...iscoloration and concentration Is coolant condition OK 83 J CHECK FOR AIR FLOW OBSTRUCTION Visually inspect A C condenser core and radiator for obstructions such as leaves or bugs Is there any obstruction 84 I CHECK HEATER CORE OPERATION Install pressure relief cap or radiator cap Start engine and allow to run As engine starts to warm up feel the heater inlet and outlet hoses They should feel the ...

Page 219: ...minutes Yes REPLACE waterthermostat as Feel heater inlet and outlet hoses and underside of described RETEST system upper radiator hose No GOto Section 13 01 for proper Are hoses cold Temperature Gauge Diagnosis PINPOINT TEST D ENGINE BLOCK HEATER DOES NOT OPERATE PROPERLY Test Step D1 CHECK POWER CABLE OPEN Checkresistanceof Circuits 1 2 and 3 in power cable using Rotunda 73 Digital Multimeter 105...

Page 220: ... limit of the radiator cap Replace any radiatorcap that exceeds the specified upper limit pressure without discharging bubbles 7 Ifthe pressure relief cap does not hold pressure remove and wash the radiator cap in clean water to dislodge all foreign particles from the gaskets Check the sealing surface in the filler neck Then inspect the cam lock flanges on both sides of the filler neck for maximum...

Page 221: ...ithin the specified upper and lower pressure limits Observe the gauge reading for approximately two minutes Refer to Specifications Pressure should not drop during this time If the system holds pressure proceed to Step 8 8 Release system pressure by loosening the pressure relief cap Check engine coolant level and replenish if necessary with the correct engine coolant mixture as described Radiator ...

Page 222: ...cap heater hoses radiator hoses vent plug on bypass elbow located on the intake manifold behind the water hose connection 8592 water hose connection gasket head gasket water pump housing gasket 8507 Replace leaking components as necessary before continuing 2 Check the coldenginecoolant level in the radiator a NOTE On 3 8L engine remove vent plug before filling cooling system and securely install a...

Page 223: ...hose connection Position water thermostat and water hose connection on the intake manifold Install the two retaining bolts and tighten to 8 12 N m 7 1 106 lb in 3 Connect upper radiator hose to water hose connection Move new hose clamp to water hose connection Make sure clamp is between alignment marks on hose 4 Fill cooling system with a 50I50 mixture of Premium Cooling System Fluid E2FZ 19549 AA...

Page 224: ...ery reservoir on 3 8L engines or degasbottle on 4 6L 2V engine coolant levels Radiator Coolant Recovery Reservoir Degas Bottle Removal 1 WARNING ON VEHICLES EQUIPPED WITH 3 8L ENGINES NEVER REMOVE THE RADIATOR CAP 8100 UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING FAILURE TO FOLLOWTHESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND OR PERSONAL INJURY TO AVOID HAVING ...

Page 225: ...low removal procedure in reverse order 2 Tighten constant control relay module bracket retainer bolt to 2 3 N m 12 18 1b in 3 Tighten electrical connector bolt securely Engine Cooling Fan Motor Fan Blade and Fan Shroud Assembly Electrical Removal 1 Disconnect pull apart the male female cooling fan motor wiring connector at the sideof the fan shroud 8146 Remove the male terminal connector retaining...

Page 226: ...Coolant Recovery 7 8K621 8600 Cooling Fan Motor and Reservoir 8146 Shroud Assembly 2 N800369 S2 Screw 2 Req d 8 8075 Radiator OverflowHose 3 16138 Radiator Support 9 14301 Battery Ground Cable 4 8260 Upper Radiator Hose 10 16055 Front Fender Apron 5 N3831352 S2 Bolt 2 Req d 1 1 8005 Radiator 6 8286 Lower Radiator Hose A Tighten to 5 2 7 2 N m 46 63 Continued Lb ln 1997 Thunderbird Cougar July 1996...

Page 227: ... system as described FRONT OF VEHICLE Part Item Number Description 8 Power Distribution Box Part of 14516 9 8A080 Degas Bottle 10 N605891 S2 Bolt 2 Req d 1 1 8K621 8600 Cooling Fan Motorand 8146 Shroud Assembly 12 6881 Oil Filter Adapter A Tighten to 5 2 7 2 N m 46 63 Lb ln 2 Turn the radiator draincock counterclockwise to loosen When the radiator draincock is unscrewed to the end of the threads p...

Page 228: ...e retainer if equipped and remove block heater power cable from vehicle Installation 1 Follow removal procedure in reverse order 2 NOTE Make sure power cable is routed and secured away from rotating or hot components Block Heater Removal 1 Open hood 166 1 2 and install protective fender covers 2 Disconnect battery ground cable 14301 Refer to Section 14 Q1 3 WARNING NEVER REMOVE THE PRESSURE RELIEF...

Page 229: ...g 1200 primer or equivalent using a brush Allow to dry for 10 minutes at room temperature Apply Dow Corning Silastic 734RTV or equivalent in undiluted form around the leaking connection and allow it to dry for one hour CLEANING AND INSPECTION Radiator Coolant Level Check NOTE If radiator coolant recovery reservoir 8A080 on 3 8L engines or degas bottle on 4 6L 2V are empty allow engine to cool and ...

Page 230: ...r radiator cap Observe the level of fluid in the radiator coolant recovery reservoir on 3 8L engines or degas bottle on 4 6L 2V engine Adjust coolant mixture to the FULL COLD mark on the radiator coolant recovery reservoir on 3 8L engines or degas bottle on 4 6L 2V engine c Start theengine and run untilthewater thermostat 8575 opens d Shut off the engine and allow itto cool down This permits engin...

Page 231: ...cock is closed and cylinder block drain plugs are installed if equipped 4 Place heatertemperature selector in maximum heat position 5 CAUTION The vent plug must be removed before radiator fill or the engine may not fill completely Do not turn plastic cap under vent plug or the gasket may be damaged Do not try to add coolant through vent plug hole Install vent plug after filling radiator 8005 and b...

Page 232: ...direction through the heater core 18476 All engine cooling system flushing and back flushing procedures must include a separate back flushing of the heater core afterthe flushing or back flushing of the engine cooling system This will prevent engine cooling system particlesfrom clogging theheatercore tubes and reducing or eliminating coolant flow through the heater core The correct heatercore back...

Page 233: ...diator cleaning agents on aluminum radiators To clean internal aluminum tubes use sonic cleaning equipment Rinse the core with clean waterwhen completed Fan Blade WARNING DO NOT ATTEMPT TO STRAIGHTEN OR SERVICE A FAN BLADE 8600 REPLACE FAN BLADE IF HUB OR BLADES ARE DAMAGED Check fan bladefor cracks or damage Replaceas described SPECIFICATIONS COOLING SYSTEM REFILL CAPACITIES Capacity Engine Uters...

