1993 Ford Thunderbird - 3.8L V6-VIN (4) & 3.8L SC V6 - VIN (R)

3.8L V6 - VIN [4] & 3.
8L SC V6 - VIN [R] Article Text

1993 Ford Thunderbird For 1
Copyright 1998 Mitchell Repair Information Company, LLC Wednesday, July 27, 2011 03:29AM
ARTICLE BEGINNING 1993 ENGINES Ford Motor Co. 3.8L & 3.8L Supercharged (SC) V6 Ford: Taurus, Thunderbird Lincoln: Continental Mercury: Cougar, Sable ENGINE IDENTIFICATION NOTE: For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section. Engine may be identified by eighth character of Vehicle Identification Number (VIN). VIN is located on top of instrument panel, near lower left corner of windshield. An emission calibration number is located on driver's door or door-post pillar. This label identifies engine calibration number, engine code and revision label. Engine code label is located on valve cover. Label contains engine calibration number, engine build date, plant code and engine code. Information from labels are required when ordering replacement parts. ENGINE IDENTIFICATION CODES TABLE Application VIN Code
3.8L V6 PFI All Models ........................................... 4 3.8L V6 SC PFI Thunderbird ........................................... R
ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT NOTE: Hydraulic valve lifters are used; no valve adjustment is required. When valve and/or valve seat is machined, valve clearance is reduced and may cause improper valve operation. Different length push rods are available for correcting clearance. Valve lifter must be collapsed to check valve clearance. 1) With valve cover removed, position cylinder No. 1 at TDC of compression stroke. Completely collapse cylinder No. 1 intake valve lifter and hold valve lifter collapsed. Using feeler gauge, measure clearance between rocker arm and valve stem.
2) Clearance should be within specification. See, at the end of this article, COLLAPSED VALVE LIFTER CLEARANCE table. Replace push rod, if necessary, to obtain correct clearance. 3) Position crankshaft as specified in VALVE CLEARANCE CHECKING SEQUENCE table, and check appropriate valves. Replace push rods if clearance is not within specification. 4) If push rod(s) is replaced, ensure corresponding cylinder piston is below TDC. It will be necessary to loosen or remove rocker arm to replace push rod. CAUTION: DO NOT operate or crank engine after installing push rod until valve lifter has leaked down to normal operating position. COLLAPSED VALVE LIFTER CLEARANCE TABLE Application In. (mm)
3.8L & 3.8L SC ......................... .09-.19 (2.3-4.8) VALVE CLEARANCE CHECKING SEQUENCE TABLE Crankshaft Position (1) Intake Valve Exhaust Valve
Cyl.No. 1 At TDC ....... No. 1, 3 & 6 ..... No. 1, 2 & 4 Rotate 360 ............ No. 2, 4 & 5 ..... No. 3, 5 & 6 (1) - Begin with cylinder No. 1 at TDC of compression stroke. Check corresponding valves clearance, rotate crankshaft 360 degrees, and recheck clearance of corresponding valves.
REMOVAL & INSTALLATION ENGINE MOUNT (FWD) NOTE: See Fig. 1 for the location and identification of the engine mounts in their perspective place on the subframe. NOTE: Refer to Fig. 2 for R.H. Front Hydraulic Engine Mount illustration.
R.H. Front Hydraulic Engine Mount Removal 1) Remove mount upper retaining nut through engine compartment using a long extension and a 18mm swivel socket. See Fig. 2. 2) Install Engine Support D88L-6000-A or equivalent. 3) Raise vehicle on hoist. 4) Loosen R.H. Rear Lower Mount Retaining Nut. See Fig. 2. & 3.8L SC V6 - VIN [R] Article Text (p. 2)1993 Ford T 3.8L V6 - VIN [4]
5) Remove R.H. Front Lower Retaining Nut. 6) Lower vehicle. 7) Raise engine approximately 25mm (1 inch) using engine support tool. 8) Raise vehicle. 9) Remove engine mount. NOTE: Refer to Fig. 2 for R.H. Front Hydraulic Engine Mount illustration. R.H. Front Hydraulic Engine Mount Installation 1) Install engine mount. 2) Lower vehicle. 3) Lower engine using engine support tool. 4) Raise vehicle. 5) Install R.H. front lower mount retaining nut. 6) Tighten R.H. front lower mount retaining nut. NOTE: During installation of mount, hold lower can to prevent twisting when lower nut is run down. 7) Lower vehicle on hoist. 8) Remove engine support tool. 9) Install mount upper retaining nut through engine compartment using a long extension and a 18mm swivel socket. NOTE: Refer to Fig. 3 for L.H. Assembly Transaxle Hydramount illustration. Fig. 4 illustrates the Support Assembly to Transaxle Retaining Bolts (Front) illustration and Fig. 5 illustrates the Support Assembly to Transaxle Retaining Bolts (Rear). L.H. Assembly Transaxle Hydramount Removal 1) Raise vehicle on hoist. 2) Remove tire and wheel. 3) Place a jack and wood block in a suitable place under the transaxle and support the transaxle. 4) Remove two bolts (if applicable) retaining the vertical restrictor assembly (6F069). 5) Remove the nut retaining the transaxle mount to the support assembly. 6) Remove two through bolts retaining the transaxle mount to the frame. 7) Raise the transaxle with the jack (enough to unload mount). 8) Remove the bolts retaining the support assembly to the transaxle. 9) Remove mount and/or transaxle support assembly. NOTE: Refer to Fig. 3 for L.H. Assembly Transaxle Hydramount illustration.
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Tex
L.H. Assembly Transaxle Hydramount Installation 1) Loosely install transaxle mount to support assembly and frame. 2) Attach support assembly to the transaxle and tighten to 34-44 ft. lbs. (45-61 N.m). 3) Attach mount to frame with two through bolts and tighten to 60-86 ft. lbs. (81-116 N.m). 4) Lower the transaxle down (enough to load the mount). 5) Install transaxle mount retaining nut insulator to support assembly and tighten to 55-75 ft. lbs. (74-102 N.m). 6) Install two bolts retaining vertical restrictor assembly (6F069). See Fig. 3. 7) Remove jack. 8) Install tire and wheel. Tighten lug nuts to 85-105 ft. lbs. (115-142 N.m) 9) Lower vehicle. NOTE: Refer to Fig. 6 for illustration.
R.H. Rear Engine Mount Removal 1) Raise vehicle on hoist. 2) Remove the nuts retaining the R.H. front and R.H. rear engine mounts to the frame. 3) Lower vehicle. 4) Use Engine Support Bar D88L-6000-A or equivalent to support engine. 5) Loosen retaining nut on the R.H. rear mount and heat shield assembly. 6) Raise vehicle on hoist. 7) Remove R.H. rear insulator retaining nut. Remove R.H. rear insulator and heat shield assembly. NOTE: Refer to Fig. 6 for illustration.
R.H. Rear Engine Mount Installation 1) Install mount and position R.H. rear mount and heat shield assembly upper stud and anti-rotation pin to the transaxle support bracket. Hand start lower retaining nut. 2) Lower vehicle. 3) Tighten top retaining nut on the R.H. rear insulator. Tighten to 40-55 ft. lbs. (54-75 N.m). 4) Lower engine and remove the Engine Support Bar D88L-6000-A or equivalent. 5) Raise vehicle. 6) Tighten retaining nuts on R.H. front and R.H. rear engine mounts. Tighten to 55-75 ft. lbs. (68-95 N.m) 7) Lower vehicle.
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 4)1993 Ford ThunderbirdFor 1
Copyright 1998 Mitchell Repair I
Fig. 1: Engine & Transmission Mount Locations/ID
Fig. 2: R.H. Front Hydraulic Engine Mount
Fig. 3: L.H. & Assembly Transaxle Hydraulic Mount
Fig. 4: Support Assembly to Transaxle Retaining Bolts (Front)
Fig. 5: Support Assembly to Transaxle Retaining Bolts (Rear)
Fig. 6: R.H. Rear Engine Mount
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before
removal. CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS WARNING: Fuel system is under pressure. Pressure must be released before servicing fuel system components. 1) Disconnect battery ground cable. Remove fuel cap to release fuel tank pressure. Using EFI Pressure Gauge (T80L-9974-B), release fuel pressure from fuel-pressure relief valve on fuel rail. 2) To disconnect fuel lines, remove retaining clip from outside of fuel line coupling. Use Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line. Install spring lock coupling remover on fuel line coupling so it enters cage opening. See Fig. 7. Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove spring lock coupling remover. 3) When installing fuel lines, install new "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown). Before installing, lightly coat "O" rings with clean engine oil. Clean fittings, and replace garter spring (if necessary). Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting. Ensure lines are locked together and garter spring is over female fitting flared end. Install retaining clip. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line. NOTE: Install Black retaining clip on fuel supply line and Gray clip on fuel return line.
Fig. 7: Disconnecting Fuel Lines Courtesy of Ford Motor Co. ENGINE R & I
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (
NOTE:
Engine is removed with transaxle remaining in vehicle.
Removal (Continental) 1) Remove negative battery cable. Release fuel pressure, and disconnect fuel lines. Refer to, in the beginning of this article, FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS. 2) Drain cooling system. Remove hood and air cleaner assembly. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant lines at A/C compressor, and plug line openings. Remove A/C compressor. Remove electric cooling fan assembly, fan shroud, coolant recovery reservoir and radiator sight shield. 3) Remove engine oil dipstick tube. Disconnect necessary electrical connections, vacuum hoses and coolant hoses. Remove power steering hoses and routing brackets. 4) Disconnect control cables at throttle body. Remove accelerator cable mounting bracket. Remove air suspension compressor and position it aside. Remove integrated controller relay and position it aside. 5) Remove transaxle support at rear of transaxle. Raise and support vehicle. Drain engine oil, and remove oil filter. Disconnect oxygen sensor. Remove accessory drive belts and crankshaft pulley. 6) Remove accessory drive belt tensioner assembly. Remove starter. Remove catalytic converter cover, catalytic converter and inlet pipe. Remove torque converter nuts. 7) Remove retaining nuts from engine and transaxle mounts. Disconnect oil level sensor. Loosen, but do not remove, transaxle-tocylinder block bolts. Partially lower vehicle. 8) Remove front tires. Remove water pump pulley. Remove radiator. Remove distributor cap and rotor. Remove air pump assembly. Remove oil pressure sending unit. Support engine with hoist. Support transaxle with floor jack. 9) Remove transaxle-to-cylinder block bolts. Slightly raise transaxle, and lift engine from vehicle. Installation 1) To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. 2) When installing fuel lines, install new "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown). Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary). 3) Adjust control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system. NOTE: Engine is removed with transmission remaining in vehicle.
Removal (Cougar & Thunderbird) 1) Release fuel pressure, and disconnect fuel lines. Refer to FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS. Drain cooling system. Remove hood, left cowl vent screen and wiper module. 2) On 3.8L SC, remove charge air cooler (intercooler) and 3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 9)1993 Ford ThunderbirdFor 1
