Page 1 Pressure Regulator Valve Inspection •••••••••••••••••••• 03-Go-30 Push Rods ...•..••••••.••.•••••••••••••••••••••••••••••••••••••••••.. 03-G0- 38 Bearings ••.•••.••..••..•..•..••••.•••.•••••••••••.••••••••••. 03-oo-20 Rocker Arm .•...•••••••••.•••••••••••••••••••••••••••••••••.••••.••• 03-G0-38 Crank shaft Main or Connecting Rod Valve Train Analysls- Dynamlc •••••••.•••••••••••.••.••.•• 03-Go- 1 3 Bearings- Fitting •••••.•••••••••••••••••••••••.••••••••••••.. 03-Go-20 1997 Thunderbird, Cougar July 1996...
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Page 3 Engine label information is located in Section 03-Q 1 A condition and meet recommended adjustment (3.8L) or Section 03-Q1 8 (4.6L). specifications: engine • fuel system • Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 4 • Inspect to determine if any of the following mechanical concerns apply: revisions • The Ford Master Parts Catalog contains a complete VISUAL INSPECTION CHART listing of the codes and their application. Mechanical Emission Calibration Number Label • Engine coolant leaks The emission calibration number label is located on the •...
Page 5 SERVICE or replace piston or cylinder blocks. • • Worn valve stem seal. REPLACE valve stem seal. • • Worn valve stem or valve guide. REPLACE valve and guide . Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 6 REPLACE cylinder head. Cracked or distorted cylinder head. • • SERVICE or REPLACE piston Damaged, worn or sticking piston ring(s). ring(s). • • REPLACE piston. Worn or damaged piston. Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 7 • oil filter adapter {688 1) must first be added to crankcase. • engine front cover {60 1 9) • oil pump and filter body {6603) {3.8L engine) Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 8 1641 kPa 1 227 kPa ( 1 1 1 PSI) ( 1 56 PSI) (238PSI) ( 1 78 PSI) ( 1 48 PSI) ( 1 78 PSI) ( 1 33 PSI) (208 PSI) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 9 If, after checking the compression pressures in all meeting Ford specification WSS-M2C 1 53-F on top of cylinders, the highest reading obtained was 1 35 1 kPa the pistons (6 1 08) in the low-reading cylinders.
Page 10 Plug all crankcase openings except the one used for connecting the leakage detector. Connect the detector to a crankcase opening {an oil level indicator tube {6754) is convenient). AA0197-A Adjust the air pressure to approximately 34 kPa {5 psi). 1997 Thunderbird, Cougar July 1 996...
Page 11 POOR VALVE SEATING: A small but regular • trailer towing applications downscale flicking can mean one or more valves • severe loading applications are not seating. • sustained high speed operation 1997 Thunderbird, Cougar July 1996...
Page 12 Shut off the engine and allow oil to drain back Make sure the selected engine oil mee t s Ford for at least five minutes. Mark the oil level specification WSS-M2C 153-F and the recommended dipstick, using the procedure above.
Page 13 Check for bent push rods (6565} and restricted oil Oil Pressure Test passage. SP ECIAL SERVICE TOOL(S) REQUIRED Valve Springs Description Tool Number • Check for broken or damaged parts. Engine Oil Pressure Gauge T73L·6600-A 1997 Thunderbird, Cougar July 1996...
Page 14 {6571) or guide mounted valve stem seals. Continue to rotate crankshaft slowly until valve tappet is in fully-raised position {highest indicator • Check for plugged oil metering orifice in cylinder reading). head oil reservoir {4.6L engine only). 1997 Thunderbird, Cougar July 1 996...
Page 15 This may be caused by too high or too low an oil level in the oil pan (6675) or by air being drawn into the system through a hole, crack or leaking gasket on the oil pump screen cover and tube (6622). 1 997 Thunderbird, Cougar July 1 996...
Page 16 Push camshaft toward rear of engine. Install Dial Indicator with Bracketry TOOL -420 1-C or equivalent so indicator point is on camshaft sprocket bolt. NOTE: P RY CRANKSHAFT IN DIRECTION OF ARROWS AND NOTE TOTAL END P LAY AA1008-A 1997 Thunderbird, Cougar July 1 996...
Page 17 Push cap toward rear of engine and observe condition of the cylinder blocks or sand holes, service amount of side clearance on dial indicator. with an epoxy sealer meeting Ford specification If side clearance exceeds specification, replace M3D35-A (E). Do not service cracks with this connecting rod (6200) and cap.
Page 18 CYLINDER BORE TAPER specification M3D35·A (E) will not stick to a dirty or oily surface. Mix an epoxy sealer base meeting Ford specification M3D35·A (E) and hardener as directed on container. Stir thoroughly until uniform. Apply an epoxy sealer meeting Ford specification M3035·A (E) with a suitable clean tool (such as...
Page 19 After honing, thoroughly clean cylinder bores with a detergent and water solution. 1997 Thunderbird. Cougar July 1 996...
Page 20 Inspect the plug bore before installation for any damage that would interfere with the proper sealing of the plug. If the bore is damaged, true the surface by boring for the next specified oversize plug. 1997 Thunderbird, Cougar July 1 996...
Page 21 It is not necessary to replace the bearing if the bearing clearance is within recommended limits. Check the clearance of bearings that appear to be satisfactory with Plastigage 081 L-6002-8 or equivalent as described. 1 997 Thunderbird, Cougar July 1 996...
Page 22 After bearing has been fitted and cleaned, apply a Crankshaft End Play light coat of clean engine oil meeting Ford Install crankshaft into cylinder blocks (60 1 0) as specification WSS-M2C 1 53-F to journal and described in Section 03-Q 1 A (3.8l) or Section bearings.
Page 23 Dress minor imperfections such as scores, nicks or PISTON RING GROOVE burrs with an oil stone. If the journals are severely CLEANER 081 L-600 2 -D marred or exceed the service limit, refinish to size for A15059-C the next undersize bearing. 1997 Thunderbird, Cougar July 1 996...
Page 24 Cylinder Bore Diameter Gauge CENTRALIZING CENTRALIZING PLUNGERS PLUNGERS GAUGING PLUNGER POSmVE CENTRALIZATION CENTRALIZING PLUNGERS AUTOMAncALLY LOCATE lltE GAUGING-CONTACTS CENTRALLY ON lltE BORE DIAMETER EVEN WHEN lltE GAUGE INSERTED AT AN ANGLE. A23321-A 1 997 Thunderbird, Cougar July 1 996...
Page 25 T73L -60 1 1-A. Remove only if there is no visible sign of cross-hatch markings on the cylinder walls. (Refer to Cylinder Block, Cylinder Walls, Refinishing.) Always clean the cylinder bore thoroughly with detergent and water solution. 1 997 Thunderbird. Cougar July 1 996...
Page 26 (within the same grade size) that is either slightly larger or smaller to achieve the specified clearance. A14483-B Replace piston that is not within specifications. For Specifications, refer to Section 03-Q 1 A (3.8L) or Section 03-D 1 B (4.6L). 1997 Thunderbird, Cougar July 1996...
Page 27 (6 1 08} to provide 0.007-0.0 1 3 mm (0.000 3 -0.0005 inch} clearance (light slip fit}. Assemble the piston, piston pin and connecting rod as described. 1 997 Thunderbird, Cougar July 1 996...
Page 28 If readings do not meet specification, replace inch). camshaft. For Specifications, refer to Section Camshaft Journal Diameters 03-Q 1A. Measure the journal diameters in the X and Y directions at points A and B as shown. JOURNAL A16624·B 1 997 Thunderbird, Cougar July 1996...
Page 29 Cleaning Indicator with Bracketry TOOL -420 1 -c or Thoroughly clean all the parts in clean solvent and equivalent so indicator point is on camshaft wipe them with a clean lint-free cloth. sprocket bolt. 1997 Thunderbird, Cougar July 1 996...
Page 30 Step 7. (60 19) and measure for wear or warpage tJsing a feeler gauge. If surface is out of flat by more than 0.04 mm (0.00 1 6 inch), replace engine front cover. 1 997 Thunderbird, Cougar July 1 996...
Page 31 Check the cylinder head for cracks and inspect the compressed air. gasket surface for burrs and nicks. Small imperfections can be dressed down using an oil stone. Replace the cylinder head if it is cracked. 1997 Thunderbird, Cougar July 1 996...
Page 32 If the runout exceeds the wear limit, reface the valve and valve seat. For Specifications, refer to Section 03-Q 1 A (3.8L) or Section 03-Q 1 B (4.6L). VALVE SEAT RUNOUT GAUGE A6658-C 1997 Thunderbird, Cougar July 1 996...
Page 33 However, when overhauling or reconditioning a cylinder head, the service clearance should be regarded as having a practical working value, and used to determine installation of the next oversize valve. 1997 Thunderbird, Cougar July 1 996...
Page 34 If the edge of the valve head is less than 0. 794 mm (0.03 1 inch) thick after grinding, replace the valve because the valve will run too hot in the engine. 1997 Thunderbird, Cougar July 1996...
Page 35 Use a seat width scale or a machinist scale to measure the seat width. Narrow the seat, if necessary, to bring it within specification. Refer to Section 03-0 1A (3.8L) or Section 03-Q 1 8 (4.6L) for Specifications. 1997 Thunderbird, Cougar July 1 996...
Page 36 Section 03-o 1 A (3.8L) or Section 03-0 1 8 (4.6L), replace the valve. Valve Spring Length Inspection Inspect each valve spring for cracks or damage and replace as necessary. Measure the free length of each valve spring as shown. A8516-C 1997 Thunderbird, Cougar July 1 996...
Page 37 Inspect the push rod rocker arm bore for nicks, scratches, scores or scuffs. Replace any damaged Check the ends of the push rods for nicks, grooves, parts. roughness or excessive wear. Replace damaged push rods. 1997 Thunderbird, Cougar July 1996...
Page 38 Remove all gasket or foreign material from all inlet and outlet sealing surfaces of the exhaust manifolds (9430). !""'" "" "' Inspection Inspect the cylinder head joining flanges of the exhaust manifolds for evidence of exhaust gas leaks. 1 997 Thunderbird, Cougar July 1 996...
Page 39 Vacuum I Pressure Tester 0 1 4-R1054 107-R092 1 Sav-A-Thread Spark Plug Kit Tool Number Description 164-R0756 Oil Leak Detector D81 L-420 1 -A Feeler Gauge 164-R3705 Fluorescent Oil Additive D81 L-6002-B Plastigage (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 40 • 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. 1997 Thunderbird, Cougar July 1 996...
Page 41 (6256). Induction System • the distributor drive gear (6255). Sequential multiport fuel injection (SFI) provides the fuel I air mixture needed for burning in the cylinder. Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 42 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. 1997 Thunderbird, Cougar July 1996...
Page 43 Engine, 3.8L 03·01A·4 03-01A·4 IN-VEHICLE SERVICE Engine Components 3.8L Engine-Disassembled View 1 997 Thunderbird, Cougar July 1 996...
Page 44 03-01 A-5 Engine, 3.8L 03-01 A-5 IN-VEHICLE SERVICE (Continued) 3.8L Engine- Disassembled View (Continued) 1 997 Thunderbird, Cougar July 1 996...
Page 45 03·01A·6 Engine, 3.8L 03·01 A·6 IN-VEHICLE SERVICE (Continued) 3.8L Engine-Disassembled View (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 46 ,..,..,.,..,. -.- ..,.- ..,....,..,..,. ..,. .,..,..,..,. ___,. ..,. , . _ ..,. ..,.-- •...