Page 234: ...TIADHESIVEICLEANER SPECIFICATIONS Ford Description Part Number Specification Premium Cooling E2FZ 19549 AA ESE M97B44 A System Fluid Premium Cooling F5FZ 19549 CC ESE M97B44 A System Oregon Continued LUBRICANTIADHESIVE CLEANER SPECIFICATIONS Cont d Ford Description Part Number Specification Premium Cooling E2FZ 19549 B ESE M97B44 A System Fluid CXC 8 B Canada Recycled Cooling ESE M97B44 A System F...

Page 235: ...ting the vehicle if it becomes necessary manual transmission only All engines use a closed type positive crankcase ventilation PCV system and an exhaust emission system to control engine emissions within government specifications 1 Can be purchased as a separate item REMOVAL AND INSTALLATION Cont d Post Service Procedures 03 04A 7 Pre Service Procedures 03 04A 7 Fuel Charging Wiring 03 o4A 13 Fuel...

Page 236: ...upplies filtered air to the engine to mix with the fuel for combustion purposes and consists of the following engineintakeair resonator 9F763 engine air cleaner with aircleanerelement ACL elementX9601 2 Can be purchased as a separate item air cleaner outlet tube 98659 mass air flow sensor MAF sensorX12B579 throttle body 9E926 upperintakemanifold 9424 lower intake manifold Throttle Body The throttl...

Page 237: ...nsist ofthe upperintake manifold and the lower intake manifold runner lengths are tuned to optimize engine torque and power output provide mounting flanges for the throttle body 9E926 fuel injection supply manifold 9F792 and accelerator cable bracket 9723 and the EGR valve EGR valve 9D475 Fuel Charging System vacuum taps are provided to support various engine accessories pocketsfor the fuel inject...

Page 238: ...n electrical control signal from the powertrain control module PCMX12A650 activates the fuel injector solenoid causing the needle to move inward off the seat allowing the fuel to flow Since the fuel injector flow orifice is fixed and the fuel pressure drop across the injectortip is constant fuel flow to the engine is regulated by the length of time the solenoid is energized atomization of the fuel...

Page 239: ...Injection Supply Manifold Continued Part Item Number Description A Tighten to 20 30 N m 15 22 Lb Ft B Tighten to 8 1 1 N m 71 97 Lb ln Fuel Pressure Regulator The fuel pressure regulator 9C968 is mounted on the fuel injection supply manifold 9F792 downstream of the fuel injectors regulates the fuel pressure supplied to the fuel injectors is a diaphragm operated relief valve in which one side of th...

Page 240: ... control module determine the fuel injection sequence and duration each fuel injector will stay open to allow fuel into the combustion chambers Inertia Fuel Shutoff IFS Switch The inertia fuel shutoff switch IFS switch 9341 is used in conjunction with an electric fuel pump 9350 shutsoffthe fuel pump in the event of a collision consists of a steel ball held in place by a magnet When a sharpimpactoc...

Page 241: ...m is installed into the engine the following steps must be taken 1 Install fuel tank filler cap at fuel tank 2 Connect battery ground cable 3 Add engine coolant if required Refer to Section 03 Q3 3 Can be purchased as a separate item 4 WARNING THE FUEL SYSTEM IS NORMALLY PRESSURIZED TO 276 KPA 40 PSI USE CARE WHEN SERVICING THE FUEL SYSTEM OR POSSIBLE PERSONAL INJURY MAY OCCUR NOTE Check all conne...

Page 242: ...149 A 4 Pull the coupling male and female fittings apart 5 Remove thedisconnecttoolfrom the disconnected spring lock coupling V10150 A V10151 A 6 NOTE Inspect coupling for missing ordamaged 0 rings If either 0 ring is damaged both 0 rings must be replaced Replace 0 rings or garter springs with the appropriate replacement parts only Clean fittings with solvent Installation 0 RINGS SPRING V10156 A 1...

Page 243: ...alve 9F715 4 Remove four throttle body retaining nuts 5 Carefully separate throttle body 9E926 from upper intake manifold 9424 6 Remove and discard throttle body gasket TB gasket 9E936 Installation 1 NOTE If scraping is necessary do not damage gasketsurfacesor allow material to drop into upper fuel charging wiring Clean gasket mating surfaces 2 Install throttle body with new throttle body gasket o...

Page 244: ...4 Req d Intake Manifold Upper Gasket 1 Perform Pre Service and Fuel Pressure Relief Procedures Refer to Fuel Charging System 2 Remove upperintakemanifold 9424 as described in Section 03 01A V9236 B Part Item Number Description 13 9424 Intake Manifold Lower 14 9E936 Throttle Body Gasket 15 N804758 S2 Nut 4 Req d 16 9E926 Throttle Body 17 90475 EGR Valve A Tighten to 0 6 N m 5 Lb ln B Tighten to 7 7...

Page 245: ...isting pushing motion 3 Reinstall fuel injector retaining clips as required 4 Install fuel injection supply manifold as described 5 Install connectorsfromfuel charging wiring to fuel injectors 6 Install upper intake manifold as described in Section 03 o1A Perform Fuel Charging System Post Service Procedures as described Fuel Pressure Relief Valve SPECIAL SERVICE TOOL S REQUIRED Description ToolNum...

Page 246: ...e fuel pressure regulator bracket retaining bolt 6 NOTE It may be easier to removefuel injectors with the fuel injection supply manifold as an assembly Carefully disengage fuel injection supply manifold from fuel injectors and removefuel injection supply manifold 7 Use a rocking side to side motion while lifting to remove fuel injectors from cylinder head pockets V9238 B Part Item Number Descripti...

Page 247: ... on fuel injection supply manifold Tighten retaining screws to 3 Q 4 5 N m 27 39 1b in 5 Install vacuum line to fuel pressure regulator 6 Perform Fuel Charging System Post Service Procedures as described Fuel Charging Wiring Removal 1 Remove upper intake manifold 9424 as described in Section 03 Q1A 2 Disconnect fuel charging wiring 9D930 from fuel injectors 9F593 and electronic engine controls 3 D...

Page 248: ... Manifold Fuel Pressure ReliefValve Cap to Pressure Relief Valve Fuel Pressure Regulator Bracket To CylinderHead a Tighten in three steps 10 N m 88 Lb ln e20 N m 15 Lb Ft e32 N m 23 Lb Ft N m 8 1 1 3 0 4 5 8 1 1 7 75 0 6 20 30 4 Can be purchased as a separate item Lb Ft Lb ln 71 97 27 39 7 1 97 68 5 15 22 SPECIAL SERVICE TOOLS EQUIPMENT SPECIAL SERVICE TOOLS REQUIRED ToolNumberI Description Illust...