charge air cooler inlet and outlet tubes. Refer to, in this article, CHARGE AIR COOLER (FORMERLY INTERCOOLER) and also see in this article, CHARGE AIR COOLER INLET & OUTLET TUBES under REMOVAL & INSTALLATION. Remove supercharger drive belt. Remove radiator electric fan assembly. 3) On all models, remove radiator upper sight shield. Remove accessory drive belts. Remove air cleaner-to-throttle body tube. Remove fan and shroud assembly. 4) Disconnect necessary electrical connections, coolant hoses and vacuum hoses. Remove radiator. Remove power steering pump with hoses attached, and secure them aside. 5) Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant lines from A/C compressor, and plug line openings. Remove A/C compressor. Remove wiring shield. Remove accelerator cable mounting bracket. Disconnect control cables at throttle body. 6) On 3.8L SC, remove retaining bolts and coil pack. Secure coil pack aside. Disconnect wiring, and remove alternator. 7) On all models, raise and support vehicle. Drain engine oil, and remove oil filter. Disconnect exhaust pipe from exhaust manifold. Remove shield from left exhaust. Disconnect oxygen sensors. 8) On A/T models, remove torque converter-to-flexplate nuts. On all models, remove engine mount through bolts. On 3.8L SC, disconnect retaining strap from left engine mount. 9) On all models, remove starter. Disconnect oil level sensor connector. Place reference mark on crankshaft pulley and vibration damper for reassembly reference. Remove crankshaft pulley. 10) Partially lower vehicle. Support transmission with floor jack. Remove transmission-to-cylinder block bolts. Remove engine from vehicle. Installation 1) To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. 2) When installing fuel lines, install new "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown). Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary). CAUTION: When installing charge air cooler and charge air cooler inlet and outlet tubes, see CHARGE AIR COOLER (FORMERLY INTERCOOLER) and CHARGE AIR COOLER INLET & OUTLET TUBES under REMOVAL & INSTALLATION for proper installation procedure. 3) Adjust all control cables and fluid levels. When filling cooling system, bleed air from system by removing vent plug from elbow on intake manifold behind thermostat housing. DO NOT rotate plastic cap under vent plug, or gasket may be damaged. 4) Fill cooling system until coolant flows from vent plug. Install vent plug and tighten to 11 ft. lbs. (15 N.m). Evacuate and recharge A/C system.
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p
NOTE:
Engine is removed with transaxle remaining in vehicle.
Removal (Sable & Taurus) 1) Disconnect negative battery cable. Release fuel pressure, and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS. Drain cooling system. 2) Remove hood, engine oil dipstick tube and radiator upper sight shield. Remove air cleaner assembly. Remove cooling fan relay from top of radiator support. Disconnect radiator cooling fan and coolant hoses. Remove radiator. 3) Disconnect necessary electrical connections, coolant hoses and vacuum hoses. Disconnect power steering pressure hose assembly. Disconnect power steering hose assembly brackets. 4) Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect A/C compressor-to-condenser refrigerant line, and plug line openings. Remove coolant recovery reservoir. Remove wiring shield. 5) Disconnect control cables at throttle body. Disconnect bulkhead electrical connector and transaxle pressure switch wiring. Remove transaxle support at rear of transaxle. Raise and support vehicle. 6) Drain engine oil, and remove oil filter. Disconnect oxygen sensor. Remove drive belt. Remove crankshaft pulley, drive belt tensioner assembly and starter. 7) Remove catalytic converter housing assembly. Remove catalytic converter and inlet pipe from exhaust manifold. Remove torque converter-to-flexplate nuts. 8) Remove front transaxle mount nuts. Remove right engine mount nuts. Disconnect oil level sensor connector. Place reference mark on crankshaft pulley and vibration damper for reassembly reference. Remove crankshaft pulley. Remove engine-to-transaxle bolts. 9) Partially lower vehicle. Remove front tires. Remove water pump pulley. Remove distributor cap and rotor. Remove air pump. Support engine with hoist. Support transaxle with floor jack. Slightly raise transaxle, and lift engine from vehicle. Installation 1) To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. 2) When installing fuel lines, install new "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown). Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary). 3) Adjust control cables and fluid levels. Refill cooling system. Evacuate and recharge A/C system. CHARGE AIR COOLER (FORMERLY INTERCOOLER) Removal 1) Disconnect inlet and outlet tubes at charge air cooler. See Fig. 8. Slightly loosen inlet tube at alternator/power steering pump bracket. [4] & 3.8L SC V6 - VIN [R] Article and (p. 11)1993 Ford ThunderbirdFor 1 3.8L V6 - VINRemove charge air cooler retaining nuts Textwashers.
Copyright 1998 Mitchell Repai
2) Pull downward on charge air cooler to disengage from retaining clips. Remove charge air cooler.
Fig. 8: Exploded View Of Intake Manifold (3.8L SC) Courtesy of Ford Motor Co. Installation 1) Install Teflon tape to circumference of seat surfaces of
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article T
charge air cooler inlet and outlet tubes. Keep tape close to inner diameter, and overlap ends 1/4". 2) Install charge air cooler retaining clips. Install nuts and washers. Ensure air boot fits on charge air cooler and no gap exists. Install inlet and outlet tubes on charge air cooler. 3) Tighten inlet and outlet tube-to-charge air cooler nuts to 15-22 ft. lbs. (20-30 N.m). Ensure clamping connectors on inlet and outlet tubes at charge air cooler are parallel to charge air cooler surface. Tighten inlet tube-to-alternator/power steering bracket nut to 30-40 ft. lbs. (41-54 N.m). Start engine and check charge air cooler tubes for air leakage. CHARGE AIR COOLER INLET & OUTLET TUBES Removal (Inlet Tube) 1) Using Spanner (T89P-6634-A), disconnect inlet tube from supercharger. See Fig. 8. Remove inlet and outlet tube-to-charge air cooler nuts. CAUTION: Disconnect outlet tube from charge air cooler to prevent damage to sealing surfaces during inlet tube removal. 2) Remove inlet tube-to-alternator/power steering pump bracket nuts. It may be necessary to remove stud from alternator/power steering pump bracket during inlet tube removal. Remove inlet tube. DO NOT damage sealing surfaces. CAUTION: When installing inlet tube, tighten tube using proper procedure to provide proper sealing for all surfaces. Installation 1) Ensure all sealing surfaces are clean. Install Teflon tape to circumference of charge air cooler inlet tube sealing surfaces. Keep tape close to inner diameter, and overlap ends 1/4". Apply AntiSeize Compound (ESE-M12A-4A) to sealing surface and threads of supercharger outlet adapter collar. CAUTION: DO NOT stretch tape during installation, or a leak at sealing surface may occur. 2) Install inlet tube, and then install stud into alternator/power steering pump bracket. DO NOT damage sealing surfaces of inlet tube. Install push-on nut on stud far enough to hold inlet tube. Ensure inlet tube is free to move for alignment of sealing surfaces. 3) Hand tighten supercharger outlet adapter collar on inlet tube. Install and slightly tighten inlet tube-to-charge air cooler nuts. Ensure inlet tube is free to move at sealing areas. Using adapter, tighten supercharger outlet adapter collar to 148 ft. lbs. (200 N.m). Wait at least 10 minutes, and retighten adapter collar to 148 ft. lbs. (200 N.m).
CAUTION: Supercharger outlet adapter collar must be retightened after 10 minutes, as Teflon tape will form to sealing surfaces. 4) Tighten inlet and outlet tube-to-charge air cooler nuts to 15-22 ft. lbs. (20-30 N.m). Ensure clamping connectors on inlet and outlet tubes at charge air cooler are parallel to charge air cooler surface. 5) Tighten inlet tube-to-alternator/power steering bracket nut to 30-40 ft. lbs. (41-54 N.m). Operate engine, and check for leaks. Removal (Outlet Tube) 1) Remove outlet tube-to-intake elbow assembly retaining nuts. Raise and support vehicle. Remove outlet tube-to-cylinder block front upper support bracket bolt. 2) Loosen, but DO NOT remove, support bracket at front of cylinder block. Bracket must remain close to cylinder block so bracket can pivot during installation of outlet tube. 3) Remove nut and push-on nut for outlet tube-toalternator/power steering pump bracket. Remove inlet tube stud from alternator/power steering pump bracket. Remove power steering pump belt. NOTE: Outlet tube does not have to be removed from vehicle if only resealing tube. 4) Disconnect spark plug wires at ignition coil. Remove power steering pump bracket brace-to-water pump nuts. Remove power steering pump bracket-to-cylinder head retaining bolts and stud nut. 5) Install a long bolt in top hole of power steering pump bracket to retain pump bracket in position. Remove power steering pump filler cap. 6) Move power steering pump bracket outward on the bolt installed in step 5). Remove outlet tube by moving tube underneath power steering pump bracket and up into engine compartment. DO NOT damage sealing surfaces of outlet tube. Installation 1) Ensure all sealing surfaces are clean. Install Teflon tape to circumference of outlet tube sealing surfaces. Keep tape close to inner diameter, and overlap ends 1/4". CAUTION: DO NOT stretch tape during installation, or a leak at sealing surface may occur. 2) Install outlet tube underneath power steering pump bracket assembly. Install power steering bracket and stud retaining nut. Tighten nut to 30-40 ft. lbs. (41-54 N.m). CAUTION: DO NOT damage sealing surfaces when installing outlet tube.
3) Remove bolt installed in step 5) of REMOVAL. Install power steering pump bracket-to-cylinder head bolts and tighten them to 30-40 ft. lbs. (41-54 N.m). 4) Install power steering pump bracket brace-to-water pump retaining studs. Tighten nuts to 15-22 ft. lbs. (20-30 N.m). Install outlet tube on lower stud on alternator/power steering pump bracket. 5) Install push-on nut to hold outlet tube on pump bracket. Ensure outlet tube is free to move for alignment of sealing surfaces. 6) Install outlet tube clamping connector over intake elbow assembly studs. Install and tighten nuts to 15-22 ft. lbs. (20-30 N. m). Ensure clamping connectors on outlet tube are parallel to intake elbow surface. 7) Install nut on stud of alternator/power steering pump bracket. Tighten nut to 30-40 ft. lbs. (41-54 N.m). Install outlet tube-to-cylinder block support bracket. Tighten bolt to 30-40 ft. lbs. (41-54 N.m). 8) Tighten support bracket-to-front of cylinder block retaining nut to 15-22 ft. lbs. (20-30 N.m) and bolt to 52-70 ft. lbs. (71-95 N.m). INTAKE MANIFOLD Removal (3.8L SC) 1) Ensure all surfaces are clean before removing components. Supercharger is serviced by replacement only. 2) Disconnect negative battery cable, drain cooling system. Remove air inlet duct. Remove cowl vent screens. Disconnect right side plug wires at coil assembly. Disconnect necessary electrical connectors, vacuum hoses and coolant hoses. 3) Disconnect control cables and linkage at throttle body. Remove throttle cable bracket at throttle body. Remove supercharger drive belt. Remove charge air cooler inlet and outlet tubes. See CHARGE AIR COOLER INLET & OUTLET TUBES under REMOVAL & INSTALLATION. See Fig. 8. 4) Release fuel pressure, and disconnect fuel lines. Refer to, FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS under REMOVAL & INSTALLATION. 5) Mark and evenly remove supercharger and intake elbow mounting bolts. See Fig. 8. Remove supercharger and intake elbow assembly from lower intake manifold. Remove gasket. 6) Remove retaining bolts, fuel rail and injectors as an assembly. Remove A/C compressor support bracket (if equipped). Disconnect necessary PCV lines. Note location of lower intake manifold bolts and studs. 7) Remove lower intake manifold bolts and studs. Remove lower intake manifold. If necessary, break sealing of intake manifold by prying on front of manifold with flat screwdriver. CAUTION: Note if thread sealant is used on bolts, and note bolt location during removal. Some bolts may require thread sealant during installation.
