3.8l v6 - VIN [3] Ford Thunderbird IX

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

The engine may be identified by the Vehicle Identification Number (VIN) stamped on a metal tab attached to the instrument panel near the windshield on the driver's side of the vehicle. The VIN number is also stamped on both Safety Certification Decals, mounted on the left front door lock face panel and on the Engine Identification Label mounted on the valve cover. The VIN number contains 17 characters. The 8th character identifies the engine and the 10th character establishes the model year.

ENGINE IDENTIFICATION CODES

VALVE LASH ADJUSTMENT

1. Turn crankshaft so that No. 1 piston is at TDC end of compression stroke and check clearance of valves listed in VALVE LIFTER ADJUSTMENT SEQUENCE TABLE 1. Apply pressure to push rod end of rocker arm to slowly bleed down lifter until plunger is completely bottomed.
2. Hold lifter in this position and check clearance between rocker arm and valve stem tip with a feeler gauge. If clearance is less than specification, install shorter push rod; if greater, install longer push rod. After checking all valves in TABLE 1, rotate crankshaft 360° and check clearance of valves shown in TABLE 2.

VALVE LIFTER ADJUST SPECIFICATIONS #1

VALVE LIFTER ADJUSTMENT SEQUENCE 1

VALVE LIFTER ADJUST SPECIFICATIONS #2

VALVE LIFTER ADJUSTMENT SEQUENCE 2

ENGINE REMOVAL

1. Drain cooling system. Disconnect negative battery cable. Disconnect under hood wiring connector (if equipped). Mark hinges for reinstallation and remove hood.
2. Remove air cleaner assembly, air intake duct and heat tube. Remove fan shroud attaching screws. Remove fan/clutch assembly and shroud. Loosen accessory drive belt idler. Remove drive belt. Remove water pump pulley.
3. Disconnect upper and lower radiator hoses at radiator. Disconnect thermactor hose from downstream air tube check valve. Remove downstream air tube bracket bolt from rear of right cylinder head.
4. Remove coil secondary wire from coil. Remove power steering pump attaching bolts (if equipped). Place pump aside with hoses connected.
5. Remove A/C compressor attaching bolts (if equipped). Position compressor aside leaving refrigerant lines connected. Remove alternator. Disconnect heater hoses from heater tube and water pump.
6. Remove cruise control servo and bracket (if equipped). Disconnect all vacuum hoses, electrical wiring and linkages from engine. Disconnect engine ground strap at dash panel. Disconnect transmission linkage at fuel charging assembly.
7. Disconnect flexible fuel hoses from steel lines over the rocker arm cover. Plug the hoses to prevent leakage. Remove CFI throttle body. Install Engine Lifting Plate (T75T-6000-A) over throttle body mounting studs. Tighten nuts securely. CAUTION: As intake manifold is die-cast aluminum and of light weight design, all studs must be used to secure lifting plate. When using lifting plate, do not remove engine with transmission attached.
8. Raise vehicle. Drain crankcase. Remove dust shield from converter housing. Remove flex plate-to-torque converter bolts. Disconnect battery cable from starter motor. Remove starter motor.
9. Remove transmission oil cooler line routing clip. Remove exhaust inlet pipe at exhaust manifold. Disconnect exhaust heat control valve vacuum line (if equipped). Remove valve from exhaust manifold studs.
10. Remove transmission-to-engine lower attaching bolts. Remove engine mount-to-crossmember bolts. Lower vehicle. Support transmission with a jack.
11. Remove upper transmission-to-engine attaching bolts. Slightly raise engine. Carefully pull engine away from transmission. Remove engine from engine compartment.

Removal

1. Drain cooling system. Remove air cleaner assembly and heat tube. Disconnect accelerator cable and transmission linkage (auto. trans.) at carburetor. Remove accelerator mounting bracket. Disconnect cruise control unit (if equipped) and move aside.
2. Disconnect carburetor bowl vent hose at carburetor. Disconnect thermactor air supply hose at check valve (located in back of intake manifold). Disconnect fuel line at carburetor.
3. Disconnect coolant by-pass hose and heater hose at manifold and upper radiator hose at thermostat housing. Remove heater tube at manifold and tube support bracket and move assembly aside.
4. Disconnect necessary vacuum lines at carburetor and intake manifold. Disconnect necessary electrical connectors. If equipped with air conditioning, remove support bracket at manifold.
5. Loosen EGR tube at EGR valve adaptor and disconnect PCV line at carburetor. Remove carburetor and carburetor hold-down studs from manifold. Remove EGR spacer attaching screws from manifold.
6. With EGR adaptor and valve attached, loosen EGR spacer from manifold. Disconnect EGR tube from adaptor and slide spacer forward. Remove spacer assembly and discard old gasket. Remove PCV line, intake manifold attaching bolts, and remove intake manifold.