Page 249: ...the entire engine operational range sends acommand to the fuel injectors to meterthe appropriate quantity of fuel determines and compensates for the age of the vehicle and its uniqueness Automatically senses and compensatesfor changes in altitude for example from sea level to mountains 1 Can be purchased as a separate item REMOVAL AND INSTALLATION Cont d Fuel Injector 03 o4B 8 Installation 03 o4B ...

Page 250: ...rature sensors The outgoing signals of the electronic engine control sensors are processed by the powertrain control module The powertrain control module determines the needed fuel injector pulse width and outputs a command to the fuel injectors to meter the exact quantity of fuel 2 Can be purchased as a separate item Sequential Multiport Fuel Injection SFI The sequential multiportfuel injection S...

Page 251: ...ctorfuel spray immediately in front ofeach engine intake valve 6507 machined pockets for the fuel injectors 9F593 to prevent both air and fuel leaks 3 Can be purchased as a separate item FUEL INJECTOR 9F593 8 REO D FRONT OF ENGINE Fuel Injectors The eight fuel injectors are INTAKE MANIFOLD 9424 V10121 A electro mechanical devices which both meter and atomize fuel delivered to the engine mounted in...

Page 252: ...uel injectors is a diaphragm operated relief valve in which one sideof the diaphragm sensesfuel pressureand the other side is subjected to intake manifold vacuum nominal fuel pressure is established by a spring preload applied to the diaphragm balances one side of the diaphragm with manifold pressure to maintain a constant fuel pressure drop across the fuel injectors bypassesand returnsexcessfuel ...

Page 253: ...tia Fuel Shutoff IFS Switch The inertia fuel shutoff switch IFS switch 9341 is used in conjunction with an electricfuel pump 9350 shuts off thefuel pump in the event of a collision consists of a steel ball held in place by a magnet When a sharpimpact occurs the ball breaks loose from the magnet rolls up a ramp and strikes atargetplatethat opens the electrical contacts of the inertia fuel shutoffsw...

Page 254: ...d Refer to Section 03 Q3 4 WARNING THE FUEL SYSTEM IS NORMALLY PRESSURIZED TO 276 KPA 40 PSI USE CARE WHEN SERVICING THE FUEL SYSTEM OR PERSONAL INJURY COULD OCCUR NOTE Check all connections at fuel injection supply manifold fuel injector or fuel line push connect fittings Turn ignition switch ONIOFF several times without starting engine to check for fuel leaks 4 Can be purchased as a separate ite...

Page 255: ...Q ring is damaged both Q rings must be replaced Replace0 rings or garter springs with the appropriate replacement parts only Clean fittings with solvent Installation 0 RINGS SPRING V10156 A 1 Lubricate the Q rings with clean engine oil 2 CHECK FOR CORROSION USE ONLY SPECIFIED FUEL RESISTANT 0 RINGS COLOR BLACK LUBRICATE 0 RINGS WITH CLEAN ENGINE OIL AV0219 A Insert male fitting into femalefitting ...

Page 256: ...to drop into intake manifold 9424 Clean gasket mating surfaces 2 Install throttle body new throttle body gasket and four boltsto the intakemanifold adapter lighten retaining boltsto 8 12 N m 7 1 106 Ib in 3 Connect the fuel charging wiring to the throttle position sensor as well as accelerator cable to the throttle lever 4 Install air cleaner outlet tube as described in Section 03 12 BOLT 4 REQ D ...

Page 257: ...ibed Fuel PressureRelief Valve SPECIAL SERVICE TOOL S REQUIRED Description Tool Number Fuel PressureGauge TSOL 9974 8 Removal 1 NOTE Fuel pressure relief valve cap 9H323 on fuel pressure relief valve 9H321 must be removed Iffuel injection supply manifold 9F792 is mounted to engine removefuel tank filler cap 9030 Then release pressure from system at fuel pressure relief valve on fuel injection supp...

Page 258: ... injection supply manifold 9 Usea rocking side to side motion while lifting fuel injectors to removefuel injectors from intake manifold 9424 __ FRONT OF ENGINE V10122 A Part Item Number Description 1 Bolt 4 Req d 2 9C968 Fuel Pressure Regulator 3 9F792 Fuel Injection Supply Manifold 4 9F593 Fuel Injector 8 Req d 5 9424 Intake Manifold A Tighten to 8 12 N m 71 106 Lb ln Installation 1 CAUTION When ...

Page 259: ...edures as described Fuel Charging Wiring Removal 1 Remove air cleaner outlet tube 98659 Refer to Section 03 12 2 Disconnect battery groundcable 14301 Refer to Section 14 Q1 3 Disconnect fuel charging wiring 9D930 from fuel injectors and electronic engine controls 4 Disconnectfuel charging wiring from engine control sensor wiring 12A581 5 Remove fuel charging wiring retaining bolts and fuel chargin...

Page 260: ...Pressure ReliefValve Cap 0 6 5 Fuel Charging Wiring to Intake 8 12 71 106 Manifold Bolts LUBRICANTIADHESIVE CLEANER SPECIFICATIONS Ford Description PartNumber Specification Engine Oil WSS M2C153 F 5 Can be purchased as a separate item SPECIAL SERVICE TOOLS EQUIPMENT SPECIAL SERVICE TOOLS REQUIRED Tool NumberI Description Illustration T80L 9974 B Fuel Pressure Gauge TIOL 91174 11 SPECIAL SERVICE TO...

Page 261: ...llowing Loose or stripped bolts Replace or tighten bolts as required lighten all bolts to specification including fan blade to fan clutch if equipped fan clutch to water pump if equipped all bracket and accessory bolts and drive belttensioner retaining bolts Drive belt flutter Observe drive belt with engine running and transmission in PARK NEUTRAL for manual transmission with parking brake set Slo...

Page 262: ...ional capability CAUTION If drive belt chirp is present determine the cause and correct it Do not use any type of lubricant on the drive belt NOTE V ribbed serpentine drive beltsare sensitive to pulley alignment If a pulley is not in the same plane as the others the drive belt may exhibit a periodic chirp Sometimes a chirp will occur in a system thatis perfectly aligned Removing and installing the...