Page 47 9P76 1 EGA Vacuum Control Valve Hose N801647 Bolt (2 Req'd) 9P76 1 EGA Vacuum Control Valve N62 1939 Nut (2 Req'd) Hose N62 1939 Nut (2 Req'd) 9E936 Throttle Body Gasket (Continued) (Continued) 1 997 Thunderbird, Cougar July 1996...
Page 48 N8054 16 8501 Water Pump Stud Bolt N8054 1 7 8507 Water Pump Housing Gasket Oil Pump Screen Cover and 6622 Tube 6A618 Oil Pump Intermediate Shaft Bolt (2 Req'd) 1 7 1 N801689 (Continued) (Continued) 1997 Thunderbird, Cougar July 1996...
Page 49 NOTE: Lightly oil bolt and stud threads before installation. Using solvent, clean cylinder head ( 6 049) and valve cover sealing surfaces to remove all gasket material and dirt. Position and install a new valve cover gasket onto valve cover. 1997 Thunderbird, Cougar July 1996...
Page 50 (22-29 1b-ft). For final tightening, the camshaft over valve stem. (6250) may be in any position. Compress valve spring using a suitable valve Install valve covers as described. spring compressor and install valve spring retainer keys. 1 997 Thunderbird, Cougar July 1996...
Page 51 When using a remover tool, rotate valve tappet back and forth to loosen it from gum or varnish that may have formed on the valve tappet. 1997 Thunderbird, Cougar July 1996...
Page 52 Remove throttle body if necessary. Refer to 10 N · m (8 Lb-Ft) Section 03-04A. 20 N·m ( 15 Lb-Ft) • 32 N·m (24 Lb-Ft) Remove the EGR valve {EGR valve){9D475) from the upper intake manifold. Refer to Section 03-QS. 1 997 Thunderbird, Cougar July 1996...
Page 53 Remove fuel injectors and fuel injection supply manifold (9F792). Refer to Section 03-Q4A. Remove heater water inlet hose. A20849-C Part Item Number Description 9424 Intake Manifold, Upper Stud (Part of 9424) (Continued) Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 54 Cylinder Head W701 775 Bolt (4 Req'd) Tighten to 8- 1 1 N·m (7 1-97 9F792 Fuel Injection Supply Lb-ln) Manifold Tighten to 20-30 N·m (15-22 9424 Intake Manifold Lb-Ft) N606689 Bolt (Continued) 1 997 Thunderbird, Cougar July 1 996...
Page 55 If it is necessary to pry on the lower intake manifold, use care to prevent damage to machined surfaces. Remove lower intake manifold. 1 997 Thunderbird, Cougar July 1 996...
Page 56 NOTE: Prior to applying sealer, clean sealing surfaces of cylinder heads {6049) and lower intake manifold with Metal Surface Cleaner F4AZ - 1 9A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.
Page 57 605 1 Head Gasket 5 N·m (44 1b-in). Carefully lower intake manifold into position on cylinder blocks and cylinder head. Use locating pins as necessary to guide intake manifold. 1997 Thunderbird, Cougar July 1996...
Page 58 {60 1 0) using cylinder head to block dowels drive belt {8620). Refer to Section 03-Q5. {6A008) for alignment. If LH cylinder head {6049) is being removed, perform the following: Remove oil filler cap {6766). 1997 Thunderbird, Cougar July 1996...
Page 59 Tighten to 2Q-30 N·m ( 1 5-22 1b-ft). 20 N·m ( 1 5 1b-ft). • Rotate an additional 1 75- 1 85 degrees. 40 N·m (30 lb-ft). • Go to next bolt in sequence. 50 N·m (37 lb-ft). 1 997 Thunderbird, Cougar July 1996...
Page 60 Front Cover Seal Replacer T70P-6B070-B Lubricant D9AZ- 1 9579-D or equivalent meeting Damper 1 Front Cover Seal Replacer T82L-63 16-A Ford specification ESR-M99C8Q-A. Vibration Damper Remover Adapter T82L -63 1 6-B Install rocker arms as described. 1 997 Thunderbird, Cougar July 1 996...
Page 61 CAUTION: Use care to prevent damage to engine front cover (601 9)and crankshaft (6303) or engine oil leakage may occur. Remove crankshaft front seal (6700) from the engine front cover using a hammer and punch. 1997 Thunderbird, Cougar July 1996...
Page 62 CAUTION: If using a prying device to assist in NOTE: Gasket and Trim Adhesive water pump removal, be careful not to 07 AZ -1 98508-B or equivalent meeting Ford damage the mating surfaces. specifications ESR-M 1 1 P 1 7-A and...
Page 63 (60 1 9). fan shroud (81 46) assembly. Refer to Section 1 2. Raise vehicle on hoist. Refer to Section OO-Q2. 03-Q3_ Remove drive belt (8620) and water pump pulley (8509). 1997 Thunderbird, Cougar July 1 996...
Page 64 *THOROUGHLY COAT GASKET NOTE: Gasket and Trim Adhesive SEALING SURFACE WITH CLEAN D7 AZ - 1 98508-8 or equivalent meeting Ford ENGINE OIL MEETING FORD specifications ESR-M 1 1 P 1 7 -A and SPECIFICATION WS8-M2C153-F PRIOR TO FILTER INSTALLATION...
Page 65 1 1 . NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface cleaner Install oil pan as described. F4AZ - 1 9A536-RA or equivalent meeting Ford Connect lower radiator hose. lighten clamp specification WSE-M5B392-A, to remove all securely.
Page 66 Remove timing chain vibration damper (6284} 27. Fill crankcase to proper level with engine oil (three bolts} from front of cylinder blocks (6010}. meeting Ford specification WSS-M2C 1 53-F. (This requires pulling back on ratcheting 28. CAUTION: The engine has aluminum cylinder...
Page 67 6256 Camshaft Sprocket N805256-S Camshaft Sprocket Key 6306 Crankshaft Sprocket 6250 Camshaft 6268 Timing Chain /Belt 6265 Camshaft Sprocket Spacer 6K305 Engine Balance Shaft Gear Spacer Tighten to 40-50 N·m (30-36 Lb-Ft) (Continued) 1 997 Thunderbird, Cougar July 1 996...
Page 68 (6266) for damage or leakage. Replace or reseal if necessary (engine removed). Lubricate the camshaft lobes and bearing surfaces with Engine Assembly Lubricant D9AZ- 1 9579-D or equivalent meeting Ford specification ESR-M99C8Q-A. CAMSHAFT Install camshaft. Be careful not to damage...
Page 69 Disconnect ignition wire from ignition coil ( 1 2029) Y -pipe retaining nuts. and ignition wires from spark plugs ( 1 2405). Lower vehicle. Refer to Section 03-Q7 A. Disconnect EGR valve to exhaust manifold tube (9D477)from exhaust manifold (9430). 1997 Thunderbird, Cougar July 1996...
Page 70 14. Start engine and check for exhaust leaks. Tighten to 34-47 N·m (25-34 Lb-Ft) Removal Loosen retaining nut and remove oil level indicator tube support bracket. Disconnect ignition wires from spark plugs. Refer to Section 03-Q7 A. 1997 Thunderbird, Cougar July 1996...
Page 71 Install Rotunda 3.8L Engine Lifting Brackets 0 1 4-Q0792 and Three Bar Engine Support D88L-600Q-A or equivalent. Raise vehicle on a hoist. Refer to Section OO-Q2. Remove front engine support insulator through-bolts. 10. Partially lower vehicle. 1 997 Thunderbird, Cougar July 1996...
Page 72 After this time, the sealer may start to set-up and its sealing effectiveness may be reduced. Apply Silicone Gasket and Sealant F6AZ- 19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to oil pan. � 1 997 Thunderbird, Cougar July 1 996...
Page 73 Install oil pan retaining bolts at cylinder blocks and bell housing. Install crankshaft position sensor lower shield. lighten in two steps; in sequence to 4-5 N·m (36-44 lb-in) then in sequence to 9- 1 2 N·m (8Q- 106 1b-in). 1 997 Thunderbird, Cougar July 1996...
Page 74 2 1 . Install hood weather seal. would cause premature crankshaft main bearing wear. 22. Install radiator upper sight shield and two retaining bolts. 23. Install air cleaner outlet tube. Refer to Section 03- 1 2. 1997 Thunderbird, Cougar July 1996...
Page 75 If rear crankshaft main bearing was removed, 6337 Crankshaft Thrust Main perform the following: Bearing, Lower Remove all traces of sealant from main Crankshaft Main Bearing, 6333 bearing cap to cylinder block parting line. Upper (3 Req'd) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 76 Engine Assembly lubricant D9AZ - 19579-D or equivalent I'TlE!eting Ford specification Tool Number Description ESR-M99C80-A. T64L-60 1 1 -EA Cylinder Ridge Reamer Install ignition wire spark plug boots or suitable protection on connecting rod (6200). 1997 Thunderbird, Cougar July 1 996...
Page 77 12. Install lower intake manifold and upper intake manifold as described. 1 5. Start engine and check for oil and coolant leaks. 13. Fill crankcase with the correct amount of clean engine oil meeting Ford specification WSS-M2C 1 53-F. 1997 Thunderbird, Cougar July 1996...
Page 78 Install spark plugs as described inSection same position as on original flywheel. 03-07A. Coat threads of flywheel retaining bolts with Pipe Sealant with Teflon® DBAZ- 1 9554-A or equivalent mee t ing Ford specification WSK-M2G35Q-A2. 1997 Thunderbird, Cougar July 1996...
Page 79 SPECIAL SERVICE TOOL(S) REQUIRED Remove transmission. Refer to Section 0 7 -o 1 . Remove flywheel (6375) as described. Description Tool Number Remove engine rear plate (7007). Jet Plug Remover T77L-9533-B Rear Main Seal Replacer T82L-670 1-A 1997 Thunderbird, Cougar July 1996...
Page 80 2Q-30 N·m { 1 5-22 Remove oil pan drain plug and drain. lb-ft). Remove oil bypass filter {67 1 4). Installation Install oil pan drain plug. lighten to 20-34 N·m{1 5-25 1b-ft). 1 997 Thunderbird. Cougar July 1 996...
Page 81 Tighten to 1 1-24 N·m (98-2 1 2 Lb-ln) Tighten to 1 1 - 1 6 N·m (98- 1 4 1 Lb-ln) Sensors Oil Pressure Sensor Removal Disconnect wiring connector from oil pressure sensor (9278). 1997 Thunderbird, Cougar July 1996...
Page 83 N-m (2Q-33 lb-ft). Install inspection plug to engine 45. Refill crankcase to proper level with clean engine rear plate. oil meeting Ford specification WSS-M2C 1 53-F. 10. Install and tighten front engine support insulator 46. Refill engine cooling system. Refer to Section through bolts.
Page 84 Description Pulling Plate (Part of Expanding Collet (Part of T65L-6250-A) T65L-6250-A) Puller Screw (Part of B ack-Up Nut (Part of T65L -6250-A) T65L-6250-A) Pulling Nut (Part of Camshaft Bearing 626 1 T65L-6250-A) (Continued) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 85 Rear Intermediate Main Bearing Cap (Part of 60 10) Refer to Section 03-QO for crankshaft cleaning, 6337 Crankshaft Thrust Main inspection and refinishing. Bearing - Lower 6333 Crankshaft Main Bearing - Upper (3 Req'd) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 86 REMOVAL AND INSTALLATION (Continued) NOTE: Prior to applying sealer, clean sealing surfaces with Metal Parts Cleaner Item Number Description F4AZ- 1 9A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all 6337 Crankshaft Thrust Main residues that may interfere with the sealers Bearing-Upper ability to adhere.
Page 87 ( 1 8663) from water (6565). The location of each rocker arm, push pump (850 1). rod and rocker arm seat (6A528) should be noted. When engine is assembled, each component should be installed in its original position. 1997 Thunderbird, Cougar July 1996...