Installation 1) Ensure gasket surfaces are clean. Apply a small amount of Gasket and Trim Adhesive (D7AZ-19B508-AA) to cylinder head surface to hold intake gaskets in place. Install side gaskets. 2) Apply 1/8" bead of Silicone Sealer (D6AZ-19562-B) at cylinder head-to-cylinder block joining surfaces. Install front and rear intake manifold end seals. CAUTION: Some bolts may enter coolant passages and require thread sealant. If bolt originally contained thread sealant, apply thread sealant to bolt threads before installing. 3) Install lower intake manifold. If thread sealant is not required, lightly oil bolt and stud threads. 4) Install bolts and studs finger tight in original location. Tighten bolts and studs to specification in sequence. See Fig. 9. See TORQUE SPECIFICATIONS.
Fig. 9: Lower Intake Manifold Bolt Tightening Sequence Courtesy of Ford Motor Co. 5) Install fuel rail and injectors with new "O" rings. Lubricate "O" rings with engine oil before installing. 6) When installing fuel lines, install new "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown). Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary). CAUTION: When installing charge air cooler inlet and outlet tubes, refer to CHARGE AIR COOLER (FORMERLY INTERCOOLER) and CHARGE AIR COOLER INLET & OUTLET TUBES under REMOVAL & INSTALLATION for proper installation procedure. 7) Install supercharger and intake elbow assembly. Install bolts and tighten to specification. See TORQUE SPECIFICATIONS. Install charge air cooler inlet and outlet tubes. 8) To install remaining components, reverse removal procedure. Adjust all control cables. When filling cooling system, bleed air from system by removing vent plug from elbow on intake manifold behind thermostat housing. DO NOT rotate plastic cap under vent plug, or gasket may be damaged. 3.8L 9) Refill cooling system until coolant flows from vent plug. 16)1993 Ford ThunderbirdFor 1 V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p.
Install vent plug and tighten it to 11 ft. lbs. (15 N.m). Removal (3.8L) 1) Release fuel pressure and disconnect fuel lines. Refer to FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS under REMOVAL & INSTALLATION. 2) Disconnect negative battery cable. Drain cooling system. Remove air cleaner assembly and heat tube. Disconnect control cables and linkage at throttle body. Disconnect accelerator cable bracket and secure it aside. 3) Disconnect necessary linkages at intake manifold. Disconnect necessary electrical connectors, vacuum hoses, coolant hoses and PCV hoses. Remove heater tube with fuel lines attached. 4) Remove A/C compressor support bracket (if equipped). Remove throttle body and EGR valve assembly. Note location of upper intake manifold bolts and studs. Remove upper intake bolts and studs. Remove upper intake manifold. See Fig. 10.
Fig. 10: Exploded View Of Intake Manifold Assembly (3.8L) Courtesy of Ford Motor Co. 5) Remove fuel rail and injectors as an assembly. Note location of lower intake manifold bolts and studs. Remove lower intake manifold bolts and studs. CAUTION: Note if thread sealant is used on bolts, and note bolt location during removal. Some bolts may require thread sealant during installation.
6) Remove lower intake manifold. If necessary, break intake manifold sealing by prying on front of manifold with flat screwdriver. Remove and discard gaskets. 3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p
Installation 1) Ensure gasket surfaces are clean. Apply a small amount of Trim Adhesive (D7AZ-19B508-AA) to cylinder head surface to hold intake gaskets in place. Install side gaskets. 2) Apply 1/8" bead of Silicone Sealer (D6AZ-19562-B) at cylinder head-to-cylinder block joining surfaces. Install front and rear intake manifold end seals. CAUTION: Some bolts may enter coolant passages and require thread sealant. If bolt originally contained thread sealant, clean threads and apply thread sealant before installing. 3) Install lower intake manifold. If thread sealant is not required, lightly oil bolt and stud threads. 4) Install bolts and studs finger tight in original location. Tighten bolts and studs to specification in sequence. See Fig. 9. See TORQUE SPECIFICATIONS. 5) Install fuel rail and injectors with new "O" rings. Lubricate "O" rings with engine oil before installing. 6) When installing fuel lines, install new "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown). Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary). 7) Install upper intake manifold. Tighten bolts to specification starting with 4 center bolts, and proceed to 2 outer bolts. See TORQUE SPECIFICATIONS. 8) To install remaining components, reverse removal procedure. Adjust all control cables. Refill cooling system. CAUTION: On Cougar and Thunderbird, when filling cooling system, bleed air from system by removing vent plug from elbow on intake manifold behind thermostat housing. DO NOT rotate plastic cap under vent plug, or gasket may be damaged. Fill cooling system until coolant flows from vent plug. Install vent plug and tighten it to 11 ft. lbs. (15 N.m). EXHAUST MANIFOLD Removal (Left Manifold) 1) On 3.8L SC, remove charge air cooler (intercooler) inlet and outlet tubes. See CHARGE AIR COOLER INLET & OUTLET TUBES. Remove oil cooler tube support brackets. 2) On all models, remove oil dipstick tube support bracket. Disconnect spark plug wires from spark plugs. It may be necessary to disconnect oxygen sensor. Separate exhaust pipe from exhaust manifold. Remove retaining bolts and exhaust manifold. CAUTION: When installing charge air cooler inlet and outlet tubes, refer to CHARGE AIR COOLER (FORMERLY INTERCOOLER) and CHARGE AIR COOLER INLET & OUTLET TUBES under REMOVAL & INSTALLATION for proper installation procedure.
Installation 1) To install, reverse removal procedure. Lightly oil all bolt and stud threads before installing. A slight warpage, causing misalignment, may be corrected by elongating bolt holes as necessary. DO NOT elongate lower front bolt hole on cylinder No. 5. 2) Tighten bolts to specification. See TORQUE SPECIFICATIONS. If oxygen sensor is removed, apply anti-seize to threads before installing. DO NOT allow anti-seize to contact any area except threads of oxygen sensor. Removal (Right Manifold) 1) Remove air cleaner assembly and heat tube. Disconnect downstream air injection hose from check valve (if equipped). Remove coil wire and plug wires from spark plugs. Remove spark plugs. 2) Remove outer heat shield from exhaust manifold. Disconnect EGR tube (if equipped). Remove transmission/transaxle dipstick tube. Separate exhaust pipe from exhaust manifold. Remove retaining bolts, and remove exhaust manifold. Installation To install, reverse removal procedure. Lightly oil all bolt and stud threads before installing. A slight warpage, causing misalignment, may be corrected by elongating bolt holes as necessary. DO NOT elongate lower rear bolt hole on cylinder No. 2. Tighten bolts to specification. See TORQUE SPECIFICATIONS. CYLINDER HEAD Removal 1) Disconnect negative battery cable. Drain cooling system. Remove air cleaner assembly and heat tube. Remove accessories with hoses attached and set them aside. Remove accessory drive belt and accessory drive belt idler. 2) On 3.8L SC, remove charge air cooler inlet and outlet tubes. See CHARGE AIR COOLER INLET & OUTLET TUBES under REMOVAL & INSTALLATION. 3) On all models, remove lower intake manifold and exhaust manifold. See INTAKE MANIFOLD and EXHAUST MANIFOLD under REMOVAL & INSTALLATION. 4) Remove valve covers. Loosen rocker arm bolts, and pivot rocker arms from push rods. Mark component location for reassembly reference. Remove cylinder head bolts, noting location of different size bolts for installation. Discard cylinder head bolts. DO NOT reuse bolts. Remove cylinder head and gasket. NOTE: On Continental, Sable and Taurus, if cylinder head bolts and head gasket are replaced due to overheating or coolant loss, refer to Ford TSB 98-4-9, dated March 1998 for revised gasket, bolts and torque specifications. Inspection
3.8L 1) Inspect [4] & 3.8L SC V6 - VIN [R] Article Text (p. 19)1993 Ford ThunderbirdFor 1 V6 - VIN cylinder head for cracks or warpage. Machine
cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. CAUTION: DO NOT machine more than .010" (.25 mm) from original cylinder head thickness. 2) Check cylinder block deck surface. Machine cylinder block if warpage exceeds specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. CAUTION: DO NOT machine more than .010" (.25 mm) from original cylinder block surface. CAUTION: Always use NEW cylinder head bolts. Apply sealant to threads of short cylinder head bolts ONLY. Coat all other cylinder head bolts with engine oil before installing. Installation 1) Ensure bolt holes in cylinder block are clean. Install gasket and cylinder head. Apply a thin coat of Teflon Pipe Sealant (D8AZ-19554-A) to threads of new short cylinder head bolts (closest to exhaust manifold). Lubricate all other bolts with light coat of engine oil. DO NOT apply sealant to long cylinder head bolts. NOTE: Ensure proper type head bolts are used. Supercharged engines use different head bolts from other engines. 2) Install cylinder head bolts. Tighten cylinder head bolts to specification in sequence. See Fig. 1. See TORQUE SPECIFICATIONS.
Fig. 11: Cylinder Head Bolt Tightening Sequence Courtesy of Ford Motor Co.
3) Coat ends of push rods with Engine Assembly Lubricant V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 3.8L (D9AZ-19579-D) and install them in original position. Before