Page 263: ...ll perfectly functional until rib chunking occurs Drive belt chunking is where the rubber material actually chunks out between the cracks The drive belt should be replaced if the chunks are 5 mm 0 0 19 inch or longer Symptom Chart Check all pulleys except crankshaft pulley 6312 and accessories for smooth free operation Service any components as required V Ribbed Serpentine Drive Belt With Chunks o...

Page 264: ...ation 2 With engine off check for proper drive belt routing Refer to the illustrations under Removal and Installation Service as required 3 Inspectthe drive belt tensioner wear indicator as described under Drive Belt Tensioner Automatic in Adjustments to make sure the drive belt is within operating range Replace the drive belt as required 4 Rotatethedrive belt tensioner and check for a binding or ...

Page 265: ...ic drive belt tensioner away from drive belt On 3 8L SFI engines lift drive belt tensioner pulley by applying counterclockwise torque to pulley bolt with wrench and socket On 4 6L engines depress drive belt tensioner pulley by applying clockwise torque to square slot with 1 I2 inch drive breaker bar 2 Remove drive belts 3 CAUTION Incorrect drive belt installation will cause excessive drive belt we...

Page 266: ... Continued 4 6L SFI Engine Removal and Installation 1 Remove serpentine drive belt as described 2 Remove RH ignition coil bracketfrom drive belt tensioner as described in Section 03 078 VIEW B 03271 A Part Item Number Description 6 3A733 Power Steering Pump Pulley 7 6312 Crankshaft Pulley 8 8509 Water Pump Pulley 9 N805901 S2 Bolt A Tighten to 70 95 N m 52 70 Lb Ft 3 Remove drive belt tensioner re...

Page 267: ...T OF ENGINE I 03003 C Part Item Number Description 1 10300 Generator 2 8509 Water Pump Pulley 3 3A733 Power Steering Pump Pulley 4 6312 Crankshaft Pulley 5 19703 AI C Compressor 6 8620 Drive Belt 7 6B209 Drive BeltTensioner 8 8678 Belt Idler Pulley ADJUSTMENTS Drive Belt Tension Adjustment Serpentine Drive Belt Drive belts 8620 have an automatic drive belt tensioner 68209 and DO NOT require adjust...

Page 268: ...n Minimum Number Usage Torque E9SE 6B209 GA 3 8L SFI 28 5 N m Accessory 21 Lb Ft Drive F4AE 6B209 AA 4 6L Accessory 44 8 N m Drive 33 Lb Ft The only mechanical checkthatneed be made if there is any doubt as to the tensioner function would be to remove the belt in the area of the tensioner to avoid belt contact then using the proper tool rotatethe tensioner from its relaxed position thru its full s...

Page 269: ...ions or partially broken cables result in slowerthan normal cranking speeds These concerns may even prevent the starter motor from cranking the engine In case of starting system difficulty the operator may have discharged the batterybefore calling for assistance DIAGNOSIS AND TESTING Cont d Inspection and Verification 03 06 3 Pinpoint Tests 03 06 4 Symptom Chart 03 06 3 REMOVAL AND INSTALLATION St...

Page 270: ...rdistribution box to the starter solenoid 1 1390 The starter interrupt relay is energized by the anti theft controller and opens the starter circuit Sequence of Operation When the ignition switch is turned to the START position Voltage is provided to the starter solenoid 1 1390 The starter solenoid is energizeddirectlyfromthe ignition circuit A magneticfield is created in the solenoid coil The iro...

Page 271: ...fter the inspection determine the symptoms and go to the Symptom Chart Symptom Chart Refer to Electrical and Vacuum Troubleshooting Manual for the connector numbers cited in the pinpoint tests Use Rotunda 73 Digitai iVIultimeter 105 R0051 or equivalent to perform pinpoint tests 2 Inspect to determine if any of the following mechanical or electrical concerns apply STARTER SYSTEM DIAGNOSIS Condition...

Page 272: ...A4 I CHECK STARTER GROUND CIRCUIT RESISTANCE Connect voltmeter positive lead to the starter motor Yes SERVICE connections between housing battery negativeterminal and Connect voltmeter negative lead to battery negative engine block starter terminal motor to transmission housing Disconnect inertia fuel shutoff switch electrical connection connectorto prevent enginefrom starting No GOto A5 Crank eng...

Page 273: ...RVICE ignition switch REFER to Measure resistance of Circuit 32 RILB between Section 1 1 05 RESTORE vehicle C21 1 STAto C1057 4 RETESTsystem Is resistance 5 ohms or less No SERVICE open in Circuit 32 RILB RESTORE vehicle RETEST system 86 I CHECK CIRCUIT 33 FOR OPEN Disconnect TR sensor Yes REPLACE transmission range Measure resistance of Circuit 33 WIPK between sensor C1057 1 and C1064 No SERVICE ...

Page 274: ...ents the coil from activating the secondary ignition and the engine from starting 2 Disconnect inertia fuel switch power tothefuel pump to disable fuel flow on vehicles equipped with electronic fuel injection EFI 3 NOTE Make sure battery terminals and cable connections are clean Clamp the blackload lead of the Rotunda Alternator Regulator Battery and Starter Tester ARBSD 01Q 00725 or equivalent to...

Page 275: ...gain to display the starter motor diagnosis The display will read either GOOD STARTER or BAD STARTER 016444 A Part Item Number Description 4 Gray Amps Probe Connect Around Negative Battery Cable withArrowon Probe PointingTowardBattery 5 1 1001 StarterMotor 6 10653 Battery 1 1 To view cranking volts again press the CONTINUE key To display cranking amps again press the CONTINUE key a second time Toe...

Page 276: ...s the lastmechanical point that waschecked is the concern Motor Feed Circuit S TERMINAL REMOTE STARTER SWITCH r ROTUNDA 73 DIGITAL MULTIMETER 105 R0051 BATTERY 10653 AJ0130 A Motor Ground Circuit A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit Check the voltage drop in the ground circuit as follows 1 Prevent the engine from starting by ...

Page 277: ...ure core Todetermine if the armature windings are grounded checkwith a multimeter Infinite resistance indicates a normal condition ROTUNDA 73 DIGITAL MULTIMETER 105 R0051 Starter Solenoid Make sure that the starter solenoid is isolated electrically from the starter motor Check for continuity between solenoid S terminal and solenoid M terminal and between 8 terminal and ground starterframe and magn...

Page 278: ... terminal from starter solenoid 4 Remove upper bolt 5 Remove one lower bolt on3 8Lengine and two lower bolts on 4 6L engine and starter motor Installation 1 Position starter motor to engine and install upper and lower bolts finger tight 2 lighten the upper boltto 2Q 27 N m 15 20 lb ft 3 On 3 8L engine tighten the lower boltto 2Q 27 N m 15 20 lb ft On 4 6L engine tighten lower two bolts to 2Q 27 N ...