Page 88 When engine is assembled, each from front of cylinder blocks. (This requires pulling component should be installed in its original back on ratcheting mechanism and then installing position. pin through hole in bracket to relieve tension.) 1 997 Thunderbird, Cougar July 1 996...
Page 89 Rubber D6AZ- 1 9562-BA or AA or equivalent meeting Ford specifications ESB-M4G92-A Crankshaft Main Bearing, 6333 and ESE-M4G 1 95-A to cylinder block rear Upper (3 Req'd) main bearing cap parting line. 6337 Crankshaft Thrust Main Bearing, Upper (Continued) 1 997 Thunderbird, Cougar July 1996...
Page 90 Install connecting rod bearings in connecting rods (6200) and connecting rod caps. NOTE: Lubricate piston and cylinder walls with Engine Assembly Lubricant D9AZ- 1 9579-D or equivalent meeting Ford specification ESR-M99C8Q-A before installation. NOTE: Scratching of crankshaft journal can be prevented by covering connecting rod bolts with ignition wire spark plug boots or flexible hose.
Page 91 Perfect-Seal Sealing Compound B5A- 1 9554-A or equivalent meeting • tighten to 20-25 N·m ( 1 5- 1 8 1b-ft). Ford specification ESE-M4G 1 1 5-A before • installation. tighten retaining nuts to 40-45 N·m (30-33 lb-ft).
Page 92 1 1 . Lubricate timing chain with clean engine oil sealer which may have bee n squeezed into meeting Ford specification WS5-M2C 1 53-F. seal groove when rear main bearing cap was 1 2. Rotate crankshaft, as necessary, to position installed.
Page 93 Front and rear crankcase ventilation tube. using Damper / Front Cover Seal Replacer • Positive crankcase ventilation valve. T82L -631 6-A and Front Cover Seal Replacer T70P-68070-A. Tighten retaining bolt to 1 4Q-180 N·m (103-132 1b-ft). 1997 Thunderbird. Cougar July 1 996...
Page 94 Compressor T8 1 P-65 1 3-A. Remove valve spring -- ENGINE retainer keys (65 1 8) and release valve springs. FRONT OF_ ENGINE VIEW A24300- A Part N umber Description 6049 Cylinder Head 9448 Exhaust Manifold Gasket (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 95 ESR-M99C80-A. Apply Multi-Purpose Mark piston (6 1 08) to ensure assembly with Grease DOAZ- 1 9584-AA or equivalent meeting Ford same connecting rod and installation in same specification ESB-M 1 C93-A and ESR-M 1 C 1 59-A to cylinders from which they were removed.
Page 96 Oil Pressure Relief Valve piston rings. Refer to Section 03-00. Removal After drilling a hole through valve plug, remove plug with a slide hammer or by prying. Remove spring and pressure relief valve from bore. 1997 Thunderbird, Cougar July 1 996...
Page 97 20-30 N·m ( 1 5-22 lb-ft). Cylinder Block Assembly Disassembly Mount the engine in a workstand and remove all parts not furnished with the new cylinder blocks (60 1 0) following the procedures in Removal and Installation. 1997 Thunderbird, Cougar July 1996...
Page 98 0.038·0.083 mm pressure in a direction to collapse valve tappet. (0.00 1 5-0.0033 in) Valve Head Diameter • Intake 45.3 mm ( 1 .78 in) • Exhaust 37. 1 mm ( 1 .46 in) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 99 • Journal Runout Limit 0.05 mm (0.002 in) (2) (2. 192·2. 1 9 1 in) 0.05 mm (0.002 in) (3) (Continued) • Surface Finish (RMS) 0.3 micrometers ( 1 1 . 8 micro in) (Continued) 1997 Thunderbird, Cougar July 1996...
Page 100 0.075 per 25 mm (0.003 • Service Limit Side Clearance 0. 1 5 mm per in) MAX (0.0006 in MAX) • Bend 0.04 per 25 mm (0.00 1 6 (Continued) per in) (Continued) 1 997 Thunderbird, Cougar July 1 996...
Page 101 New belt installed and tensioned; engine not rotated. Bracket Bolt Used belt is any belt that has been rotated on an engine. Cold belt (i.e., 3-hour soak; 0 warm up.) Heater Water Hose Retaining 20-30 15-22 (Continued) 1 997 Thunderbird, Cougar July 1 996...
Page 102 Tighten in sequence as follows: Shock Absorber to Control 1 40- 195 1 04- 1 43 20 N·m ( 1 5 1b-ft). Arm - Bolt 40 N·m (30 lb-ft). (Continued) 50 N·m (37 lb-ft). 1997 Thunderbird, Cougar July 1 996...
Page 103 T82L-63 16-B T59L- 100-B Vibration Damper Remover � Impact Slide Hammer Adapter T51L-1GO-I T1121.-e31&-l T64L-60 1 1 -EA Cylinder Ridge Reamer T82L-670 1 - A • ® Rear Main Seal Replacer �� T1121.-17D1-A TML-4101 1-EA (Continued) 1997 Thunderbird, Cougar July 1996...
Page 104 Description D81 L-600-A Lb-ln Torque Wrench 0 14-00792 Engine Lifting Brackets (3.8L) D81 L-600-B Lb-Ft Torque Wrench 0 1 4-00793 Separator Bar D81 L-420 1-A Feeler Gauge Main Bearing Insert Tool TOOL-633 1 -E 1997 Thunderbird, Cougar July 1 996...
Page 105 • single overhead camshafts (6250) (OHC). two valves per cylinder. • Engine Identification It is imperative that the engine codes and the calibration number be used when ordering parts or making inquiries about the engine. 1997 Thunderbird, Cougar July 1996...
Page 106 ,_...,.._ 10 u.& PA _,_ AM.ICMU TO I .. - =-.� - - - - CATALYST .... . 1'11C I HOal ... l _. A14873-D Can be purchased as a separate item. 1997 1996 Thunderbird, Cougar July...
Page 107 (6250) by two sprockets and two timing chains. The crankshaft thrust main bearing (6337) and crankshaft thrust washer (6334) limits crankshaft end play and absorbs thrust loads applied to the crankshaft ends. 1997 Thunderbird, Cougar July 1 996...
Page 108 Oil is pumped through the oil bypass filter (67 1 4) on lubrication. the left front side of the cylinder blocks (60 1 0). • Oil enters the main oil gallery where it is distributed to the crankshaft main journals, and to both cylinder heads (6049). 1997 Thunderbird, Cougar July 1996...
Page 109 (850 1 ), then returns to the radiator (8005) • System pressure is limited by an integral, internally through the water hose connection (8592). vented relief valve which directs the bypass oil back to the inlet side of the oil pump. 1997 Thunderbird, Cougar July 1 996...
Page 110 (68209) that will not require any drive belt tension adjustment for the life of the drive belt. • A loose drive belt will result in slippage which may cause a noise complaint or improper accessory operation. 1997 1996 Thunderbird. Cougar July...
Page 111 03-018-7 Engine, 4.6L (2V} 03-01 8-7 IN-VEHICLE SERVICE Engine Components Disassembled View A24843- A 1997 Thunderbird, Cougar July 1996...
Page 112 < • :::t • < ::::u < � � ; · ::;, - · ::;, � < :::1 � � � � ..A24844- A...
Page 113 Engine, 4.6L (2V) 03-G1B·9 03-018-9 IN-VEHICLE SERVICE (Continued) Disassembled View (Continued) 1997 Thunderbird, Cougar July 1996...
Page 114 6345 Manifold Tube Cap Stud (10 Req'd) 9L437 Intake Manifold Water 6C070 Torque Converter Inspection Connection Gasket Hole Cover Bolt (2 Req'd) N806 156 0-Ring N806807 N81 1017 Stud Bolt (4 Req'd) (Continued) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 115 Bolt (24 Req'd) N806300 Stud Bolt (5 Reef d) 6B280 Camshaft Bearing Cap 601 9 Engine Front Cover 6A247 Camshaft LH N606543 Bolt (4 Req'd) 6500 Valve Tappet (16 Req'd) 6L266 Timing Chain Tensioner (Continued) (Continued) 1997 Thunderbird, Cougar July 1996...
Page 116 Oil Pressure Sensor 9278 N806155 Bolt 6881 Oil Filter Adapter 12043 Ignition Coil Mounting Strap 1 9 1 6840 Oil Filter Adapter Gasket N804178 Nut (3 Req'd) 1 92 N806007 Dowel (2 Req'd) Bolt N806177 (Continued) (Continued) 1997 Thunderbird, Cougar July 1996...
Page 117 Section 1 4-o 1 . into valve cover. Use Gasket and Trim Adhesive Disconnect spee d control actuator cable D7 AZ- 1 98508-8 or equivalent meeting Ford (9A825) from throttle body (9E926). Position specifications ESR-M 1 1 P 1 7-A and speed control actuator cable out of the way.
Page 118 ESR-M 1 1 P 1 7 -A and ESE-M2G52-A. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ - 1 9A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
Page 119 Install Valve Spring Spacer T9 1 P-6565-AH Remove valve spring compressor and spacer. between valve spring coils. Repeat Steps 1 through 4 until all rocker arms are installed. Install valve cover, as described. Start engine and check for leaks. 1997 Thunderbird, Cougar July 1996...
Page 120 Install Valve Spring Spacer T9 1 P-6565-AH between valve spring coils. Compress valve spring using Valve Spring Compressor T9 1 P-6565-A and install valve spring retainer key. Remove valve spring compressor and spacer. 1997 Thunderbird, Cougar July 1996...
Page 121 SPECIAL SERVICE TOOL(S) REQUIRED NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner Description Tool Number F4AZ - 1 9A536-RA or equivalent meeting Ford Crankshaft Damper Remover T58P-6316-D specification WSE-M5B392-A, to remove all T7 4P-6700-A residues that may interfere with the sealer's Front Cover Seal Remover ability to adhere.
Page 122 (CKP sensorX6C3 1 5). Remove drive belt (8620). Refer to Section 20. Remove eight stud bolts and seven bolts retaining 03-QS. engine front cover to engine. Remove water pump pulley (8509). Raise vehicle on hoist. 1997 Thunderbird, Cougar July 1 996...
Page 123 NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner Installation F4AZ- 1 9A536-RA or equivalent meeting Ford Remove all traces of dirt, oil or previously applied specification WSE-M5B392-A to remove all sealant from the engine front cover, cylinder residues that may interfere with the sealer's heads and cylinder block sealing surfaces.
Page 124 Install studs and bolts retaining engine front cover four minutes after applying sealant. to engine in location as shown in illustration. lighten to 2Q-30 N·m ( 1 5-22 lb-ft) in no more than four minutes after applying sealant. 1997 Thunderbird, Cougar July 1 996...
Page 125 1 2. Install valve covers as described. ( 1 5-22 1b-ft). 1 3. Raise vehicle. Install LH ignition coil bracket. Tighten nuts to 2Q-30 N·m ( 1 5-22 1b-ft). Install LH ignition coil and ignition wires as an assembly. 1997 Thunderbird, Cougar July 1 996...
Page 126 03-01 8-22 IN-VEHICLE SERVICE (Continued) 14. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ - 1 9A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
Page 127 Do not tighten at this time. Remove two bolts retaining RH timing chain tensioner (6L266) to cylinder head and remove If removed, position RH camshaft sprocket timing chain tensioner. spacer and sprocket on camshaft. 1997 Thunderbird, Cougar July 1996...