installing rocker arm on push rod, rotate crankshaft until push rod is fully downward and valve lifter is on base circle of camshaft. Position rocker arm on push rod, and tighten bolt to 43 INCH lbs. (5 N.m). 4) Repeat procedure for remaining push rods and rocker arms. Tighten rocker arm bolt to final specification. See, in this article, TORQUE SPECIFICATIONS. Final tightening of rocker arms may be done with camshaft in any position. NOTE: If cylinder head or valve train components are serviced, check valve clearance adjustment. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS. 5) To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. Refill cooling system. CAUTION: On Cougar and Thunderbird, when filling cooling system, bleed air from system by removing vent plug from elbow on intake manifold behind thermostat housing. DO NOT rotate plastic cap under vent plug, or gasket may be damaged. Fill cooling system until coolant flows from vent plug. Install vent plug and tighten it to 11 ft. lbs. (15 N.m). CRANKSHAFT FRONT OIL SEAL NOTE: Crankshaft pulley and vibration damper are balanced together and must be installed in original location. If vibration damper is being replaced, note if original vibration damper contains balance pins. If balance pins are used, install new pins in same location on replacement vibration damper. Removal (Cougar & Thunderbird) 1) Remove fan shroud retaining screws. Reposition fan shroud back over fan. Remove fan clutch assembly. Remove electric cooling fan (if equipped). 2) Remove accessory drive belts. Place reference mark on crankshaft pulley and vibration damper for reassembly reference. Remove crankshaft pulley. 3) On 3.8L SC, remove upper and lower crankshaft shields. On all models, remove vibration damper retaining bolt. 4) Using Vibration Damper Remover (T58P-6316-D) and Adapter (T82L-6316-B), remove vibration damper. Using screwdriver, pry seal from front cover. Installation 1) Lubricate seal and sealing surfaces with engine oil. Install seal using Seal Installer (T82L-6316-A and T70P-6B070-A). 2) Coat seal surface of vibration damper with engine oil. If key is removed from crankshaft, apply small amount of silicone sealant to keyway in crankshaft, and install key. 3) Install vibration damper. To install remaining components, reverse removal procedure.
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 2
4) Tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure reference marks align on crankshaft pulley and vibration damper. Removal (Continental, Sable & Taurus) 1) Remove accessory drive belts. Place reference mark on crankshaft pulley and vibration damper. Remove vibration damper retaining bolt. 2) Using Vibration Damper Remover (T58P-6316-D) and Adapter (T82L-6316-B), remove vibration damper. Using screwdriver, pry seal from front cover. Installation 1) Lubricate seal and sealing surfaces with engine oil. Using Seal Installer (T82L-6316-A and T70P-6B070-A), install seal. 2) Coat seal surface of vibration damper with engine oil. Using Vibration Damper Installer (T82L-6316-A), install vibration damper. 3) To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure reference marks align on crankshaft pulley and vibration damper. FRONT COVER NOTE: Oil pump is attached to front cover and is driven by distributor or synchronizer assembly. Removal (Cougar & Thunderbird) 1) Disconnect negative battery cable. Drain cooling system. Remove air cleaner assembly and air intake duct. 2) On 3.8L SC, remove electric cooling fan. On 3.8L, reposition fan shroud back over cooling fan. Remove fan clutch assembly. 3) On all models, remove drive belts and water pump pulley. Remove power steering pump and mounting bracket bolts with hoses attached and secure them aside. Remove A/C compressor front support bracket, leaving compressor in place (if equipped). 4) Disconnect coolant hoses at water pump. Disconnect upper radiator hose at thermostat housing. 5) On 3.8L SC, rotate engine, and position cylinder No. 1 at 26 degrees ATDC of compression stroke. Note location of camshaft sensor assembly electrical connection. See Fig. 2. 6) Remove camshaft sensor assembly, and note direction of synchronizer assembly installation. See Fig. 2. Remove synchronizer assembly retaining bolt. Remove synchronizer assembly along with intermediate shaft.
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 22)1993 Ford Thunderbird
Fig. 12: Exploded View Of Synchronizer Assembly (3.8L SC) Courtesy of Ford Motor Co. 7) On 3.8L, disconnect coil wire, and remove distributor cap and wire assembly. Position cylinder No. 1 on TDC of compression stroke. Ensure ignition rotor aligns with cylinder No. 1 on distributor cap. Mark rotor-to-distributor and distributor-to-engine positions. Remove distributor. 8) On all models, raise and support vehicle. Place reference mark on crankshaft pulley and vibration damper. Remove crankshaft pulley. Remove vibration damper retaining bolt. 9) Using Vibration Damper Remover (T58P-6316-D) and Adapter (T82L-6316-B), remove vibration damper. CAUTION: Crankshaft pulley and vibration damper are balanced together and must be installed in original location. If vibration damper is replaced, note if original vibration damper contains balance pins. If balance pins are used, 3.8L installVIN [4] &in same locationVINreplacement vibration. 23)1993 Ford ThunderbirdFor 1 V6 - new pins 3.8L SC V6 - on [R] Article Text (p. 10) On 3.8L SC, note oil cooler position for installation reference. Oil cooler is installed between the oil pump and oil filter. Remove oilcooler. 11) On all models, remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Oil pan must be lowered to remove front cover.
12) Lower vehicle. Remove front cover bolts. Two front cover bolts are behind oil filter mounting flange. See Fig. 3. Remove front cover and water pump as an assembly. Remove gasket. CAUTION: Ensure hidden bolts behind oil filter adapter are removed before removing front cover. See Fig. 3.
Fig. 13: Identifying Front Cover Mounting Bolts & Studs Courtesy of Ford Motor Co. Installation 1) Lightly oil threads of bolt and stud before installing. Use Gasket and Trim Adhesive (D7AZ-195O8-A) to hold front cover gasket in place on cylinder block. 2) Coat crankshaft front seal lip with engine oil. Install front cover and water pump as an assembly. Install front cover bolts. Apply Loctite to bolt closest to oil filter mounting flange and tighten this bolt last. See Fig. 3. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 3) Coat seal surface of vibration damper with engine oil. If key is removed from crankshaft, apply small amount of silicone sealant to keyway in crankshaft, and install key. Using Vibration Damper Installer (T82L-6316-A), install vibration damper. 4) On 3.8L SC, when installing synchronizer assembly, position engine so cylinder No. 1 is at 26 degrees ATDC of compression stroke. CAUTION: Synchronizer assembly must be installed using Synchro Positioner (T89P-12200-A) or plastic cover supplied with replacement synchronizer assembly. Proper alignment must be obtained for correct ignition and fuel system operation. 5) Engage synchronizer assembly vane in radial slot of
synchro positioner. See Fig. 2. Rotate synchro positioner until boss area engages with base notch of synchronizer assembly. Ensure synchro positioner contacts entire surface of synchronizer assembly. 6) Install synchronizer assembly so gear engages when arrow on synchro positioner is approximately 30 degrees counterclockwise from cylinder block face. See Fig. 4.
Fig. 14: Installing Synchronizer Assembly (3.8L SC) Courtesy of Ford Motor Co. 7) Install synchronizer assembly retaining bolt and clamp. Tighten bolt to 15-22 ft. lbs. (20-30 N.m). Remove synchro positioner. Install camshaft sensor. CAUTION: If camshaft electrical sensor connector is not contacting A/C bracket, or if it is not forward of supercharger drive belt, DO NOT reposition camshaft electrical connector by rotating synchronizer assembly. Remove synchronizer assembly, and repeat installation procedure.
8) On all models, reverse removal procedure to install remaining components. Ensure reference marks align on crankshaft pulley and vibration damper. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 9) When filling cooling system, bleed air from system by removing vent plug from elbow on intake manifold behind thermostat housing. DO NOT rotate plastic cap under vent plug, or gasket may be damaged. 3.8L 10) Refill cooling system until coolant flows from vent plug. V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 2
Install vent plug and tighten it to 11 ft. lbs. (15 N.m). Removal (Continental, Sable & Taurus) 1) Disconnect battery ground cable. Drain cooling system. Remove air cleaner assembly and air intake duct. 2) Remove accessory drive belts and water pump pulley. Remove power steering pump/bracket assembly with hoses attached (if equipped). Remove A/C compressor front bracket (if equipped). Disconnect by-pass hose, heater hose and radiator hoses. 3) Disconnect coil wire. Remove distributor cap and wire assembly. Position cylinder No. 1 on TDC of compression stroke. Ensure ignition rotor aligns with cylinder No. 1 position on distributor cap. Mark rotor-to-distributor and distributor-to-engine positions. Remove distributor. 4) Raise and support vehicle. Place reference mark on crankshaft pulley and vibration damper. Remove crankshaft pulley. Remove vibration damper retaining bolt. 5) Using Vibration Damper Remover (T58P-6316-D) and Adapter (T82L-6316-B), remove vibration damper. CAUTION: Crankshaft pulley and vibration damper are balanced together and must be installed in original location. If vibration damper is replaced, note if original vibration damper contains balance pins. If balance pins are used, install new pins in same location on replacement vibration. 6) Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Lower vehicle. Remove ignition timing indicator and front cover bolts. Two front cover bolts are behind oil filter mounting flange. Refer to Fig. 3. Remove front cover and water pump as an assembly. Remove gasket. CAUTION: Ensure hidden bolts behind oil filter adapter are removed before removing front cover. See Fig. 3. Installation 1) Lightly oil threads of bolt and stud before installing. Use Gasket And Trim Adhesive (D7AZ-195O8-A) to hold front cover gasket in place on cylinder block. 2) Coat crankshaft front seal lip with engine oil. Install front cover and water pump as an assembly. Install front cover bolts. Apply Loctite to bolt closest to oil filter mounting flange and tighten this bolt last. See Fig. 3. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 3) Coat seal surface of vibration damper with engine oil. Using Vibration Damper Installer (T82L-6316-A), install vibration damper. To install remaining components, reverse removal procedure. Align reference marks on crankshaft pulley and vibration damper. 4) Tighten bolts to specification. See TORQUE SPECIFICATIONS. Refill cooling system. TIMING CHAIN
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text
NOTE: Balance shaft is not used on Cougar and Thunderbird. A spacer replaces balance shaft drive gear behind camshaft gear. Removal 1) Remove front cover. See FRONT COVER under REMOVAL & INSTALLATION. Ensure timing marks on all gears are aligned. Refer to Fig. 16. Remove retaining bolt, and remove distributor or synchronizer assembly drive gear. 2) Remove camshaft gear, crankshaft gear and timing chain. See Fig. 15. If crankshaft gear is difficult to remove, position a pair of screwdrivers evenly on gear and carefully pry it off. 3) Remove tensioner/snubber assembly by pulling back on ratcheting mechanism and installing a pin through hole in bracket. Remove retaining bolts, and remove tensioner/snubber assembly. See Fig. 15.
Fig. 15: Exploded View Of Timing Chain & Components Courtesy of Ford Motor Co. Installation 1) Lightly oil threads of bolts and studs. Ensure crankshaft key is at 12 o'clock position. Install tensioner/snubber assembly with ratcheting mechanism in retracted position and pin in bracket hole facing outward. 2) Install crankshaft gear, camshaft gear and timing chain as an assembly. Ensure timing marks and keyways align. See Fig. 16. With all timing marks aligned, remove pin from tensioner/snubber assembly to apply tension to timing chain. 3) Tighten bolts to specification. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure.