Page 279: ...ter Solenoid 3 1 1A171 Housing Seal 4 1 1 135 Bushing 5 1 1 130 DriveEnd Housing 6 N805405 Solenoid Screw 2 Req d 7 1 1002 Starter Motor 8 1 1067 Drive Leverand Pin 9 1 1350 Starter Drive Continued Part Item Number 10 1 1223 1 1 1 1222 12 13 1 1075 14 1 1061 15 1 1059 16 17 1 1049 18 N805406 Continued 03 06 1 1 AJ0126 A Description Stop Ring Retainer StarterDriveStop Ring Magnet Retainer 6 Req d P...

Page 280: ... Output Shaft 21 1 1A172 Armature Thrust Ball 29 1 1A167 PlanetGear Retainer 22 1 1K190 Planet Gear A Tighten to 9 14 N m 80 123 23 1 1A165 Stationary Gear Lb ln 24 N805404 Truarc E Ring B Tighten to 5 10 N m 45 88 Lb ln 25 Magnet Pole Piece 6 Req d Partof 1 1075 c Tighten to 2 3 N m 18 26 Lb ln 26 Pole Shunt 6 Req d Part of 1 1075 Continued Starter Motor Disassembled VIew 4 6L Engine 17 AJ0127 A ...

Page 281: ...A172 Armature Thrust Ball 22 1 1K190 Planet Gear 23 1 1A165 StationaryGear 24 N805404 Truarce E Ring 25 Magnet Pole Piece 6 Req d Part of 1 1075 26 Pole Shunt 6 Req d Part of 1 1075 27 1 1036 Pinion Thrust Washer 28 1 1355 Output Shaft 29 1 1A167 Planet Gear Retainer 30 1 1355 Output Shaft 31 1 1A167 Planet Gear Retainer A Tighten to 9 14 N m 80 123 Lb ln B Tighten to 5 10 N m 45 88 Lb ln c Tighte...

Page 282: ...o housing and install through bolts lighten to 5 10 N m 45 88 1b in 8 Install starter solenoid Refer to Starter Motor Assembly Armature Replacement Starter Motor 1 Remove positive brush connector from starter solenoid M terminal 2 Remove through bolts and separate motor from starter drive gear assembly and drive end housing 3 Remove brush end platescrews brush end plate and bushing 1 1049 and brus...

Page 283: ...Iiron armature bushings in the drive housing and brush end plate and bushing 1 1049 Replace bushings whenever excessive starter motor armature shaft side play is evident maximum allowable 0 2 mm 0 008 inch 2 Replace bushings ifworn or scored Check the output shaft 1 1355 for wear if the bushings are excessively scored or worn Service or replace output shaft as necessary Starter Frame and Magnet 1 ...

Page 284: ...erMotor Minimum Stall 14 7 N m 1 1 0 Lb Ft Torque 5 Volt Maximum Load 800 Amps No Load 60 80 Amps Starter Brushes Manufactured 14 mm 0 55 1nch Length StarterBrushes Spring 18 N 64 oz Tension Maximum Commutator Runout 0 12 mm 0 005 1nch Maximum Starting Circuit 0 5 Volt Voltage Drop Battery Positive Terminal to Starter Terminal at Normal Engine Temperature LUBRICANTIADHESIVE CLEANER SPECIFICATIONS ...

Page 285: ...es 2 degreesbeforetop dead center BTDC and is not adjustable Thecrankshaftposition sensor CKP sensor 6C315 is a variable reluctance sensor which is mounted on the enginefront cover 6019 and is triggered by a 36 minus 1 tooth triggerwheel located on the crankshaft puHey and damper The crankshaft position CKP signal from the crankshaft position sensorprovides base timing crankshaft speed rpm The pow...

Page 286: ... 1 PIN 2 COIL 3 PIN 1 COIL 2 8491G B Refer to the Powertrain Control IEmissions Diagnosis Manual1 1 Can be purchased as a separate item REMOVAL AND INSTALLATION Crankshaft Position CKP Sensor Removal 1 Disconnect battery ground cable 14301 Refer to Section 14 Q1 2 Raise vehicle on hoist 3 Disconnect engine controlsensor wiring 12A581 from the crankshaft position sensor CKP sensor 6C315 4 Remove cr...

Page 287: ...alentmeeting Ford specification ESE M1C171 A to all ignition wire boots 4 Install each ignition wire connector to the proper terminal on the ignition coil Make sure boots are fully seated 5 Connectenginecontrol sensor wiring to the ignition coil and radio ignition interference capacitor Bracket Ignition Coil Removal 1 Remove the ignition coil 12029 as described 2 Removethe two ignition coil bracke...

Page 288: ...n wire separators 12297 and remove ignition wire Installation 1 Whenever an ignition wire is removed from a spark plug or ignition coil or a new ignition wire is installed coat the entire interior surface of the boot with Silicone Brake Caliper Grease and Dielectric Compound D7AZ 19A331 A Motorcraft WA 10 or equivalent meeting Ford specification ESE M1C17 1 A with a small clean tool prior to insta...

Page 289: ...SPARK PLUG BOOTS MUST BE SECURELY PRESSED ONTO SPARK PLUGS 0REFER TO LEGEND FIRING ORDER NUMBER 1 4 2 5 3 6 SPARK PLUG BOOTS NUMBERS 1 2 3 4 AND 5 NOTE WIRE SEPARATORS TO BE FULLY SEATED IN VALVE COVER STUDS 03 07A 5 t FRONT OF ENGINE SPARK PLUG BOOT NUMBER 6 I NOTE MAKE SURE RETAINER CUP IS FULLY ENGAGED ON COIL TOWER NOTE INSTALLAnoN ORDER FOR RH IGNmON WIRES ARE e e e 85197 A 1997 Thunderbird C...

Page 290: ...inders 4 5 and 6 AWSF 44EG spark plugs have a platinum enhanced ground side electrode and are used in cylinders 2 and 3 If any spark plug is removed and re installed it must be installed in the same cylinder from which it was removed If any spark plug is replaced use only spark plugs with part number AWSF 44EE as listed on thevehicleemission control information label This replacement spark plug ha...

Page 291: ...ACKORGRAYBROWNSPOTS ANDWITHBLUISH BURNT APPEARANCEOFELECTRODES CAUSEDBYENGINEOVER HEATING WRONGTYPEOF FUEL LOOSESPARKPLUGS TOO HOTAPLUG LOWFUELPUMP PRESSUREORINCORRECT IGNITIONTIMING REPLACE SPARKPLUG 03 07A 7 OIL FOULED IDENTIFIEDBYWETBLACK DEPOSITSONTHEINSULATOR SHELLBOREELECTRODES CAUSEDBYEXCESSIVEOIL ENTERINGCOMBUSTIONCHAMBER THROUGHWORNRINGSAND PISTONS EXCESSIVECLEARANCE BETWEENVALVEGUIDESAND...