Page 128 Refer to the following illustration for proper crankshaft sprocket installation. NOTE: Make sure tapered part of crankshaft sprocket faces away from cylinder blocks (60 10). If removed, install LH crankshaft sprocket. 1997 Thunderbird, Cougar July 1996...
Page 129 WOODRUFF KEY WITH the timing chain guide. KEYWAY ON TOOL A16254-B 1 4. Lubricate timing chain tensioner arm contact surfaces with clean engine oil and install RH and LH timing chain tensioner arms on their dowels. 1997 Thunderbird, Cougar July 1996...
Page 130 Tool Number Cam Positioning Tool T91 P·6256·A Cam Positioning Tool Adapters T92P·6256·A Install camshaft timing chains and timing chain tensioners as described. Removal Remove camshaft timing chains and timing chain tensioners (6L266) as described. 1997 Thunderbird, Cougar July 1 996...
Page 131 13. Remove three nuts retaining LH ignition coil bracket to engine front cover and remove. 14. Remove water pump pulley (8509). 15. Remove positive crankcase ventilation valve (PCV valve)(6A666) from valve cover (6582) and position out of the way. 1997 Thunderbird, Cougar July 1 996...
Page 132 Lb-ln) 32. Remove engine front cover as described. FRONT ENGINE APPLY SILICONE LH SIDE SHOWN GASKET SEALER RH SIDE SIMILAR AA0636·A Part Item Number Description Valve Cover (RH) 6582 Valve Cover Gasket 6584 (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 133 Install Valve Spring Compressor T9 1 P-6565-A damage to pistons and/ or valve train will under camshaft and on top of valve spring result. retainer (65 1 4). Rotate crankshaft counterclockwise 45 degrees from toe. CRANKSHAFT KEYWAY A13655-B 1997 1996 Thunderbird, Cougar July...
Page 134 40. Remove camshaft straight upward to avoid NOTE: Each camshaft bearing cap is tightened bearing damage. individually. lighten camshaft bearing cap retaining bolts in sequence to 8- 1 2 N-m (7 1 - 1 06 lb-in}. 1997 Thunderbird, Cougar July 1996...
Page 135 If necessary, install Cam Positioning Tool surfaces with Metal Surface Cleaner Adapters T92P-6256-A and Cam Positioning Tool F4AZ- 1 9A536-RA or equivalent meeting Ford T91 P-6256-A on flats of camshaft and install specification WSE-M5B392-A, to remove all camshaft sprocket spacer (6265) and camshaft residues that may interfere with the sealer's sprocket (6256).
Page 136 1 2A227 Crankshaft Position Sensor 601 9 Engine Front Cover Pulse Wheel 6049 Cylinder Head 6020 Engine Front Cover Gasket N806040-S Dowel (2 Req'd) 6010 Cylinder Blocks 6303 Crankshaft 67 10 Oil Pan Gasket (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 137 18. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ - 1 9A536-RA or equivalent meeting Ford specification WSE-M58392-A to remove all residues that may interfere with the sealer's ability to adhere.
Page 138 23. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ - 1 9A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
Page 139 44. Connect fuel lines. Refer to Section 1 o-o 1 . 14. Slide ignition coil brackets and ignition wire and bracket ( 1 2280) assembly off mounting studs and remove from vehicle. 1997 Thunderbird, Cougar July 1996...
Page 140 (9278). 3 1 . Position fuel charging wiring out of the way. 32. Disconnect EGR valve to exhaust manifold tube (9D477) from RH exhaust manifold (9430). 1997 Thunderbird, Cougar July 1996...
Page 141 N81 10 1 1 -S309 Bolt (2 Req'd) (Continued) 46. Remove intake manifold gaskets (946 1 ). 47. Remove eight stud bolts and seven bolts retaining engine front cover to engine. Remove engine front cover. 1997 Thunderbird, Cougar July 1996...
Page 142 Remove 1 0 bolts retaining LH cylinder head to cylinder blocks. A1383&-a 50. NOTE: Cylinder head must not be set on head face. If valves are open damage may occ u r. Remove LH cylinder head. 1997 Thunderbird, Cougar July 1 996...
Page 143 CAUTION: Cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused. Install lower rear cylinder head bolts and retain in position with rubber bands or similar items as described. 1997 Thunderbird, Cougar July 1996...
Page 144 Rotate head bolts in sequence an additional block dowels (6A008). 85-95 degrees. Apply clean engine oil meeting Ford specification 1 5. Position heater water hose on cylinder head and WSS-M2C 153-F to all head bolt spot-faces. install two bolts. Tighten retaining bolts to 2Q-30 N-m ( 1 5-22 1b-ft).
Page 145 1 2A227 Crankshaft Position Sensor 6019 Engine Front Cover Pulse Wheel 6049 Cylinder Head 60081 Engine Front Cover Gasket N806040-S Dowel (2 Req'd) 60 10 Cylinder Blocks 6303 Crankshaft 67 10 Oil Pan Gasket (Continued) 1997 Thunderbird, Cougar July 1996...
Page 146 NOTE: Make sure alignment tabs on intake radiator hose and install two bolts. Tighten to manifold gaskets are aligned with holes in 2Q-30 N·m ( 1 5-22 1b-ft). cylinder heads. Position new intake manifold gaskets on cylinder heads. 1997 Thunderbird, Cougar July 1996...
Page 147 Bolt (2 Req'd) N81 101 1 -S309 Lb•Ft) 9424 Intake Manifold (Continued) 27. Connect heater water hose. 29. Connect vacuum hose to throttle body adapter vacuum port. 28. Connect fuel charging wiring to heated oxygen sensors. 1997 Thunderbird, Cougar July 1996...
Page 148 Apply Silicone Gasket and Sealant F6AZ - 1 9562-AA or equivalent meeting Ford specification WSE-M4G323-A6 at both places engine front cover meets cylinder head. 3 1 . Position and, using Gasket and Trim Adhesive...
Page 149 4 1 . NOTE: Prior to applying sealer, clean sealing T74P-6316-B surfaces with Metal Surface Cleaner F4AZ - 1 9A536-RA or equivalent meeting Ford specification WSE-M58392-A to remove all 44. Install crankshaft pulley bolt and crankshaft pulley residues that may interfere with the sealer's retaining washer.
Page 150 (8507) and clean sealing surface of cylinder 16. Lower vehicle. blocks (60 1 0). 1 7. Disconnect accelerator cable (9A758) and speed Lubricate water pump housing gasket with Ford control actuator cable (9A825) from throttle body Premium Cooling System Fluid E2FZ - 19549-AA (9E926).
Page 151 9424 Intake Manifold N808130-S309 Bolt (8 Req'd) 6049 Cylinder Head, LH 8592 Water Hose Connection 6049 Cylinder Head, RH N81 101 1 -S309 Bolt (2 Req'd) (Continued) Remove intake manifold gaskets {946 1 ). 1997 Thunderbird, Cougar July 1 996...
Page 152 Part Item Number Description Item Number Description 9424 Intake Manifold N808130·S309 Bolt (8 Req'd) 6049 Cylinder Head, LH 8592 Water Hose Connection 6049 Cylinder Head, RH N81 101 1 -S309 Bolt (2 Req'd) (Continued) (Continued) 1997 Thunderbird, Cougar July 1996...
Page 153 For LH exhaust manifold, disconnect the steering engine oil meeting Ford specification shaft and position out of the way. Refer to Section WSS-M2C 1 53-F. 1 1 -Q4. 26. Start engine and check for leaks. 1997 Thunderbird, Cougar July 1 996...
Page 154 Position two exhaust manifold gaskets and LH exhaust manifold to cylinder head and studs and install eight retaining nuts. Tighten in sequence to 18-22 N·m ( 1 4- 1 6 1b-ft). Refer to above illustration. 1997 Thunderbird, Cougar July 1996...
Page 155 With a screw-type jackstand raise the extension transducer hoses from EGR valve to exhaust housing (7 A039) of the transmission slightly to manifold tube (9D477). remove oil pan. 16. Remove two bolts retaining EGR valve to throttle body adapter. 1997 Thunderbird, Cougar July 1 996...
Page 157 Part surfaces with Metal Surface Cleaner Item Number Description F4AZ -1 9A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all Tighten to 1 1 - 1 6 N·m (9-1 1 residues that may interfere with the sealer's Lb-Ft) ability to adhere.
Page 158 29. Install windshield wiper governor and retaining bracket. Refer to Section 0 1 - 1 6. 30. Fill crankcase to specified level on oil level dipstick (6750) with engine oil meeting Ford specification WS8-M2C 1 53-F. 3 1 . Evacuate and recharge air conditioning. Refer to Section 1 2-oo .
Page 159 Tighten to 8- 12 N-m (7 1-106 6675 Oil Pan Lb-ln) Oil Pan Gasket 6710 Cylinder Blocks 6010 Tighten to 20 N·m ( 1 5 Lb-Ft) Tighten to 1 1 - 16 N·m (9- 1 1 Lb-Ft) 1997 Thunderbird, Cougar July 1 996...
Page 160 Section 03-QO. 08 1L-6002-C Piston Ring Compressor Tool If required, disassemble piston from connecting T93P-6 136-A Connecting Rod Guide Tool rod as described. (Continued) If required, replace piston rings as described. 1 1 . 1997 Thunderbird, Cougar July 1 996...
Page 161 Install oil pump screen cover and tube. N606021 -S Bolt (4 Req'd) 6600 Oil Pump N80738-S96 0-Ring N806 1 55-S2 Bolt (2 Req'd) Tighten to 20-30 N·m (15-22 Lb-ln) Tighten to 8- 1 2 N·m (7 1-106 Lb-ln) 1997 Thunderbird, Cougar July 1996...
Page 162 Turn crankshaft until connecting rod (6303) bearing to be removed is accessible. If more than one connecting rod bearing is being removed, identify the connecting rod caps, connecting rods and connecting rod bearings for cylinder position. 1997 Thunderbird, Cougar July 1996...
Page 163 {6375) crankshaft and remove flywheel. Lubricate crankshaft and connecting rod bearing {6303) surfaces with clean engine oil meeting Ford specification WS8-M 1 53-F. CAUTION: Be sure not to scratch cylinder wall or crankshaft journal with connecting rod. Pull piston (6 1 08) down until connecting rod bearing seats on crankshaft journal.
Page 164 T95P-6701-BH NOTE: Prior to applying sealer, clean sealing AA0243-A surfaces with Metal Surface Cleaner F4AZ- 1 9A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere. NOTE: Crankshaft rear oil seal retainer must be installed and bolts tightened to specification within five minutes of sealer application.
Page 165 Unscrew the oil bypass filter from oil filter adapter (688 1 ) using an oil filter wrench. Coat rubber seal of oil bypass filter with clean engine oil meeting Ford specification Clean the sealing surface of oil filter adapter. WS8-M2C 1 53-F.
Page 166 (EVAP canister Inspect Q-ring and replace as needed. purge valveX9C9 1 5). Disconnect positive battery cable from power Lubricate Q-ring with engine oil meeting Ford specification WSS-M2C 1 53-F and route oil level distribution box. indicator tube through exhaust manifold (9430) Disconnect body vacuum supply hose from main 1 1 .
Page 167 42. Remove LH and RH front engine support insulator flange. Support rear axle assembly (4200) with through bolts. jackstand. 29. Remove two nut and bolt assemblies retaining the front of the rear axle assembly to the rear sub-frame. 1997 Thunderbird, Cougar July 1996...
Page 168 LH Engine Lift Eye (Part of Position transmission case to cylinder block Rotunda Engine Lift Bracket brackets and install three bolts and one stud. Set) Tighten bolts and stud to 25-43 N·m ( 1 9-3 1 1b-ft). (Continued) 1997 Thunderbird. Cougar July 1 996...