Fig. 16: Aligning Timing Marks Courtesy of Ford Motor Co. VALVE LIFTER R & I Removal 1) Remove upper and lower intake manifolds. See, in this article, INTAKE MANIFOLD under REMOVAL & INSTALLATION. Remove valve covers. 2) Loosen rocker arm bolts, and pivot rocker arms from push rods. Mark push rod location, and remove push rods. Remove guide plate retainers. See Fig. 17. Remove guide plate. Mark valve lifter location for reassembly reference. Remove valve lifters.
Fig. 17: Exploded View Of Valve Lifter & Components Courtesy of Ford Motor Co. 3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 28)1993 Ford ThunderbirdFor 1 Inspection Inspect valve lifter for damage. Ensure roller rotates
smoothly. Measure valve lifter O.D. and cylinder block lifter bore I. D. If oil clearance is not as specified, replace components. See VALVE LIFTERS table under ENGINE SPECIFICATIONS. Installation 1) Lubricate valve lifter and cylinder block bore with Assembly Lubricant (D9AZ-19579-D) or heavy engine oil. Install valve lifter in original location. 2) Align flat sides of valve lifters, and install guide plates with the word UP showing. Install guide plate retainer. Tighten bolts to specification. See TORQUE SPECIFICATIONS. 3) Coat push rods with Assembly Lubricant (D9AZ-19579-D) and install them in original position. Before installing rocker arm on push rod, rotate crankshaft until push rod is fully downward and valve lifter is on base circle of camshaft. Position rocker arm on push rod, and tighten bolt to 43 INCH lbs. (5 N.m). 4) Repeat procedure for remaining push rods and rocker arms. Tighten all rocker arms to specification. See TORQUE SPECIFICATIONS. Final tightening of rocker arms may be done with camshaft in any position. To install remaining components, reverse removal procedure. CAMSHAFT NOTE: On Continental, Sable and Taurus, engine must be removed from vehicle for camshaft removal. See ENGINE R & I under REMOVAL & INSTALLATION. On all models engine must be removed from vehicle when servicing camshaft or balance shaft bearings. Removal 1) On Cougar and Thunderbird, disconnect negative battery cable, and drain cooling system. Remove radiator, A/C condenser (if equipped) and grille. 2) On all models, remove valve lifters and timing chain. See VALVE LIFTER R & I and TIMING CHAIN under REMOVAL & INSTALLATION. Remove camshaft key, spacer, thrust plate and camshaft. 3) If replacing camshaft bearings, remove engine from vehicle. Remove flexplate/flywheel. Remove rear camshaft bore plug. Use Camshaft/Balance Shaft Bearing Set (T65L-6250-A) to remove camshaft bearings. Inspection Inspect components for damage. Measure camshaft bearing I.D., journal O.D., lobe lift and oil clearance. Replace components if damaged or not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. Installation 1) To install, reverse removal procedure. Ensure oil holes in camshaft bearings and cylinder block align. Apply sealant to rear camshaft bore plug before installing.
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 29)
NOTE: Oversize rear camshaft bore plug can be identified by oversize stamped on flat area of plug. Ensure proper size plug is installed. 2) Lubricate camshaft lobes and bearing surfaces with Assembly Lubricant (D9AZ-19579-C). Install camshaft. Tighten thrust plate bolts to specification. See TORQUE SPECIFICATIONS. 3) Ensure camshaft end play is within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. To complete installation, reverse removal procedure. Refill cooling system. CAUTION: On Cougar and Thunderbird, when filling cooling system, bleed air from system by removing vent plug from elbow on intake manifold behind thermostat housing. DO NOT rotate plastic cap under vent plug, or gasket may be damaged. Fill cooling system until coolant flows from vent plug. Install and tighten vent plug to 11 ft. lbs. (15 N.m). BALANCE SHAFT NOTE: Balance shaft is not used on Cougar and Thunderbird.
Removal (Continental, Sable & Taurus) 1) Engine must be removed in order to remove balance shaft. See ENGINE R & I under REMOVAL & INSTALLATION. Remove timing chain and gears. See TIMING CHAIN under REMOVAL & INSTALLATION. 2) Remove balance shaft drive gear from camshaft. Remove balance shaft thrust plate bolts. Remove balance shaft. See Fig. 18. 3) If replacing balance shaft bearings, remove rear bore plug. Use Camshaft/Balance Shaft Bearing Set (T65L-6250-A) to remove balance shaft bearings.
Fig. 18: Locating Balance Shaft & Thrust Plate Courtesy of Ford Motor Co.
3.8L Inspection [4] & 3.8L SC V6 - VIN [R] Article Text (p. 30)1993 Ford ThunderbirdFor 1 V6 - VIN
Inspect components for damage. Measure balance shaft journal
O.D. and runout. Replace components if damaged or not within specification. See BALANCE SHAFT SPECIFICATIONS table. BALANCE SHAFT SPECIFICATIONS TABLE Application In. (mm)
End Play ............................. .003-.008 (.08-.20) Journal O.D. ............... 2.0505-2.0515 (52.083-52.108) Runout ........................................ .001 (.03) Installation 1) To install, reverse removal procedure. Lubricate all components with engine oil before installation. Apply sealant to rear bore plug before installing. NOTE: Oversize rear bore plug can be identified by oversize stamped on flat area of plug. Ensure proper size plug is installed. 2) Ensure all timing marks align. See Fig. 6. Check balance shaft end play. Replace thrust plate if end play is not within specification. See BALANCE SHAFT SPECIFICATIONS table. CRANKSHAFT REAR OIL SEAL Removal Rear main bearing oil seal is a one-piece seal. Remove transmission or transaxle. Remove flexplate/flywheel. Punch hole in metal portion of seal with an awl. Remove seal with a slide hammer. Installation 1) Lubricate seal and mating surfaces with engine oil. Install seal on crankshaft with spring side toward crankshaft. Using Seal Installer (T82L-6701-A), install seal so rear face of seal is within .005" (.13 mm) of rear surface of cylinder block. 2) To install remaining components, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. CAUTION: Apply thread sealant on threads of drive plate or flywheel bolts before installing. WATER PUMP Removal (Cougar & Thunderbird) 1) Disconnect negative battery cable. Drain cooling system. On 3.8L, remove shroud screws, fan clutch assembly and shroud. 2) On all models, remove accessory drive belts and water pump pulley. Remove power steering pump pulley. Remove water pump-to-power steering pump brace. 3) On 3.8L SC, charge air cooler may need to be removed in
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article T
order to access power steering pump pulley. See, in this article CHARGE AIR COOLER (FORMERLY INTERCOOLER) under REMOVAL & INSTALLATION. Disconnect oil cooler tube and by-pass hose. Remove upper crankshaft sensor cover. 4) On all models, disconnect necessary coolant hoses. Remove water pump bolts and nuts. Note bolt location. Note if sealant is applied to bolt threads. Remove water pump assembly. CAUTION: When bolts are removed, note if sealant is applied to threads. Some bolts are coated with sealant to prevent coolant leakage. Installation 1) Install gasket using Gasket and Trim Adhesive (D7AZ-19B508-AA). To complete installation, reverse removal procedure. Lightly oil threads of bolt and stud not containing thread sealant. 2) If bolts originally contained thread sealant, clean and reapply thread sealant to bolts. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. Fill cooling system. 3) Bleed air from cooling system by removing vent plug from elbow on intake manifold behind thermostat housing. DO NOT rotate plastic cap under vent plug, or gasket may be damaged. Fill cooling system until coolant flows from vent plug. Install and tighten vent plug to 11 ft. lbs. (15 N.m). Removal (Continental, Sable & Taurus) 1) Disconnect negative battery cable. Drain cooling system. Remove lower nut on both right-side engine mounts. Raise and support engine. 2) Remove accessory drive belts and water pump pulley. Remove air suspension pump (if equipped). Remove power steering with hoses attached and secure aside (if equipped). 3) Remove A/C compressor front bracket, leaving compressor in place (if equipped). Disconnect necessary coolant hoses. Remove water pump bolts and nuts. Note bolt location. Note if sealant is applied to bolt threads. Remove water pump and gasket. CAUTION: When bolt is removed, note if sealant is applied to threads. Some bolts are coated with sealant to prevent coolant leakage. Installation 1) Install gasket using Gasket and Trim Adhesive (D7AZ19B508-AA). To complete installation, reverse removal procedure. Lightly oil threads of bolt and stud not containing thread sealant. 2) If bolts originally contained thread sealant, clean and reapply thread sealant to bolts. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. Fill cooling system. OIL PAN Removal (Cougar & Thunderbird)
1) Disconnect negative battery cable. Remove air inlet tube. Remove radiator sight shield. Remove hood weather seal. Remove wipers, left cowl vent screen and wiper module. 2) On 3.8L SC, remove charge air cooler inlet and outlet tubes. See CHARGE AIR COOLER INLET & OUTLET TUBES under REMOVAL & INSTALLATION. 3) On all models, install Engine Support (D88L-6000-A) and lifting eyes. Raise and support vehicle. Remove engine mount through bolts. On 3.8L SC, remove retaining strap from left engine mount. 4) On all models, partially lower vehicle. Slightly raise engine with engine support. Raise and support vehicle, and remove starter. Drain engine oil, and remove oil filter. Remove wiring loom and ground strap. On A/T models, disconnect transmission cooler lines. 5) On all models, remove oil pan-to-transmission housing bolts. Remove oil pan-to-crankshaft sensor shield bolts (if equipped). Remove remaining oil pan bolts. 6) Remove steering shaft-to-steering gear pinch bolt. Separate steering shaft from steering gear. 7) Place transmission jack under front of subframe. Loosen, but DO NOT remove, front subframe bolts. Remove lower control arm-tostrut bolts. Lower subframe. Remove oil pan and seals. Installation 1) Apply Silicone Sealant (E3AZ-19652-A) on oil pan rails of cylinder block, rear main bearing cap, and front cover-to-cylinder block areas. CAUTION: Ensure silicone sealant fills groove between rear main bearing cap and cylinder block at both edges of main bearing cap. 2) Install oil pan and seals. Tighten oil pan bolts to specification. See TORQUE SPECIFICATIONS. 3) Raise subframe, and install lower control arm-to-strut bolts. Loosely install all subframe bolts. Install a 3/4" O.D. alignment rod in front subframe alignment holes. These holes are located near front bolt, on each side of subframe. 4) Tighten one bolt in each corner of subframe to specification. Remove alignment rods, and tighten remaining subframe bolts to specification. See TORQUE SPECIFICATIONS. CAUTION: When installing charge air cooler and charge air cooler inlet and outlet tubes, refer to, in the begining of this article, CHARGE AIR COOLER (FORMERLY INTERCOOLER) and CHARGE AIR COOLER INLET & OUTLET TUBES under REMOVAL & INSTALLATION for proper installation procedure.
5) To install remaining components, reverse removal procedure. When lowering engine, ensure locating pin in left engine mount is seated before allowing pin on right side to seat. 6) Fill oil system. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. 3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 33)1993 Ford Thunde