Page 292: ... different styles of platinum enhanced spark plugs are produced for the 3 8L engine Each plug has a different part number and use AWSF 44E spark plugs have a platinum enhanced center electrode and are used in cylinders 4 5 and 6 AWSF 44EG spark plugs have a platinum enhanced ground side electrode and are used in cylinders 1 2 and 3 If any spark plug is removed and re installed it MUST be installed...

Page 293: ... dead center BTDC and is not adjustable The crankshaft position sensor CKP sensor 6C31 5 is a variable reluctance sensor triggered by a 36 minus 1 tooth trigger pulsewheel located on the crankshaft 6303 inside the enginefront cover 6019 The signal generated from the crankshaft position sensor providestwo types of information One is the position ofthe crankshaft in 10 degree increments The other is...

Page 294: ...unted on ignition coil brackets retained to the engine front cover 6019 There are two cylinder numbers on each ignition coil terminal to allow the ignition coil to be interchangeable 1 Can be purchased as a separate item NOTE The numbers on the ignition coil tower terminals shown in the illustration are engine cylinder numbers These numbers are shown for information only and are not shown on ignit...

Page 295: ...en crankshaft position sensor retaining screw or damage to the crankshaft position sensor may occur Position crankshaft position sensor and install retaining screw lighten to 8 12 N m 7 1 106 lb in 3 Install A C compressor Evacuate and recharge AIC system Referto Section 12 00 4 Properly route engine control sensor wiring and connect electrical connectors to AIC compressor and crankshaft position ...

Page 296: ...tion ESE M1C171 A to all ignition wire spark plug boots 4 Install each ignition wire connector to the proper terminal on the ignition coil Make sure boots are fully seated 5 Connect theengine control sensor wiring to the ignition coils and radio ignition interference capacitors FRONT OF _ ENGINE Part Item Number 1 N606502 S309 2 18801 3 12029 4 12043 5 12043 A Bracket Ignition Coil Removal 85192 A...

Page 297: ...r inside the boot When removing ignition wires from spark plug 12405 use Spark Plug Wire Remover T74P 6666 A Grasp and twist the ignition wire spark plug boot back and forth on the spark plug insulator to free the boot A6626 D 2 CAUTION Do not pull on the ignition wire directly as the wire may separate from the connector inside the boot Disconnect the ignition wire from the ignition coil 12029 by ...

Page 298: ...ad Install each ignition wire to the proper terminal on the ignition coils The terminals on the ignition coils are numbered Make sure the boots are fully seated and that both locking tabs are engaged 3 Route ignition wire through ignition wire separators and close ignition wire separators 4 NOTE Ignition wire spark plug boot must be positioned 90 degrees from crankshaft centerline outboard and for...

Page 299: ...RANKSHAFT VIEW C TYPICAL RH FRONT OF ENGINE CRANKSHAFT ct VIEW D TYPICAL LH NOTE MAKE SURE IGNITION COIL RETAINER CLIP IS FULLY ENGAGED ON COIL TOWER 03 078 7 NOTE REVERSE LETTERS AND NU ERS ON IGNITION WIRES INDICATE INSTALLATION LOCATIONS ON CORRESPONDING REVERSE LETTERS AND NUMBERS ON ENGINE VIEW D SECTION E AB0061 A 1997 Thunderbird Cougar July 1996 ...

Page 300: ...ilMounting Bracket RH Tightento5 7N m 45 61 Lb ln 1 Disconnect ignition wires from spark plugs 12405 as described 2 Loosen spark plugs a 1 I4 turn and remove dirt or foreign material from spark plug areas of cylinder heads 6049 with compressed air 3 NOTE Threedifferent styles of platinum enhanced spark plugs are produced for the 4 6L 2V engine Each plug has a different part number and use AWSF 32P...

Page 301: ...12405 CYLINDER HEAD RH 4 REQ D 6049 HAND START AND TIGHTEN TO 9 20 N m 80 177 LB IN FRONT OF __ ENGINE A80054 A CLEANING AND INSPECTION Spark Plugs Inspect the electrode and outer surface Refer to Spark Plug Inspection Chart Replace spark plugs 12405 if they are worn or damaged Use the following inspectionchart when inspecting spark plugs 1997 Thunderbird Cougar July 1996 ...

Page 302: ...HEAnNG NORMAL IDENTIFIED BY LIGHT TAN OR GRAY DEPOSITS ON THE FIRING TIP 03 078 10 OIL FOULED IDENTIFIED BY WET BLACK DEPOSITS ON THE INSULATOR SHELL BORE ELECTRODES CAUSED BY EXCESSIVE OIL ENTERING COMBUSTIONCHAMBER THROUGH WORN RINGS AND PISTONS EXCESSIVE CLEARANCE BETWEEN VALVE GUIDES AND STEMS OR WORN OR LOOSE BEARINGS CORRECT OIL PROBLEM REPLACE SPARK PLUG PRE IGNITION IDENTIFIED BY MELTED EL...

Page 303: ...DJUSTABLE a Three different styles of platinum enhanced spark plugs are produced for the 4 6L 2V engine Each plug has a different part number and use AWSF 32P spark plugs have a platinum enhanced center electrode and are used in cylinders 5 6 7 and 8 AWSF 32PG spark plugs have a platinum enhanced ground side electrode and are used in cylinders 1 2 3 and 4 If any spark plug is removed and re instal...

Page 304: ...ine performance and shorten engine life The positive crankcase ventilation PCV system cycles crankcase gases back through the engine where they are burned The positivecrankcase ventilation valve PCV valve 6A666 regulates the amount of ventilating air and blow by fuel vapor to the intake manifold 9424 prevents backfire from traveling into the crankcase is mounted in a vertical position IN VEHICLE S...

Page 305: ...ure feedback EGA is a subsonic closed loop EGA system The differential pressure feedback EGA system monitors EGA flow rate by the pressure drop across the metering orifice uses an EGA backpressure transducer as the feedback device controlled pressure is varied by the valve movement _ using vacuum output of the EGA vacuum regulator solenoid usesthe EGA valve only as a pressure regulator rather than...