Page 169 26. Install two nut and bolt assemblies retaining front Refer to Section 1 2-QO. of the rear axle assembly to the rear sub-frame. lighten to 98- 1 20 N·m (73-88 lb-ft). 54. Connect battery ground cable. 1997 Thunderbird. Cougar July 1996...
Page 170 REMOVAL AND INSTALLATION (Continued) 55. Fill crankcase to specified level on oil level Remove RH and LH valve covers (6582) from dipstick (6750) with engine oil meeting Ford cylinder heads (6049). specification WSS-M2C 1 53-F. 56. Start engine and check for coolant, oil and fuel leaks.
Page 171 Tighten to 1 1 · 16 N-m (9-1 1 W701240-S309 Bolt (4 Req'd) Lb·Ft) 6B288 Camshaft Position Sensor 1 3. Remove engine front cover. Bolt N806155-S2 Bolt N806 155-S2 Tighten to 20 N·m (14 Lb-Ft, Then an Additional 60 Degrees) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 172 14. NOTE: This will position all pistons (6 1 08) below 1 5. Remove timing chains as described. top of cylinder block deck face. 1 6. Remove camshafts (6250) as described. Position crankshaft on TDC No. 1 . CRANKSHAFT KEYWAY A13658-B 1997 1996 Thunderbird, Cougar July...
Page 173 Use care to prevent 6600 Oil Pump damage to the bearing and cylinder bore 3Z728 0-Ring surfaces. N806 155-S2 Bolt (2 Req'd) Tighten to 20-30 N-m (15-22 Lb-Ft) Tighten to 8- 12 N-m (7 1- 106 Lb-ln) 1997 Thunderbird, Cougar July 1 996...
Page 174 Cap Side Bolt 6010 Cylinder Blocks 6333 Crankshaft Main Bearing, Upper Woodruff Key N80620 1-S 26. CAUTION: When removing the crankshaft, use care not to damage any of the bearing surfaces on the crankshaft. Remove crankshaft. 1997 Thunderbird, Cougar July 1996...
Page 175 Crankshaft Thrust Main Bearing, Lower 6333 Crankshaft Main Bearing, Lower 6303 Crankshaft 6334 Crankshaft Thrust Washer 6345 Crankshaft Main Bearing Cap Side Bolt 6010 Cylinder Blocks 6333 Crankshaft Main Bearing, Upper N80620 1 -S Woodruff Key 1997 Thunderbird. Cougar July 1 996...
Page 176 1 9-23 N·m ( 1 4- 1 7 lb-ft). crankshaft. 1997 Thunderbird, Cougar July 1996...
Page 177 1 1 . NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner 1 5. Tum crankshaft until the crankshaft throw is at F4AZ -1 9A536-RA or equivalent meeting Ford bottom of stroke. Install upper connecting rod specification WSE-M5B392-A, to remove all bearing onto connecting rod.
Page 178 Crankshaft Main Bearing Cap Stud 6010 Cylinder Blocks N806183-S2 Bolt (4 Req'd) Oil Pump 6600 3Z728 0-Ring N806 155-S2 Bolt (2 Req'd) Tighten to 20-30 N·m (15-22 lb-Ft) Tighten to 8- 12 N·m (7 1-106 lb-ln) 1997 Thunderbird, Cougar July 1996...
Page 179 20. CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as top dead center (TDC) No. 1 . Rotate crankshaft clockwise 45 degrees. This will position crankshaft at top dead center (TDC) No. 1 . 1997 Thunderbird, Cougar July 1996...
Page 180 12A227 Crankshaft Position Sensor 6019 Engine Front Cover Pulse Wheel 6049 Cylinder Head 60081 Engine Front Cover Gasket N806040-S Dowel (2 Req'd) Cylinder Blocks 60 10 6303 Crankshaft 67 10 Oil Pan Gasket (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 181 N806 177 Bolt (7 Req'd) (Continued) 25. Install crankshaft position sensor and camshaft position sensors into engine front cover and tighten retaining bolts to 8- 1 2 N·m (7 1 - 1 06 lb-in). 1997 Thunderbird, Cougar July 1 996...
Page 182 Tighten to 1 1-16 N·m (9- 1 1 27. Install oil pan with new oil pan gasket as Lb-Ft) described. Tighten bolts to 25-35 N·m (1 9·25 lb-ft) in no more than four minutes after applying sealer. 1997 Thunderbird, Cougar July 1 996...
Page 183 REMOVAL AND INSTALLATION (Continued) 28. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ - 1 9A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
Page 184 Clean and inspect cylinder blocks (60 1 0), ignition coils ( 1 2029). Remove fuel charging crankshaft, crankshaft main bearings (6333), wiring. crankshaft thrust main bearing (6337) and crankshaft thrust washer (6334) as described in Section 03-QO. 1997 Thunderbird, Cougar July 1 996...
Page 185 To LH Radio Ignition Part of 90930) Interference Capacitor (Part To 14290 Harness (Part of of 90930) 90930) To Crankshaft Position To Electronic Variable (CKP) Sensor (Part of Orifice (Part of 90930) 90930) (Continued) (Continued) 1997 Thunderbird, Cougar July 1996...
Page 186 Tighten to 20-30 N·m (15-22 Lb-Ft) 1 1 . Remove water hose connection (8592), water thermostat (8575) and Q-ring. 1 2. Remove remaining nine bolts retaining intake manifold (9424) to cylinder heads (6049) and remove intake manifold. 1997 Thunderbird, Cougar July 1996...
Page 187: Table Of Contents
Stud (LH 4 Req'd, RH 2 N806356-S2 N605907-S2 Bolt (4 Req'd) Req'd) 6B288 Camshaft Position Sensor 6766 Oil Filler Cap N806 155-S2 Bolt N806183-S2 Bolt (LH 7 Req'd, RH 9 N806 155-S2 Bolt Req'd) (Continued) 6582 Valve Cover (LH) (Continued) 1997 Thunderbird, Cougar July 1996...
Page 188 Cylinder Blocks Tighten to 20-30 N·m (15-22 Tighten to 20 N·m (14 Lb-Ft), Lb-Ft) Then Rotate an Additional 60 Degrees 2 1 . Remove engine front cover. Tighten to 1 1-16 N·m (9- 1 1 Lb-Ft) 1997 Thunderbird, Cougar July 1996...
Page 189 26. Remove and discard head gaskets (605 1 ). A13658-B 27. If cylinder heads are to be serviced, refer to Subassemblies, Cylinder Head Disassembly and 23. Remove timing chains as described. Assembly. 24. Rotate crankshaft counterclockwise 45 degrees. 1997 Thunderbird, Cougar July 1 996...
Page 190 Use care to prevent damage to the bearing and cylinder bore 29. Remove crankshaft rear oil seal retainer (6335). surfaces. Keep upper connecting rod bearing and connecting rod together. 1997 Thunderbird, Cougar July 1996...
Page 191 Using Piston Pin Tool D8 1 L-6 135-A or equivalent, into cylinder blocks. Install crankshaft main press piston pin from piston and connecting rod. bearings and crankshaft thrust main bearing (6337) into main bearing caps. Install crankshaft into cylinder blocks. 1997 Thunderbird. Cougar July 1 996...
Page 192 No. 5 main bearing cap rearward and position the lower crankshaft thrust main bearing 6345 Crankshaft Main Bearing rear face properly against the thrust face of the Cap Side Bolt crankshaft. 60 10 Cylinder Blocks (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 193 NOTE TOTAL END PLAY A13643-E 1 1 . NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ - 1 9A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
Page 194 Tool journal and bearing surfaces with clean engine oil T93P-6 136-A Connecting Rod Guide meeting Ford specification WSS-M2C 1 53-F. Tighten to 40-45 N-m (30-33 15. NOTE: Make sure piston ring gaps are rotated 30 Lb-Ft), then rotate an degrees apart.
Page 195 Tighten to 8-12 N·m (7 1-106 Lb-ln) 20. NOTE: Make sure cylinder heads are installed in their original positions. If cylinder heads are to be serviced, refer to Subassemblies, Cylinder Head in Disass e mbly and Assembly in this section. 1997 Thunderbird, Cougar July 1996...
Page 196 CAUTION: Cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused. RH HEAD NOTE: Apply clean engine oil meeting Ford GASKET 6051 specification WSS-M2C 1 53-F to all head bolt spot-fa�es. Tighten new cylinder head bolts as follows: A13654-B Tighten head bolts in sequence to 37-43 N·m...
Page 197 Rotate crankshaft clockwise 45 degrees. This 28. Install engine front cover as described. will position crankshaft at top dead center (TDC) No. 1 cylinder. A13658-B Retainer Locations REFER TO LEGEND TIGHTEN IN SEQUENCE 1997 Thunderbird, Cougar July 1 996...
Page 198 30. lubricate water pump housing gasket (8507) bolts to 20 N·m ( 1 4 1b-ft), then an additional SO with Ford Premium Cooling System Fluid degrees in no more than four minutes after E2FZ - 1 9549-AA (in Canada, Motorcraft applying sealer.
Page 199 WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere. NOTE: Silicone Gasket and Sealant FRONT OF F6AZ- 1 9562-AA or equivalent meeting Ford ENGINE specification WSE-M4G323-A6 must be applied to crankshaft keyway prior to installing crankshaft pulley.
Page 200: N806356-S2
36 . If intake manifold was disassembled, assemble � as follows: Install fuel injector o-rings (9C99 1) on fuel injectors with clean engine oil meeting Ford NOTE: LUBRICATE SEAL WITH CLEAN ENGINE specification WS8-M2C 1 53-F prior to OIL MEETING FORD SPECIFICATION WSS-M2C153-F assembly.
Page 201 90930) To Fuel Injectors (8 Places, Part of 90930) 90930 Fuel Charging Wiring To 14290 Harness (Part of To RH H02S (Part of 90930) 90930) To EGR Backpressure Transducer (Part of 90930) (Continued) (Continued) 1997 Thunderbird. Cougar July 1 996...
Page 202 Compress valve spring far enough to remove Install Valve Spring Spacer T9 1 P-6565-AH rocker arm. between valve spring coils. Repeat Steps 1 , 2 and 3 until all rocker arms are removed. Remove all valve tappets (6500). 1997 Thunderbird, Cougar July 1996...
Page 203: Number Description
NOTE: Each camshaft bearing cap is tightened individually. lighten camshaft bearing cap retaining bolts in sequence to 8- 1 2 N·m (7 1 - 1 06 1b-ln). Remove 1 4 bolts retaining camshaft bearing caps (68280) to cylinder head (6049). 1997 Thunderbird, Cougar July 1 996...
Page 204: Front Of
Install Valve Spring Compre sS or T91 P-6565-A, Verify piston ring end gap as described in Section under camshaft and on top of valve spring 03-00. retainer. 10. Install Valve Spring Spacer T9 1 P-6565-AH between valve spring coils. 1997 Thunderbird, Cougar July 1 996...
Page 205 Completely disassemble the used engine, following procedures in Disassembly and Remove the push rod ball, metering valve (disc), Assembly. plunger and spring. Remember to ridge ream the cylinder bores before removing pistons. 1997 Thunderbird. Cougar July 1996...
Page 206 • Gauge Diameters 42.5 mm and 32.0 mm 0.025-Q.076 mm (0.0009 8 ·0.00299 in) ( 1 .6732 in and 1 . 2598 in) • Service Limit 0. 1 2 1 mm (0.00476 in) (Continued) (Continued) 1 997 Thunderbird. Cougar July 1996...
Page 207 • Compression (Bottom) (0.00059-0.0 1 772 in) (0.009 1-0.0 1 929 in) 0.50 (0.0 196 in) MAX • Service Limit 0. 1 5-0.66 mm • Oil Ring (Steel Rail) (0.0059 1 -0.02598 in) (Continued) (Continued) 1997 Thunderbird, Cougar July 1996...