Removal (Continental, Sable & Taurus) 1) Disconnect negative battery cable. Raise and support vehicle. Drain engine oil, and remove oil filter. 2) Remove exhaust pipe assembly located below oil pan. Remove starter and torque converter housing cover. Remove retaining bolts, oil pan and seals. Installation 1) To install, reverse removal procedure. Before installing oil pan, apply Silicone Sealant (E3AZ-19652-A) on oil pan rails of cylinder block, rear main bearing cap and front cover-to-cylinder block areas. CAUTION: Ensure silicone sealant fills groove between rear main bearing cap and cylinder block at both edges of main bearing cap. 2) Tighten oil pan bolts to specification. See, in this article, TORQUE SPECIFICATIONS. Fill oil system. OVERHAUL CYLINDER HEAD NOTE: When valve and/or valve seat are machined, valve clearance is reduced and may cause improper valve operation. Valve lifter must be collapsed and clearance checked. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS at beginning of article. Cylinder Head Check cylinder head warpage. Resurface cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. CAUTION: DO NOT machine more than .010" (.25 mm) from original cylinder head surface. Valve Springs 1) Inspect pressure of valve spring. Replace valve spring if pressure is not within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. 2) Check springs for squareness, stand spring on table with closed end of spring downward. Hold square against spring and rotate spring. Measure space between spring and square. See, in the begining of article VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. 3) Measure valve spring installed height from cylinder head surface to underside of spring retainer. If installed height is not within specification, install a .03" (.8 mm) shim between cylinder head and valve spring to obtain correct height. See, in this article, 1993 Ford Thunderbird VALVES & VALVE SPRINGS 3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 34) table.
CAUTION: DO NOT install valve spring shims unless necessary. Using more shims than required can result in spring breakage or worn camshaft lobes. NOTE: Lubricate all valves, valve stems and valve guides with heavy oil during installation. Use Multi-Purpose Grease (D0AZ-19584-AA) on valve tips. Valve Stem Oil Seals Different types of valve stem oil seals are used on intake and exhaust valves. Ensure oil seal bottoms on valve guide. Oversize oil seals should be installed when using oversize valves. Exhaust valve stem oil seal can be identified by a White stripe. Valve Guides 1) Valve guides must be reamed for oversize valves if stemto-guide oil clearance exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valves are available in .015" (.38 mm) and .030" (.76 mm) oversize. 2) Valve guides may also be bored out and replaced with a service guide if oversize valves are not available, or if guide is damaged. Ream valve guides until proper stem-to-guide clearance exists. NOTE: DO NOT ream valve guides from standard to maximum oversize in one step. Ream valve guides to oversize in gradual steps so valve guides are reamed in relation to valve seat. Valve seats must be ground when valve guide is reamed or replaced. Valve Seat Ensure valve seat angle, seat width and seat runout are within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. Replacement information not available at time of publication. Valves Ensure head diameter, valve face runout, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. CAUTION: DO NOT remove more than .010" (.25 mm) from end of valve stem when resurfacing tip of valve. Valve Seat Correction Angles Use a 30-degree stone to lower seat or a 60-degree stone to raise seat. CYLINDER BLOCK ASSEMBLY Piston & Rod Assembly
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 35)1993 Ford Thunderbir
Install piston on connecting rod, with piston dome or notch on same side as button on connecting rod. See Fig. 19. Install piston and connecting rod in engine, with dome or notch on piston's top and button on connecting rod toward front of engine.
Fig. 19: Positioning Piston & Connecting Rod Courtesy of Ford Motor Co. Fitting Pistons 1) Standard size pistons are color-coded Red, Blue and Yellow on piston dome. Measure piston skirt diameter at 90-degree angle to piston pin. Replace piston if piston diameter is not within specification. See PISTONS PINS & RINGS table under ENGINE SPECIFICATIONS. 2) Measure cylinder bore 1/2" below top of cylinder block head surface and 1/2" above piston when at bottom of cylinder bore. 3) Using bore diameter, determine color-coded piston to be used. See PISTON SELECTION table. Ensure piston-to-bore clearance is within specification. See PISTONS PINS & RINGS table under ENGINE SPECIFICATIONS. 4) Check piston top-to-deck height. Measurement must be .011" (.27 mm) below deck to .010" (.25 mm) above deck. Measure with piston at TDC and parallel to crankshaft on true center line of piston. No information not available at time of publication. PISTON SELECTION TABLE Bore Diameter: In. (mm) Piston: Color Code
3.8095-3.8101 (96.761-96.777) ........................ Red 3.8107-3.8113 (96.791-96.807) ....................... Blue 3.8119-3.8125 (96.8210-96.837) .................... Yellow Piston Rings Ensure ring end gap and side clearance are within 3.8L V6 - VIN [4] & 3.8L SC V6 specification. See PISTONS PINS & RINGS table under ENGINE - VIN [R] Article Text (p. 36)1993 Ford Thunderbird
SPECIFICATIONS. Ensure ring gaps are NOT aligned. Rod Bearings 1) Coat rod bearings with Oil Conditioner (D9AZ-19579-CA). Coat connecting rod bolts with oil before installing nuts. Ensure piston and connecting rod are installed so dome or notch on piston's top and button on connecting rod are toward front of engine. See Fig. 19. 2) Ensure bearing oil clearance and side play are within specification. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS tables under ENGINE SPECIFICATIONS. CAUTION: On Continental, crankshaft main journals should not be machined. On all other models, crankshaft main journal should not be ground more than .010" (.25 mm). DO NOT grind rear main journal on 3.8L SC, as journal is already .010" (.25 mm) undersize. Because crankshaft incorporates deep rolling of main journal fillets, journal refinishing should not exceed .010" (.25 mm) undersize, otherwise fatigue failure may result. Crankshaft & Main Bearings 1) Main bearing caps are marked for location, with No. 1 at front and No. 5 at rear of engine. Arrow on main bearing cap must point toward front of engine. 2) Apply a 1/8" bead of silicone sealant to parting line between rear main bearing cap and cylinder block before installing. Install main bearing caps with arrow on cap pointing toward crankshaft pulley end of crankshaft. 3) Tighten bolts finger tight. Pry crankshaft forward, and tighten main bearing cap bolts to specification. See, in this article, TORQUE SPECIFICATIONS. Ensure rear main bearing cap is even with rear of cylinder block. 4) Ensure main bearing oil clearance and crankshaft end play is within specification. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. Replace thrust bearing if end play is not within specification. Thrust Bearing Thrust bearing is located on No. 3 main bearing. Replace bearing if crankshaft end play is not within specification. Cylinder Block 1) Using a straightedge and feeler gauge, check cylinder block head surface warpage. Machine cylinder block if warpage exceeds specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. CAUTION: DO NOT machine more than .010" (.25 mm) of material from original cylinder block head surface. 2) Check cylinder bore diameter, out-of-round and taper.
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text
Cylinder bore is measured 1/2" below top of cylinder block deck and 1/2" above piston when at bottom of cylinder bore. Cylinder block must be bored if measurement is not within specification. See, in this article CYLINDER BLOCK table under ENGINE SPECIFICATIONS. CAUTION: If cylinder block must be bored, ensure main bearing caps are installed and bolts are tightened to specification. This prevents main bearing bores from being distorted when boring cylinder block. LUBRICATION ENGINE OILING SYSTEM Force-feed type system supplies pressurized oil to crankshaft, connecting rods, camshaft and balance shaft bearings, and valve lifters. A controlled volume of oil is supplied to rocker arms and push rods. Oil pump is driven by intermediate shaft connected to distributor or synchronizer assembly. Crankcase Capacity Crankcase capacity, including filter, is 5 qts. (4.7L) on Cougar and Thunderbird. On Continental, Sable and Taurus, crankcase capacity, including filter, is 4.5 qts. (4.3L). Oil Pressure Oil pressure is 40-60 psi (2.8-4.2 kg/cm ) at 2500 RPM with engine at normal operating temperature. OIL PUMP Removal & Disassembly Oil pump is bolted to front cover. Remove oil filter and oil cooler (if equipped). Remove oil pump-to-front cover bolts, and remove oil pump. Disassemble oil pump. Note direction of component installation. Inspection 1) Place straightedge across mounting surface of oil pump cover. Measure warpage between oil pump cover and straightedge. Replace oil pump or cover if warpage exceeds specification. See, in this article OIL PUMP SPECIFICATIONS table. 2) Measure gear thickness and gear pocket depth in pump body. Check gear side clearance by measuring from tip of gear to pump housing. Measure gear diameter and gear pocket diameter in front cover. Replace components if measurements are not within specification. See OIL PUMP SPECIFICATIONS table. 3) Check relief valve tension and relief valve-to-bore clearance. Replace components if measurements are not within specification. See OIL PUMP SPECIFICATIONS table. OIL PUMP SPECIFICATIONS TABLE
Application
In. (mm)
Oil Pump Gear Backlash ............... .008-.012 (.02-.03) Idler Shaft-To-Gear Clearance ....................... .0005-.0017 (.044-.010) Driver Shaft-To-Housing Clearance ....................... .0015-.0030 (.076-.038) Oil Pump Gear Height (1) ......... .0055-.0005 (.050-.140) Oil Pump Gear Radial Clearance ....... .002-.005 (.05-.13) Oil Pump Cover Warpage ...................... .0016 (.041) Relief Valve-To-Bore Clearance ... .0017-.0029 (.043-.074) Relief Valve Spring Tension (2) .... 15.2-17.1 @ 1.20 (6.9-7.8 @ 28.2) (1) - Measure amount gear extends from housing (2) - Lbs. @ In. (Kg @ mm). Reassembly & Installation 1) To reassemble, reverse disassembly procedure. Ensure components are installed in original location. Lubricate components thoroughly. 2) Tighten oil pump cover bolts to specification. See TORQUE SPECIFICATIONS. To install, reverse removal procedure. Tighten bolts to specification. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS TABLE Application Ft. Lbs. (N.m)
Camshaft Sprocket Bolt ..................... 30-37 (41-50) Connecting Rod Nut Step 1 ................................... 31-36 (42-49) Step 2 .............................. Back Off 2-3 Turns Step 3 ................................... 31-36 (42-49) Crankshaft Pulley Bolt ................. 103-132 (140-179) Cylinder Head Bolt 3.8L SC (1) Step 1 ....................................... 37 (50) Step 2 ....................................... 45 (61) Step 3 ....................................... 52 (71) Step 4 ....................................... 59 (80) Step 5 ........................................... (2) Step 6 (Long & Short Bolts) ............ 48-55 (65-75) Step 7 .................... Tighten Additional 90-110 3.8L (Cougar & Thunderbird) (1) Step 1 ....................................... 37 (50) Step 2 ....................................... 45 (61) Step 3 ....................................... 523.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 39)1993 Ford Thunder (71)