Page 306: ...ona Diagnosis Manualforaddlllonallnfonnallori T ocheckengineliming 181 parking brake and block wheels Engine must be at normal operallng temperature transmla8lon In neulral and accessoriesOlf 1 TumOlfengine 2 Dleconnectthe In line SpoutConnector oOII 3 Re start previouslywarmed up 4 V tty 1hattheIgnitiontiming Is 10 BTDC If t bm not shopmanual 5 Tumengine Olf and restore eleclrlcalconnecllon i Use...

Page 307: ...valve 3 Remove positive crankcase ventilation valvefrom crankcase ventilation grommet in RH valve cover 6582 4 Inspect positive crankcase ventilation valve and crankcase ventilation grommet for deterioration Replace if necessary Installation 1 Follow removal procedure in reverse order VIEW A Part Item Number 1 6A666 2 6C324 3 9447 4 6758 5 6582 6 6582 7 6A892 PCV Hoses FRONT OF ENGINE _ FRONT OF N...

Page 308: ...let tube 98659 as described in Section 03 12 2 Remove crankcase ventilation tube from LH valve cover 6582 3 Inspect crankcase ventilation tubefor deterioration Replace as necessary Installation 1 Follow removal procedure in reverse order VIEW A Part Item Number 1 6A666 2 6C324 3 9447 4 6758 5 6582 6 6582 7 6A892 ___ FRONT OF ENGINE FRONT OF NE A24288 A Description PositiveCrankcase VentilationValv...

Page 309: ...adapter 3 Inspect crankcase vent connector and hose for deterioration Replace if necessary Installation 1 Follow removal procedure in reverse order VIEW A Part Item Number 1 6A666 2 6C324 3 9A589 4 6758 5 6582 6 6582 7 6A892 EGR Valve Removal ___ FRONT OF ENGINE _ FRONT OF NE A24288 A Description PositiveCrankcase VentilationValve CrankcaseVentConnector andHose ThrottleBodyAdapter CrankcaseVentila...

Page 310: ...nifold tube nut on EGR valve at this time Position EGR valve to exhaust manifold tube into EGR valve and loosely connect EGR valve to exhaust manifold tube nut to EGR valve Position EGR valve gasket and EGR valve 4 Install two bolts retaining EGR valve lighten bolts to 2Q 30 N m 15 22 1b ft 5 lighten exhaust manifold tube nut to 35 45 N m 26 33 lb ft 6 Connect vacuum hose toEGRvalve EGR Valve to E...

Page 311: ...ble 9A758 and speed control actuator cable 9A825 from the throttle body 9E926 6 Removeaccelerator cable bracket retainers and position accelerator cable bracket 9723 with the accelerator cable and the speed control actuator cable out of the way 7 Disconnect EGR valve to exhaust manifold tube from the EGR valve and removethe EGR valve to exhaustmanifold tube from the vehicle Part Item Number Descri...

Page 312: ... nutsand EGR backpressure transducer from transducer mounting bracket 9J432 4 If necessary remove the EGR vacuum regulator solenoid as described and the transducer mounting bracket from the upper intake manifold 9424 Installation 1 Follow removal procedure in reverse order 2 If removed tighten retaining nuts for the transducer mounting bracket as illustrated lighten EGR backpressuretransducer reta...

Page 313: ...mregulator solenoid 2 Disconnect main emission vacuum control connector 9E498 from EGA vacuum regulator solenoid 3 Remove retaining nuts and EGA vacuum regulator solenoid from mounting bracket Installation 1 Follow removal procedure in reverse order 2 lighten retaining nuts to 5 7 N m 45 61 1b in 4 6L Engine Removal 1 Disconnect fuel charging wiring from EGR vacuum regulator solenoid 2 Disconnect ...

Page 314: ... does not flow 3 Disconnect the fuel charging wiring 9D930 from the EGR vacuum regulator solenoid 4 Apply battery voltage and a ground to the EGR vacuum regulator solenoid at the connector 5 Lightly blow air into the EGR vacuum regulator solenoid and verify that air does flow through the EGR vacuum regulator solenoid 6 If air does not blowthrough the EGR vacuum regulator solenoid replace the EGR v...

Page 315: ...r element Air Cleaner Element Theair cleaner element ACLelementX9601 is a dry type filtering element chemically treated pleated paper air filtering element which permits air flow through the air induction system filtering out unwanted dust dirt and debris DIAGNOSIS AND TESTING Intake Air System Refer to the Powertrain Control IEmissions Diagnosis Manual1 1 Can be purchased as a separate item REMOV...

Page 316: ...lamp 2Req d 3 128579 MassAirFlowSensor 4 9601 AirCleanerElement 5 N621907 S2 Nut 3Req d Continued Installation 1 Clean all inside surfaces of the engine air cleaner ACL 9600 as described 2 Install the air cleaner element 3 Position air cleanercoverand install tabs into three slots on inboard side of air cleaner body and center the air cleaner cover Snap the two retaining clips into locked position...

Page 317: ...t ACL element 9601 as described 5 Remove engine air cleaner retaining nuts and engine air cleaner ACL 9600 Installation 1 Follow removal procedure in reverse order 2 Tighten engine air cleaner retaining nuts to 2 0 2 4 N m 18 21 1b in On 3 8L engines tighten engine air cleanertube clamp to 2 3 3 4 N m 2 1 30 lb in On 4 6L engines tighten engine air cleaner tube clamp to 2 8 4 6 N m 25 40 Ib in Air...

Page 318: ...ine operation and cause a hole Discoloration only is not a cause for replacement Engine Air Cleaner Clean the air cleaner body and the cover with a solvent or compressed air Wipe the air cleaner body and cover dry if a solvent is used Inspect the air cleaner body and cover for distortion or damage at the gasket mating surfaces Replace cover or body if they are damaged beyond service Engine Intake ...

Page 319: ...to the fuel tank filler pipe 9034 extends inside the fuel tank 9002 The evaporative emission valve 98593 mounted in thetop panel of the fuel tank and the evaporative emissions tube attached to the evaporative emissions canister EVAP canisterX9D653 also contribute to fill control by controlling pressure in the fuel tank DIAGNOSIS AND TESTING Evaporative Emissions 03 1 3 3 REMOVAL AND INSTALLATION E...

Page 320: ...e basic functions in the system fill control vent system fuel tank evaporative emissions venting and storage system evaporative emissions purge system pressure and vacuum relief fuel tank filler cap and evaporative emission valve Evaporative Emission Canister Fuel vapor emitted through the evaporative emission valve 98593 is stored in a evaporative emissions canister EVAP canister 90653 Typical Ev...