Page 208 Anaerobic Gasket WSK-M2G348-A9 Fuel Injection Supply Manifold 8 - 1 2 7 1 - 106 Compound Sealer Retaining Bolts 1 5-22 Heater Water Hose Retaining 20-30 Bolt 1 5-22 EGR Backpressure Transducer 20-30 Bracket Bolt (Continued) 1997 Thunderbird, Cougar July 1996...
Page 209 (2) lighten bolts in sequence 1 9-23 N·m ( 1 4- 1 6 Front Cover Seal Remover � Lb-Ft) lighten in 2 steps: ( 1) lighten bolts to 4Q-45 N·m (3Q-33 Lb-Ft) (2) Rotate bolts 9Q- 1 20 degrees � TSOT-4000 - W Driver Handle TIOT�W (Continued) 1997 Thunderbird, Cougar July 1996...
Page 210 Transmission Support 0 14-00765 Powertrain Lift Ta1 P-11515-A 0 14-000 7 1 Floor Crane T91 P-6565-AH � Valve Spring Spacer Tl1 P-1151 15-A H T91 P-657 1-A o:===J Valve Stem Seal Replacer Tt1 P-e571-A (Continued) 1997 Thunderbird, Cougar July 1996...
Page 211 "Walter C. Avrea, the owner of patents 3, 60 1 , 1 8 1 limiting system working pressure is reached, the and RE 27, 965, has granted Ford Motor Company pressure relief valve in the pressure relief cap is rights with respect to cooling systems covered by lifted from its seat and allows coolant to flow these patents.
Page 212 Reservoir or Degas Bottle 85 97 Water Bypass Hose 6049 Cylinder Head (RH Bank) 8592 Water Hose Connection (To 605 1 Head Gasket Radiator Inlet) Heater Inlet (Part of 18476) 6010 Cylinder Blocks (LH Bank) !""'" "' (Continued) 1997 Thunderbird, Cougar July 1996...
Page 213 3.8L engines or degas bottle on PRESS DOWN ON THE RADIATOR CAP (STILL 4.6L (2V) engines. WITH A CLOTH), TURN AND REMOVE RADIATOR CAP. The 4.6L engine is equipped with a pressure relief cap. 1997 Thunderbird, Cougar July 1996...
Page 214: Radiator
LEVEL SENSOR • are equipped with a coo l ant recovery system. COOLANT MOUNTING RECOVERY RESERVOIR SENSOR ASSY Q2061-C 1997 Thunderbird, Cougar July 1996...
Page 215 • if engine temperature is higher than desirable and cooling fan motor has bee n operating at a low speed. • at 1 09 ° C (228°F) and stops running at 1 05°C (220°F). 1997 Thunderbird, Cougar July 1 996...
Page 216 • Damaged head gasket. • Damaged intake manifold fan motor. gasket. • Damaged powertrain • Damaged water pump. control module (PCM). • Damaged radiator. • Damaged radiator coolant recovery reservoir or degas bottle. • Damaged heater core. 1997 Thunderbird, Cougar July 1996...
Page 217 Using a radiator cap pressure tester, test radiator GO to A4. cap as described in Component Testing..REPLACE damaged radiator cap. • Did pressure relief cap test OK? RESTORE vehicle. RETEST system. Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1 996...
Page 218 Allow engine to run tor 10 minutes . REPLACE water thermostat as • Feel the underside of the upper radiator hose . described. RETEST system. • Is the upper radiator hose cold? ..LEAVE engine running. GO to 86. 1997 Thunderbird, Cougar July 1 996...
Page 219 Check resistance of Circuits 1 , 2 and 3 in power system. cable using Rotunda 73 Digital Multimeter 105-R005 1 or equivalent. � REPLACE power cable. RETEST • Is resistance more than 10 K ohms? system. � _ _ _ AQ0046 -A Cougar 1997 Thunderbird, July 1996...
Page 220 Oregon, F5FZ- 1 9549-CC; in Canada, CXC-8-B), temperature indicator sender unit ( 1 0884) is recycled coolant or equivalent meeting Ford removed. specification ESE-M97B44-A and water. Disconnect the electrical connector from the Pressure Test-4.6L {2V) Engine...
Page 221 NOTE: If the plunger of the pump is depressed too fast, an erroneous pressure reading will result. Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing. Note the highest preSsure reading obtained. 1997 Thunderbird, Cougar July 1996...
Page 222 Pressure Hose Adapter (Part FULL COLD of 014-R 1072) Pump and Gauge Assy (Part of 014-R 1072) Thermostat, Water When investigating a concern of overheating or an insufficient heater I defroster performance, perform the following: 1997 Thunderbird. Cougar July 1996...
Page 223 Operate the engine for several minutes then check the hoses and connections for leaks. Premium Cooling System Fluid E2FZ- 1 9549-AA or -8 (in Oregon, F5FZ- 1 9549-CC; in Canada, CXC-8-8), recycled coolant or equivalent meeting Ford specification ESE-M97844-A. 1997 Thunderbird, Cougar July 1 996...
Page 224 On 4.6L engines, disconnect lower radiator hose (8286) from degas bottle. Disconnect electrical connector to low coolant level warning sensor ( 1 OD968) located in the radiator coolant recovery reservoir on 3.8L engines or degas bottle on 4.6L (2V) engines. 1997 Thunderbird, Cougar July 1 996...
Page 225 Follow removal procedure in reverse order. Follow removal procedure in reverse order. Tighten fan shroud retaining bolts to 5.2-7.2 N·m (46-63 1b-in). Tighten constant control relay module bracket retainer bolt to 2-3 N-m ( 1 2- 1 8 1b-in). 1997 Thunderbird. Cougar July 1996...
Page 226 N800369-S2 1430 1 Battery Ground Cable 16138 Radiator Support 16055 Front Fender Apron 8260 Upper Radiator Hose 8005 Radiator N3831352-S2 Bolt (2 Req'd) Tighten to 5.2-7.2 N·m (46-63 8286 Lower Radiator Hose Lb-ln) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 227 {8005). Remove the radiator draincock from the radiator by squeezing the sides together with a pair of Removal needlenose pliers. Then pull the radiator Drain engine cooling system as described. draincock from the radiator. 1997 Thunderbird, Cougar July 1996...
Page 228: Block Heater Wiring
Engine Coolant Temperature (ECT) Sensor Refer to Section 03- 1 4. Installation Clean the inside diameter of the cylinder block hole machined surface. Remove any burrs at the hole entrance to avoid damage to the 0-ring. 1997 Thunderbird, Cougar July 1 996...
Page 229: Transmission Fluid Cooler Connection Leaks
SERVICE PROCEDURES Apply a liberal coating of Premium Long Life Radiator Core Grease XC- 1 -K or equivalent meeting Ford NOTE: With the introduction of a new radiator braze specification ESA-M 1C75-8 to block heater process, there is no longer an approved service Q-ring and cylinder block opening.
Page 230 Disconnect electrical F5FZ-1 9549-CC; in canada, CXc-8-B), connector to low coolant level warning sensor recycled coolant or equivalent mee t ing Ford ( 1 0D968) (if equipped). Remove low coolant level specification ESE-M97844-A and water if warning sensor from radiator coolant recovery necessary.
Page 231: Cooling System Draining, Filling And
Do F5FZ- 1 9549-CC; in Canada, CXC-8-8), recycled not try to add coolant through vent plug hole. coolant or equivalent meeting Ford specification Install vent plug after filling radiator (8005) ESE-M97B44-A, to obtain the recommended and before starting engine.
Page 232: Heater Core Back-Flushing
To remove rust, sludge and other foreign material from approximately five minutes. the cooling system, use Premium Cooling System Flush F 1 AZ- 1 9A503-A or equivalent meeting Ford Remove the hose clamp and female garden specification ESR-M 1 4P7 -A that is safe for use with hose-end adapter from the end of the outlet aluminum radiators (8005).
Page 233: Radiator
NOTE: Do not use caustic cleaning solutions or copper I brass radiator cleaning agents on aluminum radiators. To clean internal aluminum tubes use sonic cleaning equipment. Rinse the core with clean water when completed. 1997 Thunderbird, Cougar July 1 996...
Page 234 1 8 1 -0000 1 Cooling System Flusher Description Number Specification Part 1 8 1 -0000 3 Coolant Recycler Premium Cooling E2FZ- 1 9549-AA ESE-M97B44-A System Fluid ESE-M97B44-A Premium Cooling F5FZ-1 9549-CC System (Oregon) (Continued) 1997 Thunderbird, Cougar July 1996...
Page 235 (PCV) system and an exhaust emission • fuel injectors which, when energized, spray a system to control engine emissions within government metered quantity of fuel into the intake air stream specifications. Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1 996...
Page 236 (9F763) • • engine air cleaner with air cleaner element (ACL elementX960 1) Can b e purchased a s a separate item. 1997 Thunderbird. Cougar July 1996...
Page 237 • 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 1997 Thunderbird, Cougar July 1 996...
Page 238 Outer 0-Ring Seal atomization of the fuel is obtained by a • (Lower)(Part of 9F593) director I metering plate where the fuel separates. End Cap (Part of 9F593) Washer (Part of 9F593) Coil Terminal (Part of 9F593) 1997 Thunderbird, Cougar July 1996...
Page 239 Bolt Tube (Part of 9C968) N8051 17-S8M Bolt (4 Req'd) Ball Seat (Part of 9C968) 9F593 Fuel Injector Spring (Part of 9C968) 9F792 Fuel Injection Supply Upper Housing (Part of Manifold 9C968) (Continued) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 240 • (9350). � shuts off the fuel pump in the event of a collision. • • consists of a steel ball held in place by a magnet. 1997 Thunderbird. Cougar July 1 996...
Page 241 CLIP Install fuel tank filler cap at fuel tank. V101 47-A Connect battery ground cable. Add engine coolant (if required). Refer to Section 03-Q3. 3 Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 242 Insert male fitting into female fitting and push together until garter spring is engaged. V10150- A GARTER SPRING Remove the disconnect tool from the V10153-A disconnected spring lock coupling. Pull on fittings to ensure coupling engagement. V10151-A 1997 Thunderbird, Cougar July 1 996...
Page 243 Connect accelerator cable to throttle body lever. Install air cleaner outlet tube and securely tighten engine air cleaner tube clamp. Refer to Section 03· 1 2 . V10155-A 1997 Thunderbird, Cougar July 1 996...
Page 244 Fuel Injector described. Removal Remove fuel injector retaining clips as required. Perform Pre-Service and Fuel Pressure Relief Procedures. Refer to Fuel Charging System. Remove upper intake manifold (9424) as described in Section 03-0 1 A. 1997 Thunderbird, Cougar July 1996...
Page 245 Silicone grease will clog the fuel injectors. Fuel Supply and Return Connectors (Part of 9F792) Lubricate 0-rings with clean engine oil meeting Ford specification WS5-M2C 1 53-F and install on Tighten to 0.6 N-m (5 Lb-ln) each fuel injectors. Tighten to 7. 75 N-m (68...
Page 246 Q-rings are fully seated in the fuel injection supply manifold cups and cylinder !""" " head pockets. Install retaining bolts while holding fuel injection supply manifold. Tighten bolts to 8-1 1 N·m (7 1 -97 lb-in). 1997 Thunderbird, Cougar July 1 996...
Page 247 Perform Fuel Charging System, Post-Service Tester I Cleaner 1 64-R3759 or equivalent. Follow tool Procedures as described. manufacturer's operating instructions. Fuel harg Wiring mova Remove upper intake manifold {9424) as described in Section 03-Q 1 A. 1997 Thunderbird, Cougar July 1 996...