Step 4 ....................................... 59 (80) Step 5 .... Back Off All Bolts ONE AT A TIME 2-3 Turns Step 6 Long Bolt 1st Step ........................... 11-18 (15-25) 2nd Step ...................... Additional 85-105 Short Bolt 1st Step ........................... 11-18 (15-25) 2nd Step ....................... Additional 65-85 3.8L (Continental, Sable & Taurus) (3) Step 1 ....................................... 15 (20) Step 2 ....................................... 30 (40) Step 3 ....................................... 37 (50) Step 4 (Retorque) Long Bolts (4) Step 1 ........................ Back Off 2-3 Turns Step 2 ............................. 30-37 (40-50) Step 3 ....................... Additional 175-185 Short Bolts (4) Step 1 ........................ Back Off 2-3 Turns Step 2 ............................. 15-22 (20-30) Step 3 ....................... Additional 175-185 Engine Mount Nut Continental .............................. 50-70 (68-95) Sable & Taurus ........................... 40-55 (54-75) Engine Mount Through Bolt Cougar & Thunderbird ...................... 35-50 (47-68) Exhaust Manifold Bolt/Nut .................. 15-22 (20-30) Fan Clutch Bolt ............................ 12-18 (16-24) Flywheel/Drive Plate Bolt (5) .............. 54-64 (73-87) Front Cover Bolt ........................... 15-22 (20-30) Guide Plate Retainer Bolt ........................ 10 (14) Inlet & Outlet Tubes-To-Charge Air Cooler Nut ............................ 15-22 (20-30) Inlet Tube-To-Alternator/Power Steering Bracket Nut ...................... 30-40 (41-54) Knock Sensor ............................... 15-19 (20-26) Lower Intake Manifold Bolt (6) 3.8L (7) Step 1 ....................................... 13 (18) Step 2 ....................................... 16 (22) Main Bearing Cap Bolt/Stud ................ 66-81 (90-110) Oil Cooler-To-Cylinder Block Bolt .......... 40-50 (54-68) Oil Filter Adapter Bolt .................... 18-22 (24-30) Oil Pick-Up Tube Bolt/Nut At Cylinder Block ........................ 15-22 (20-30) At Main Bearing Cap ...................... 30-40 (41-54) Oil Pump Cover Bolt Large Bolt ............................... 18-22 (24-30) Small Bolt ......................................... (9) Rocker Arm Bolt ..................................... (10) Steering Shaft Pinch Bolt
3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p. 40)1993 Ford Thu
Cougar & Thunderbird ..................... 30-42 (41-57) Subframe Bolt Cougar & Thunderbird .................... 70-95 (95-129) Supercharger ........................................ (11) Tension/Snubber Bolt ............................. 10 (14) Throttle Body Nut .......................... 15-22 (20-30) Torque Converter Nut ....................... 20-34 (27-46) Transmission/Transaxle-To-Cylinder Block Bolt ................................ 40-50 (54-68) Upper Intake Manifold Bolt (7) Step 1 ............................................ (12) Step 2 ......................................... 15 (20) Step 3 ......................................... 24 (32) Vibration Damper-To-Crankshaft Bolt .... 103-132 (140-179) Water Pump Bolt ............................ 15-22 (20-30) Wheel Lug Nut ........................... 85-105 (115-142) INCH Lbs. (N.m) Balance Shaft Thrust Plate Bolt ............ 72-120 (8-14) Camshaft Thrust Plate Bolt ................. 72-120 (8-14) Fuel Rail Bolt ............................. 72-106 (8-12) Oil Pan Bolt ............................... 80-106 (9-12) Valve Cover Bolt ........................... 80-106 (9-12) (1) - Use NEW cylinder head bolts. Apply sealant to shortest bolts. Tighten bolts in sequence. See Fig. 11. (2) - Back off 2-3 turns and tighten one bolt at a time, as specified in Steps 6 and 7. (3) - This procedure has been updated per Ford TSB 98-4-9 Dated March 2, 1998. Use NEW cylinder head bolts. Apply sealant to shortest bolts. Tighten bolts in sequence. See Fig. 11. (4) - DO NOT loosen all bolts at one time. Work on one bolt at a time in sequence. Sequence for long bolts is 1, 3, 5, 7. Sequence for short bolts is 2, 4, 6, 8. (5) - Apply thread sealant to bolt threads. (6) - Tighten bolts in sequence. See Fig. 9. (7) - This specification has been updated per Ford TSB 94-10-10 dated March 18, 1994. (8) - Tighten bolts to 84 INCH lbs. (9 N.m) (9) - Tighten bolts to 72-96 INCH lbs. (8-11 N.m). (10) - Tighten bolt to 43 INCH lbs. (5 N.m) with valve lifter on base circle of camshaft. Once all rocker arms are tightened, retighten bolts to 19-25 ft. lbs. (26-34 N.m). (11) - Tighten supercharger components as shown. See Fig. 8. (12) - Tighten bolts to 89 INCH lbs. (10 N.m)
ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS TABLE Application Specification
Displacement .......................... 232 Cu. In. (3.8L) Bore ..................................... 3.81" (96.8 mm) Stroke ................................... 3.39" (86.1 mm) Compression Ratio 3.8L SC .......................................... 8.2:1 3.8L ............................................. 9.0:1 Fuel System .......................................... PFI Horsepower @ RPM 3.8L SC ..................................... 210 @ 4000 3.8L ........................................ 140 @ 3800 Torque Ft. Lbs. @ RPM 3.8L SC ..................................... 315 @ 2600 3.8L ........................................ 215 @ 2400 CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS CRANKSHAFT MAIN & CONNECTING ROD BEARINGS TABLE Application In. (mm)
Crankshaft End Play .................. .004-.008 (.10-.20) Main Bearings Journal Diameter 3.8L SC Journals No. 1, 2 & 3 ........ 2.5190-2.5198 (63.983-64.003) Journal No. 4 ........ 2.5096-2.5104 (63.744-63.764) 3.8L ................... 2.5190-2.5198 (63.983-64.003) Journal Out-Of-Round ...................... .0003 (.008) Journal Taper .............. .0003 Per 1 (.008 Per 25.4) Oil Clearance 3.8L SC Journals No. 1, 2 & 3 ...... .0005-.0023 (.013-.058) Journal No. 4 .............. .0010-.0028 (.025-.071) 3.8L Standard ................... .0010-.0014 (.025-.036) Wear Limit ............................ .0023 (.058) Connecting Rod Bearings Journal Diameter ......... 2.3103-2.3111 (58.682-58.702) Journal Out-Of-Round ...................... .0003 (.008) Journal Taper .............. .0003 Per 1 (.008 Per 25.4) Oil Clearance Standard ..................... .0010-.0014 (.025-.036) Wear Limit .............................. .0027 (.069)
CONNECTING RODS SPECIFICATIONS CONNECTING RODS TABLE Application In. (mm)
Bore Diameter Pin Bore ................... .9096-.9112 (23.104-23.145) Crankpin Bore ............ 2.4266-2.4274 (61.636-61.656) Center-To-Center Length ...... 5.912-5.915 (150.16-150.24) Maximum Bend ................. .0016 Per 1 (.041 Per 25.4) Maximum Twist .................. .003 Per 1 (.08 Per 25.4) Side Play Standard ....................... .0047-.0114 (.119-.290) Wear Limit .................................. .014 (.36) PISTONS PINS & RINGS SPECIFICATIONS PISTONS PINS & RINGS TABLE Application In. (mm)
Pistons Piston Clearance 3.8L SC ...................... .0015-.0025 (.039-.064) 3.8L ......................... .0014-.0032 (.036-.081) Diameter (1) Red .................... 3.8095-3.8101 (96.761-96.777) Blue ................... 3.8107-3.8113 (96.792-96.807) Yellow ................. 3.8119-3.8125 (96.822-96.838) Pins Diameter ................... .9119-.9124 (23.162-23.175) Piston Fit 3.8L SC ...................... .0003-.0006 (.008-.015) 3.8L ......................... .0002-.0005 (.005-.013) Rod Fit ............................................ (2) Rings No. 1 End Gap .......................... .011-.021 (.28-.53) Side Clearance ............... .0016-.0034 (.041-.086) No. 2 End Gap .......................... .010-.020 (.25-.51) Side Clearance ............... .0016-.0034 (.041-.086) No. 3 (Oil) End Gap ......................... .015-.058 (.38-1.47) (1) - Piston diameter is determined by color code on dome of piston. (2) - Press fit with load of 1800 lbs. (816 kg).
3.8L V6 - VIN [4] & 3.8L SC V6
CYLINDER BLOCK SPECIFICATIONS CYLINDER BLOCK TABLE Application In. (mm)
Cylinder Bore Standard Diameter .......................... 3.81 (96.8) Maximum Taper ............................... .002 (.05) Maximum Out-Of-Round ........................ .002 (.05) Maximum Deck Warpage ...... (1) .003 Per 6 (.08 Per 152) Balance Shaft Bore I.D. ...... 2.191-2.192 (55.651-55.677) Camshaft Bearing I.D. ...... 2.0525-2.0535 (52.134-52.159) Camshaft Bearing Bore I.D. No. 1 & 4 .................. 2.191-2.192 (55.651-55.671) No. 2 & 3 .................. 2.176-2.177 (55.270-55.296) Main Bearing Bore .............. 2.712-2.713 (68.88-68.91) (1) - DO NOT machine more than .010" (.25 mm) from original cylinder block deck surface. VALVES & VALVE SPRINGS SPECIFICATIONS VALVES & VALVE SPRINGS TABLE Application In. (mm)
Intake Valves Face Angle ....................................... 45.8 Head Diameter .............................. 1.78 (45.2) Minimum Margin .............................. .031 (.79) Stem Diameter ................ .3415-.3423 (8.674-8.694) Valve Face Runout ........................... .002 (.05) Exhaust Valves Face Angle ....................................... 45.8 Head Diameter .............................. 1.46 (37.1) Minimum Margin .............................. .031 (.79) Stem Diameter ................ .3410-.3418 (8.661-8.682) Valve Face Runout ........................... .002 (.05) Valve Springs Installed Height ........................... 1.97 (50.0) Pressure (1) Valve Closed ................... 85 @ 1.65 (38 @ 41.9) Valve Open .................... 220 @ 1.18 (99 @ 29.9) (1) - Lbs. @ In. (Kg @ mm). CYLINDER HEAD SPECIFICATIONS
3.8L V6 - VIN [4] & 3.8L SC V6
CYLINDER HEAD TABLE Application In. (mm)
Maximum Warpage ........................... (1) .007 (.18) Valve Seats Intake Valve Seat Angle ..................................... 44.5 Seat Width ......................... .06-.08 (1.5-2.0) Maximum Seat Runout ....................... .003 (.08) Exhaust Valve Seat Angle ..................................... 44.5 Seat Width ......................... .06-.08 (1.5-2.0) Maximum Seat Runout ....................... .003 (.08) Valve Guides Valve Guide I.D. ............. .3433-.3443 (8.720-8.745) Valve Stem-To-Guide Oil Clearance Intake Valve ................. .0010-.0028 (.025-.071) Exhaust Valve ................ .0015-.0033 (.038-.084) (1) - DO NOT machine more than .010" (.25 mm) from original cylinder head surface. CAMSHAFT SPECIFICATIONS CAMSHAFT TABLE Application In. (mm)
Camshaft Bearing I.D. ...... 2.0525-2.0535 (52.134-52.159) Journal Diameter ........... 2.0505-2.0515 (52.083-52.108) Lobe Lift (1) Intake ..................................... .245 (6.22) Exhaust .................................... .259 (6.58) Oil Clearance ........................ .001-.003 (.02-.08) (1) - Maximum allowable lobe-lift loss is .005" (.13 mm). VALVE LIFTERS SPECIFICATIONS VALVE LIFTERS TABLE Application In. (mm)
Lifter Diameter .............. .8740-.8745 (22.200-22.212) Oil Clearance Standard ....................... .0007-.0027 (.018-.069) Wear Limit .................................. .005 (.13)
END OF ARTICLE