Page 321: ...p operates as acheck valve allowing air to enter the fuel tank 9002 as fuel is used while preventing fuel vaporsfrom escaping the fuel tank through the fuel tank filler cap 1 Can be purchased as a separate item Evaporative Emission Valve Fuel vapor in the fuel tank 9002 is vented to the evaporative emissions canister EVAP canisterX9D653 through the evaporative emission valve 98593 Theevaporative e...

Page 322: ...ly lower evaporative emissions canister EVAP canister 9D653 and disconnect evaporative emission hose evaporative emission canister purge valve EVAP canister purge valve 9C915 and front fuel supply return and vapor tube 98286 from evaporative emissions canister Installation 1 Follow removal procedure in reverse order 2 lighten evaporative emission canister retaining boltto 5 2 7 2 N m 46 63 1b in P...

Page 323: ... Ventilation Valve Canister Bracket 2 9C987 Evaporative Emission Hose 9 10218 Front Side Outer Member 3 17757 Front Bumper 10 96321 Evaporative Emission Hose 4 9C915 Evaporative Emission 1 1 96271 Evaporative Emission Hose Canister Purge Valve 12 10009 Front Side InnerMember 5 N800369 S2 Bolt 13 N388577 S Push Pin 2 Req d 6 90653 Evaporative Emissions Canister A Tighten to 5 2 7 2 N m 46 63 Lb ln ...

Page 324: ...om vehicle Installation 1 Follow removal procedure in reverse order Evaporative Emission Canister Purge Valve Removal 1 Raise vehicle on hoist 2 Disconnect evaporative emission canister purge r valve EVAP canister purge valveX9C915 at wire harness connector 3 Remove evaporative emission tube push pin from front bumper 17757 4 Carefully disconnect evaporative emission canister purge valve from evap...

Page 325: ... Ventilation Valve Canister Bracket 2 9C987 Evaporative Emission Hose 9 10218 Front Side Outer Member 3 17757 FrontBumper 10 96321 Evaporative Emission Hose 4 9C915 Evaporative Emission 1 1 96271 Evaporative Emission Hose Canister Purge Valve 12 10009 Front Side InnerMember 5 N800369 S2 Bolt 13 N388577 S Push Pin 2 Req d 6 90653 Evaporative Emissions Canister A Tighten to 5 2 7 2 N m 46 63 Lb ln 7...

Page 326: ...from vehicle Installation 1 Follow removal procedure in reverse order Evaporative Emission Canister Purge Valve Removal 1 Raise vehicle on hoist 2 Disconnect evaporative emission canister purge valve EVAP canister purge valveX9C915 at wire harness connector 3 Remove evaporative emission tube push pin from front bumper 1 7757 4 Carefully disconnect evaporative emission canister purge valve from eva...

Page 327: ...mass air flow controlled To maintain the required exhaust emission levels the fuel metering system must be kept in good operating condition and adjusted to the specifications listed inIon the following sources the applicable section of the Powertrain ControlIEmissions Diagnosis Manual1 the applicable section of this group 1 Can be purchased as a separate item REMOVAL AND INSTALLATION Cont d Engine...

Page 328: ...wertrain control module PCM 12A650 that is directly proportional tothe throttle plate position mounted to the throttle body 9E926 and is connected to the throttle plate shaft Throttle Position Sensor 3 8L Engine THROTTLE POSITION SENSOR 98989 THROTTLE BODY 9E926 V10125 A Throttle Position Sensor 4 6L Engine FRONT OF ENGINE THROTTLE POSITION SENSOR 98989 V10120 A Mass Air Flow MAF Sensor The mass a...

Page 329: ...al to the powertrain control module PCM 12A650 that indicates the engine coolant temperature Heated Oxygen Sensor H02S Theheated oxygen sensors H02S 9F472 react with the oxygen in the exhaust gases and generate a voltage based on this reaction as follows Alow voltage indicates too much oxygen or a lean condition A high voltageindicates not enough oxygen or a rich condition The heated oxygen sensor...

Page 330: ...Refer to Section 14 Q1 2 Remove RH cowl side trim panel 02344 to expose powertrain control module PCM 12A650 3 Loosen engine control sensor wiring to PCM connector retainer bolt 4 Removeengine control sensor wiring connector from PCM 5 Remove PCM from powertrain control module bracket PCM bracket 12A659 by pulling powertrain control module downward Installation 1 Follow removal procedure in revers...

Page 331: ...tion 1 Follow removal procedure in reverse order 2 Tighten retaining bolts for mass air flow sensor to the air cleaner cover to 5 7 N m 45 61 1b in 3 Tighten engine air cleaner tube clampsto 2 3 3 2 N m 2 1 28 lb in Intake Air Temperature IAT Sensor Removal 1 Disconnect battery ground cable 14301 Refer to Section 14 Q1 2 Disconnect engine control sensor wiring 12A581 from intakeair temperature sen...

Page 332: ...el charging wiring 9D930 from engine coolant temperature sensor ECT sensorX12A648 4 On 3 8L engine remove engine coolant temperature sensor from hotwaterheater elbow connection 18599 On 4 6L engine remove engine coolant temperature sensor from heater tube located on lower intake manifold 9424 Installation 1 Follow removal procedure in reverse order 2 On3 8L engine tighten engine coolant temperatur...

Page 333: ...e oil pump intermediate shaft 6A618 should be removed with the camshaft position sensor housing Remove camshaft position sensor housing from engine front cover Installation 1 CAUTION Special service tool Syncro Positioning Tool T96T 1220G A must be obtained prior to installation of the camshaft position sensor Failure to follow this procedure will result In improper camshaft position sensor alignm...

Page 334: ...sor wiring 12A581 from camshaft position sensor CMP sensorX6B288 Item 6 7 A 8 POSITION AFTER DRIVE GEAR IS ENGAGED AND CLAMP FLANGE IS SEATED AGAINSTTHE CYUNDER BLOCK VIEW A Part 2 CENTER LINE OF CMP SENSOR PARALLELTO CENTER LINE OF ENGINE I FRONT OF ENGINE AV0248 A Number Description 12126 Camshaft Position CMP Sensor N602704 S Screw 2 Req d Tighten to 20 30 N m 15 22 Lb Ft Tighten to 2 5 3 5 N m...

Page 335: ... idle air control valve lAC valve 9F715 cannot becleaned and must be replaced if required ADJUSTMENTS Throttle Position TP Sensor The throttle position sensor TP sensor 9B989 cannot be adjusted and must be replaced SPECIFICATIONS TORQUE SPECIFICATIONS Description N m Lb Ft Engine Control Sensor Wiring 2 7 3 7 Connector to PCM Throttle Position Sensor 2 8 3 8 Retaining Screws Mass Air Flow Sensor B...

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