Page 248 Pressure Relief Valve Fuel Pressure Regulator 20-30 15-22 Bracket-To-Cylinder Head Tighten in three steps: • 10 N·m (88 Lb-ln) 20 N·m ( 15 Lb-Ft) 32 N·m (23 Lb-Ft) Can be purchased as a separate item. 1997 Thunderbird. Cougar July 1996...
Page 249 • on the instrument cluster. vehicle and its uniqueness. Automatically senses and compensates for changes in altitude (for example, from sea level to mountains). Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 250 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. Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 251 The fuel injection supply manifold consists of the following: a tubular fuel rail • eight fuel injector connectors • Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 252 Spring Seat (Part of 9C968) Valve Assembly (Part of is a diaphragm-operated relief valve in which one • 9C968) side of the diaphragm senses fuel pressure and the other side is subjected to intake manifold vacuum. 1997 Thunderbird, Cougar July 1996...
Page 253 • once opened, the inertia fuel shutoff switch must be manually reset before restarting the vehicle. 1997 Thunderbird, Cougar July 1 996...
Page 254 CAGE connect fittings. OPENING V10148-A Turn ignition switch ON I OFF several times without starting engine to check for fuel leaks. Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1 996...
Page 255 Clean fittings with solvent. WRONG - WHEN FLARE OR 0-RINGS ARE SHOWING FEMALE V10154-B 0-RING S SPRING V1 0156- A Installation Lubricate the Q-rings with clean engine oil. 1997 1 996 Thunderbird, Cougar July...
Page 256 8- 1 2 N·m (7 1 - 1 06 I b-in). Connect the fuel charging wiring to the throttle position sensor as well as accelerator cable to the throttle lever. Install air cleaner outlet tube as described in Section 03- 1 2 . 1 996 1997 Thunderbird, Cougar July...
Page 257 CAUTION: Never use silicone grease. Silicone grease will clog the fuel injectors. -- Lubricate new fuel injector Q-rings with clean FRONT OF engine oil Motorcraft meeting Ford specification --- ENGINE WSS-M2C 1 53-F. V1012�A Install fuel injectors into fuel injection supply manifold using a light, twisting-pushing motion.
Page 258 Connect vacuum line to fuel pressure regulator. Connect fuel charging wiring to fuel injectors. Install air cleaner outlet tube as described in Section 03- 1 2 . Perform Fuel Charging System Post-Service Procedures. 1997 Thunderbird, Cougar July 1 996...
Page 259 Installation Silicone grease will clog the fuel injectors. Follow removal procedure in reverse order. Lubricate new fuel pressure regulator 0-rings with clean engine oil meeting Ford specification WSS-M2C 1 53-F. CLEANING AND INSPECTION Make sure sealing surfaces of fuel pressure...
Page 260 7 1 - 106 Model Description Manifold Bolts Fuel Injector Tester I Cleaner 1 64-R3759 LUBRICANT ADHESIVE/CLEANER SPECIFICATIONS Ford Specification Description Part Number WSS-M2C 1 53-F Engine Oil Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1 996...
Page 261 NOTE: Look at the pulley grooves {not at the pulley • flanges) for wobbling condition. Bent pulley: Inspect all pulleys for a wobbling condition. Service components as required. Worn accessories: Check accessories for smooth • rotation and proper operation. Service components as required. 1997 Thunderbird, Cougar July 1996...
Page 262 Other contaminants: Remove and discard drive belt. • Clean all pulleys with a suitable solvent and install a new drive belt. 1997 Thunderbird, Cougar July 1 996...
Page 263 CHECK that area with a straightedge and LOOK for the accessory pulley(s) to be out of position in the fore aft direction or at an angle to the straightedge. 1997 1996 Thunderbird, Cougar July...
Page 264 Correct any interference condition and recheck binding or frozen condition. Replace components drive belt tracking. as required. lighten all accessory mounting brackets and drive • belt tensioner retaining hardware to specification. Recheck drive belt tracking. 1997 Thunderbird, Cougar July 1 996...
Page 265 Install drive belt over pulleys through appropriate drive belt routing as shown in following illustrations. Make sure that all V-grooves make proper contact with the pulley as shown. 1997 1996 Thunderbird, Cougar July...
Page 266 Remove serpentine drive belt as described. To install, reverse Removal procedure. lighten Remove RH ignition coil bracket from drive belt drive belt tensioner retaining nut and bolts to tensioner as described in Section 03-078. 20-30 N-m ( 1 5-22 1b-ft). 1997 1996 Thunderbird, Cougar July...
Page 267 C Compressor 8620 Drive Belt 6B209 Drive Belt Tensioner 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 adjustment. 1997 Thunderbird, Cougar July 1996...
Page 268 329 N (74 Lbs) :1:: 6 mm DRIVE BELT TENSIONER SPECIFICATIONS Application/ Minimum Part Number Usage Torque E9SE·6B209·GA 3.8L SFI 28.5 N·m Accessory (2 1 Lb-Ft) Drive F4AE-6B209-AA 4.6L Accessory 44.8 N·m (33 Lb-Ft) Drive 1997 Thunderbird, Cougar July 1996...
Page 269 NEUTRAL or PARK. In case of starting system difficulty, the operator • may have discharged the battery before calling for assistance. 1997 Thunderbird, Cougar July 1 996...
Page 270 START position (as the engine starts). STARTER MOTOR 11000 DIAGNOSIS AND TESTING J5539-A Electrical Schematic Refer to Electrical and Vacuum Troubleshooting Manual, Cell 20, Starting System for schematic and connector information. 1997 Thunderbird, Cougar July 1 996...
Page 271 • • Unusual Starter Noise Clutch pressure plate . GO to Pinpoint Test C . • Ring gear tooth damage or excessive ring gear runout. • Inoperative starter motor . • Inoperative components . 1997 Thunderbird, Cougar July 1 996...
Page 272 Ignition switch OFF. Transmission in PARK or to Section 14-00 and check NEUTRAL. battery charge system. • Check for voltage from starter B+ terminal to starter drive housing (ground). • 1 2.45 Does voltmeter Indicate volts DC? 1 997 1 996 Thunderbird, Cougar July...
Page 273 Measure resistance between relay socket Pin 87 A and starter S-connector C1064, Circuit 32 (R ILB). RESTORE vehicle. RETEST • Is resistance ohms or less? system . SERVICE open in Circuit 32 (R ILB). RESTORE vehicle. RETEST system. 1997 Thunderbird, Cougar July 1996...
Page 274 NOTE: Make sure battery terminals and cable connections are clean. Clamp the black load lead of the Rotunda Alternator, Regulator, Battery and Starter Tester (ARBSD 0 1 Q-00 7 25 or equivalent to the battery negative terminal. 1997 Thunderbird, Cougar July 1996...
Page 275 The display will read either GOOD Motor Feed Circuit STARTER or BAD STARTER. Prevent the engine from starting by disconnecting the low voltage wires at the coil pack connectors. 1997 Thunderbird, Cougar July 1996...
Page 276 Crank the engine and observe multimeter. The voltage reading should be 0.2 volt or lower. H the ROTUNDA 73 DIGITAL voltage drop is too high, clean the terminal ends. MULTIMETER Retest, and if still high, replace the cable. 105-R0051 AJ0130-A 1997 Thunderbird, Cougar July 1996...
Page 277 To determine if the armature windings are grounded, ROTUNDA 73 DIGITAL check with a multimeter. Infinite resistance indicates a MULTIMETER normal condition. 105. - R0051 ROTUNDA DIGITAL STARTER MULTIMETER SOLENOID 1 05-R0051 1 1390 AJ0138-A 1997 Thunderbird, Cougar July 1 996...
Page 278 Raise the vehicle on a hoist. Connect battery ground cable. Disconnect starter cable and connector S-terminal from starter solenoid. Remove upper bolt. Remove one lower bolt on 3.8L engine and two lower bolts on 4.6L engine and starter motor. 1997 Thunderbird, Cougar July 1996...
Page 279 NOTE: Although disassembly and service procedures are shown for the starter motor ( 1 1 002) in this section, it is recommended that the starter motor be returned to Ford Return Parts Center for analysis and review. Starter Motor-Disassembled VIew 3.8L Engine...
Page 280 Truarc® E-Ring Lb-ln) Magnet Pole Piece (6 Req'd) Tighten to 2-3 N-m ( 1 8-26 (Part of 1 1075) Lb-ln) Pole Shunt (6 Req'd) (Part of 1 1075) (Continued) Starter Motor-Disassembled VIew 4.6L Engine AJ0127-A 1997 Thunderbird, Cougar July 1 996...
Page 281 Remove seal { 1 1 A 1 7 1 ) from drive end housing. Low Temperature Grease or equivalent meeting Remove starter drive and gear assembly from Ford specification WSG-M 1 C2 1 8-B2 on both drive end housing. ends of armature shaft and spline. Install brush...
Page 282 Remove positive brush connector from starter solenoid M-terminal. Remove through-bolts and separate motor from starter drive gear assembly and drive end housing. BRUSH END BUSHING PLATE AND 1 1 135 BUSHING J3732-C 1 1 049 1 997 Thunderbird, Cougar July 1996...
Page 283 Inspect the self-lubricating bronze I iron armature bushings in the drive housing and brush end plate and bushing ( 1 1 049). Replace bushings whenever excessive starter motor armature shaft side-play is evident (maximum allowable 0.2 mm (0.008 inch.) 1997 Thunderbird, Cougar July 1 996...
Page 284 Description Description Specification 0 1 0-00725 Alternator, Regulator, Battery and Starter Motor Diameter 78 mm (3 1nches) Starter Tester (ARBsn Starter Motor Current Draw 130-220 Amps 105-R005 1 73 Digital Multimeter Under Normal Load (Continued) 1997 Thunderbird, Cougar July 1996...
Page 285 ( 1 2029) Item Number Description turn on and turn off time. Stud Bolt (2 Req'd) Nut (2 Req'd) 6K342 Crankshaft Position Sensor Shield 6C3 15 Crankshaft Position Sensor (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 286 Properly route engine control sensor wiring and Ignition connect to crankshaft position sensor. Refer to the Powertrain Control I Emissions Diagnosis Lower vehicle. Manual 1 • Connect battery ground cable. Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 287 {40-6 1 1b-in}. Apply Silicone Brake Caliper Grease and Dielectric Compound D7 AZ - 1 9A33 1 -A {Motorcraft WA- 10} or equivalent meeting Ford specification ESE-M 1 C 1 7 1 -A to all ignition wire boots. Install each ignition wire connector to the proper ...
Page 288 Dielectric Compound D7AZ- 1 9A33 1 -A CAUTION: Do not pull on the ignition wire (Motorcraft WA- 1 0) or equivalent meeting Ford directly as the wire may separate from the specification ESE-M 1 C 1 7 1 -A with a small, clean connector inside the boot.
Page 289 SECURELY PRESSED FULLY ENGAGED STUDS ONTO SPARK PLUGS ON COIL TOWER NOTE: INSTALLAnoN ORDER FOR RH IGNmON WIRES ARE · e e e � FRONT OF ENGINE � REFER TO LEGEND FIRING ORDER: NUMBER 1-4-2-5-3-6 1997 Thunderbird, Cougar July 1 996...
Page 290 Use the following inspection chart when inspecting all six cylinders. spark plugs. Remove spark plugs. NOTE: Refer to the Spark Plug Inspection Chart to determine the condition of spark plugs. Check and adjust spark plug gap as described. 1997 Thunderbird, Cougar July 1996...