1993 Ford Thunderbird - 3.8L V6-VIN (4) & 3.8L SC V6 - VIN (R)

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1993 Ford Thunderbird - 3.8L V6-VIN (4) & 3.8L SC V6 - VIN (R)

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3.8L V6 - VIN [4] & 3.

8L SC V6 - VIN [R] Article Text

3.8L V6 PFI All Models ........................................... 4 3.8L V6 SC PFI Thunderbird ........................................... R

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Tex

Copyright 1998 Mitchell Repair I

Fig. 1: Engine & Transmission Mount Locations/ID

Copyright 1998 Mitchell Repair I

Fig. 3: L.H. & Assembly Transaxle Hydraulic Mount

Fig. 4: Support Assembly to Transaxle Retaining Bolts (Front)

Copyright 1998 Mitchell Repair I

Fig. 5: Support Assembly to Transaxle Retaining Bolts (Rear)

Copyright 1998 Mitchell Repair I

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (

Engine is removed with transaxle remaining in vehicle.

Copyright 1998 Mitchell Repair I

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p

Engine is removed with transaxle remaining in vehicle.

Copyright 1998 Mitchell Repai

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article T

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p

Copyright 1998 Mitchell Repai

Copyright 1998 Mitchell Repai

Copyright 1998 Mitchell Repai

Copyright 1998 Mitchell Repai

Copyright 1998 Mitchell Repai

Copyright 1998 Mitchell Repai

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Tex

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text

Copyright 1998 Mitchell Repai

Copyright 1998 Mitchell Repai

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article T

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Tex

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text

3.8L V6 - VIN [4] & 3.8L SC V6 - VIN [R] Article Text (p

GENERAL ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS TABLE Application Specification

Copyright 1998 Mitchell Repai

CONNECTING RODS SPECIFICATIONS CONNECTING RODS TABLE Application In. (mm)

3.8L V6 - VIN [4] & 3.8L SC V6

CYLINDER BLOCK SPECIFICATIONS CYLINDER BLOCK TABLE Application In. (mm)

3.8L V6 - VIN [4] & 3.8L SC V6

CYLINDER HEAD TABLE Application In. (mm)

Copyright 1998 Mitchell Repai

Copyright 1998 Mitchell Repai

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