Page 291 FUEL , L OO SE SPARK PL U GS, TOO HOT A PLUG, L O W FUEL PUMP PRESSURE OR I N CORRECT I G NI T I O N TI M I N G. REPLACE SPARK PLUG. 1997 Thunderbird, Cougar July 1996...
Page 292 This replacement spark plug has double platinum enhancement on both the center and ground electrode and may be used in all six cylinders. Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 293 One is the position of the crankshaft in 10 degree increments. The other is the crankshaft speed (rpm). • - The powertrain control module (PCM)( 1 2A650) uses this information to determine ignition coil turn on arid turn off times. 1997 Thunderbird. Cougar July 1 996...
Page 294 Crankshaft Position (CKP) Sensor Removal Disconnect battery ground cable ( 1 430 1 ). Refer to Section 1 4·0 1 . Remove serpentine drive belt (8620). Refer to Section 03-Q5. Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1 996...
Page 295 Lb-ln) 03-05. Connect battery ground cable. Ignition Coil Removal Disconnect engine control sensor wiring ( 1 2A58 1) from ignition coils ( 1 2029) and radio ignition interference capacitors ( 1 880 1 ). 1997 Thunderbird, Cougar July 1 996...
Page 296 Apply Silicone Brake Caliper Grease and _.- ENGINE Dielectric Compound D7AZ- 1 9A33 1 -A 851 92-A (Motorcraft WA- 1 0) or equivalent meeting Ford specification ESE-M 1 C 1 7 1 -A to all ignition wire spark plug boots. Part !"""'...
Page 297 Silicone Brake Caliper Grease and Dielectric Compound D7 AZ - 1 9A33 1 -A (Motorcraft WA- 1 0) or equivalent meeting Ford Lb- F t ) specification ESE-M 1 C 1 7 1 -A with a small, clean tool prior to installation.
Page 298 Install each ignition wire to the proper terminal on Connect ignition wire to spark plug. the ignition coils. The terminals on the ignition coils are numbered. Make sure the boo t s are fully seated and that both locking tabs are engaged. 1997 Thunderbird, Cougar July 1996...
Page 299 ON ENGINE. VIEW D CRANKSHAFT CRANKSHAFT VIEW C VIEW D TYPICAL RH TYPICAL LH SECTION E FRONT OF - -- ENGINE NOTE: MAKE SURE IGNITION COIL RETAINER CLIP IS FULLY ENGAGED ON COIL TOWER AB0061-A 1997 Thunderbird, Cougar July 1 996...
Page 300 Follow removal procedure in reverse order. Radi o I g n i t i o n I n t e r f e r e n c e 2 1 8 801 Capaci t o r (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 301 Use the following inspection chart when inspecting ENGINE _..- spark plugs. NOTE: USE SPARK PLUG, LH 12405 CYLINDER HEAD, RH 6049 4 REQ'D HAND START AND TIGHTEN TO 9-20 N·m (80-177 LB-IN) FRONT OF.--- __..- ENGINE A80054-A 1997 Thunderbird, Cougar July 1996...
Page 302 FUEL PUMP, TOO RICH A FUEL MIXTURE OR EXCESSIVE IDLING. CLEAN SPARK PLUG. OYERHEAnNG FUSED SPOT DEPOSIT IDENTIFIED BY MEL TED OR SPOTTY DEPOSITS RESEMBLING BUBBLES OR BLISTERS. CAUSED BY SUDDEN ACCELERATION. CLEAN SPARK PLUG. 1997 Thunderbird, Cougar July 1996...
Page 303 AWSF-32PP as listed on the vehicle emission calibration identification label. This replacement spark plug has double platinum enhancement on both the center and ground electrode and may be used in all eight cylinders. 1997 Thunderbird, Cougar July 1 996...
Page 304 I n t a k e Man i f o l d 5 9424 6 6A666 Pos i t i v e Cr a n k c as e Ven t i l a t i o n Val v e 1 997 Thunderbird, Cougar July 1 996...
Page 305 1 3 9J 4 60 1 4 EGA Back p r e s s u r e Tr a n s d u c er Vacu u m Ou t p u t 1 5 90475 EGA Val v e 1 997 Thunderbird. Cougar July 1996...
Page 306 Inspect PCV valve and crankcase ventilation grommet for deterioration. Replace if necessary. IN-VEHICLE SERVICE PCV Valve 3.8L Engine Removal Disconnect crankcase ventilation tube (6758) from positive crankcase ventilation valve (PCV valve)(6A666). Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 307 Cr a n k c as e Ven t i l a t i o n 7 6A892 Gr o mmet PCV Hoses Crankcase Ventilation Tube-3.8L Engine Removal Disconnect crankcase ventilation tube (6758) from upper intake manifold (9424). 1997 Thunderbird, Cougar July 1 996...
Page 308 Crankcase Ventilation Hose- 3.8L Engine Removal Disconnect crankcase vent connector and hose (6C324) from LH valve cover and air cleaner outlet tube. Remove crankcase vent connector and hose. Inspect crankcase vent connector and hose for deterioration. Service as necessary. 1997 Thunderbird, Cougar July 1996...
Page 309 Cr a n k c as e Ven t i l a t i o n Gr o mmet EGR Valve Removal Disconnect EGR valve to exhaust manifold tube (90477) from EGR valve (EGR valveX9D475}. Disconnect vacuum hose from EGR valve. 1997 Thunderbird, Cougar July 1 996...
Page 310 EGR VAL V E GASKET 9 D 4 7 6 BOL T 2 REQ' D TI G HTEN TO 2 0 - 3 0 N· m ( 1 5 - 2 2 L B - F T) A24289-A 1997 Thunderbird, Cougar July 1 996...
Page 311 EGR valve. Remove accelerator cable bracket retainers and Raise vehicle. position accelerator cable bracket (9723) with the accelerator cable and the speed control actuator cable out of the way. 1997 Thunderbird, Cougar July 1 996...
Page 312 Removal Disconnect fuel charging wiring connector from EGR backpressure transducer. Disconnect EGR backpressure transducer hoses from EGR backpressure transducer. Remove EGR backpressure transducer retaining nuts and EGR backpressure transducer from transducer mounting bracket. 1 997 Thunderbird, Cougar July 1996...
Page 313 (9424). Nu t ( 4 Req' d ) Disconnect fuel charging wiring (9D930) from EGR vacuum regulator solenoid. 4 601 9 En g i n e Fr o n t Cov e r (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 314 Solenoid Mounting Bracket Nut 4.6L (2V) EGR vacuum regulator solenoid. If air does not blow through the EGR vacuum regulator solenoid, replace the EGR vacuum regulator solenoid as described. 1997 Thunderbird, Cougar July 1996...
Page 315 DIAGNOSIS AND TESTING Intake Air System Refer to the Powertrain Control I Emissions Diagnosis Manual1 • Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 316 3 1 2 8579 Mas s Ai r Fl o w Sen s o r 4 9601 Ai r Cl e an e r El e men t Lb- l n ) 5 N621 9 07- S 2 Nu t ( 3 Req' d ) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 317 Tighten air cleaner outlet tube clamps to 2.8-4.6 Lb- l n ) Ti g h t e n t o 2. 0 - 2 . 4 N- m ( 1 8 - 2 1 N·m (25-40 lb-in). Lb- l n ) 1997 Thunderbird, Cougar July 1996...
Page 318 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. 1 997 Thunderbird, Cougar July 1996...
Page 319 (EVAP canisterX9D653) also the top panel of the fuel tank. contribute to fill control by controlling pressure in the fuel tank. 1 997 Thunderbird, Cougar July 1 996...
Page 320 {EVAP canisterX9D653) and controls the flow of fuel vapors out of the evaporative emissions Fuel vapor emitted through the evaporative emission canister. valve {98593) is stored in a evaporative emissions canister {EVAP canister){90653). is normally closed. • 1997 Thunderbird. Cougar July 1 996...
Page 321 (9002) as fuel is used, while preventing fuel vapors from escaping the fuel tank through the fuel tank filler cap. Can be purchased as a separate item. 1 997 Thunderbird, Cougar July 1996...
Page 322 Ti g h t e n t o 5. 2 - 7 . 2 N- m ( 4 6- 6 3 Lb- l n ) 7 N61 0 959- S 2 Bol t ( 2 Req' d ) (Continued) 1 997 Thunderbird, Cougar July 1 996...
Page 323 9C9 15 Evaporative Emission Canister Purge Valve 10009 Front Side Inner Member N800369·S2 Bolt N388577-S Push Pin (2 Req'd) 90653 Evaporative Emissions Tighten to 5.2·7.2 N-m (46·63 Canister Lb-ln) N6 10959·S2 Bolt (2 Req'd) (Continued) 1997 Thunderbird, Cougar July 1996...
Page 324 Evaporative Emission Canister 5.2-7.2 46·63 Evaporative Emission Canister Purge Valve Retaining Bolt Removal Raise vehicle on hoist. Disconnect evaporative emission canister purge valve (EVAP canister purge valveX9C9 1 5) at wire harness connector. 1 997 Thunderbird, Cougar July 1 996...
Page 325 9C9 15 Evaporative Emission Canister Purge Valve 10009 Front Side Inner Member N800369-S2 Bolt N388577-S Push Pin (2 Req'd) 90653 Evaporative Emissions Tighten to 5.2-7.2 (46-63 N·m Canister Lb-ln) N6 10959-S2 Bolt (2 Req'd) (Continued) 1997 Thunderbird, Cougar July 1 996...
Page 326 N·m Lb-ln 5.2-7.2 46-63 Evaporative Emission Canister Purge Valve Retaining Bolt Removal Raise vehicle on hoist. Disconnect evaporative emission canister purge � valve (EVAP canister purge valveX9C9 1 5) at wire harness connector. 1 997 Thunderbird, Cougar July 1 996...
Page 327 I on the following sources: • the applicable section of the Powertrain Control I Emissions Diagnosis Manual1 the applicable section of this group • Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1996...
Page 328 PCM wiU then calculate the required fuel injector pulse width in order to provide the desired air /fuel ratio. hot wire sensing element and housing are calibrated • as a unit and must be serviced as a complete assembly. 1997 Thunderbird, Cougar July 1 996...
Page 329 • A low voltage indicates too much oxygen or a lean AD007D-A condition. A high voltage indicates not enough oxygen or a rich • condition. 1997 Thunderbird, Cougar July 1996...
Page 330 Follow removal procedure in reverse order. lighten retaining screws to 2.8-3.8 N·m (25-33 lighten engine control sensor wiring connector lb-in). retainer bolt to 2.7-3.7 N-m (24-32 1b-in). Can be purchased as a separate item. 1997 Thunderbird, Cougar July 1 996...
Page 331 Section 14-Q 1 . Clean idle air control valve gasket mating Disconnect engine control sensor wiring surfaces. ( 1 2A58 1 ) from mass air flow sensor and intake air temperature sensor (JAT sensor)( 1 2A697). 1997 Thunderbird, Cougar July 1996...
Page 333 Step Install camshaft position sensor and retaining screws. lighten screws to 2.5-3.5 N·m (22-30 I b-in). Connect fuel charging wiring connector to camshaft position sensor. 1997 Thunderbird, Cougar July 1 996...
Page 334 Disconnect engine control sensor wiring surface is clean and that camshaft position ( 1 2A58 1 ) from camshaft position sensor (CMP sensor Q-ring is in proper location on camshaft sensorX6B288). position sensor. 1 997 Thunderbird, Cougar July 1 996...
Page 335 ESR·M 14P9-A or any other type of solvent or damage to the valve internal components may occur. The idle air control valve (lAC valve)(9F7 1 5) cannot be cleaned and must be replaced (if required). ST1 446-A 1997 Thunderbird, Cougar July 1 996...

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