Note. Intake manifold is sealed at each end with RTV type sealer. It may be necessary to pry on front of manifold with screwdriver blade to loosen seal. Use care not to damage machined surfaces.

Installation

1. Clean all gasket surfaces. If intake manifold was disassembled, apply a coat of sealer to temperature sending unit, all vacuum fittings, spark knock sensor adaptor assembly and electric PVS (if equipped).
2. Apply sealer to cylinder head mating surface and press new intake manifold gaskets into place. Use dowel pins as guides to position gaskets. Apply a bead of sealer at each corner where cylinder head joins cylinder block and at each end of block where manifold seats against block. NOTE: Assembly must occur within 15 minutes after silicone sealer is applied.
3. Carefully lower intake manifold into position using dowel pins as a guide. Apply a thin coat of sealer to threads of manifold bolts and underside of bolt heads. Install manifold bolts and tighten in 3 steps. (Scheme 10) Reverse removal procedure to complete installation.

Intake Manifold Tightening Sequence Tighten in 3 steps. Scheme 10

1. Remove air cleaner assembly and heat tube. Disconnect thermactor hose from the downstream air tube check valve. Remove dipstick tube support bracket. Disconnect EGO sensor and spark plug wires. Remove spark plugs and manifold outer heat shield.
2. Raise vehicle and disconnect exhaust pipe. Disconnect exhaust heat control valve vacuum line. Remove transmission dipstick tube. Remove thermactor downstream air tube using EGR Clamp Cutter and Crimper (T78P-9481-A) to cut the tube clamp at the underbody catalyst. Remove exhaust manifold-to-head attaching bolts, manifolds and inner heat shield.

To install, reverse removal procedure. Clean gasket surfaces on cylinder head and manifold. Apply anti-seize to bolts and studs before installation. Install inner heat shield, new gaskets and pilot bolts (lower front bolt hole on No. 5 cylinder and lower rear bolt hole No. 2 cylinder) on cylinder heads.

Note. Exhaust manifolds may warp slightly and cause misalignment between cylinder head and exhaust manifold bolt holes. Elongate bolt holes in manifolds as necessary to correct misalignment. DO NOT elongate pilot holes.

1. Remove intake and exhaust manifolds as previously described. To remove left cylinder head, remove oil fill cap and remove power steering pump mounting bracket bolts and move pump aside. Remove air conditioning mounting bracket bolts (if equipped) and move compressor aside.
2. To remove right cylinder head, disconnect thermactor diverter valve and hose assembly at by-pass valve and downstream air tube and remove assembly. Remove accessory drive idler, alternator, and thermactor pump pulley. Remove thermactor pump. Remove alternator bracket and PCV valve. NOTE: If equipped with tripminder, fuel supply tube must be disconnected to gain access to upper attaching bolt of alternator bracket.
3. Remove rocker arm cover attaching bolts and break silicone seal by inserting a putty knife under cover flange. Remove rocker arm covers. CAUTION: If excessive prying force is applied, plastic rocker arm covers will break.
4. Remove rocker arm bolts, rocker arms and push rods. Identify for proper installation in original position. Remove cylinder head bolts and cylinder heads.

Note. The cylinder head is aluminum and requires a special corrosion inhibited coolant to avoid radiator damage.

1. Clean all gasket surfaces. Using dowel pins for guides, place head gaskets on block. Apply a thin coat of sealer to threads of short head bolts nearest to exhaust manifold. Coat head bolt flat washers with oil and install new bolts and washers.
2. Tighten cylinder head bolts in the following steps: 37 ft. lbs. (50 N.m.); 45 ft. lbs. (60 N.m.); 52 ft. lbs. (70 N.m.); and then tighten to 59 ft. lbs. (80 N.m.). Loosen head bolts 2-3 turns. Retighten in 4 steps following previously described procedure. (Scheme 11) NOTE: Always use new cylinder head bolts to assure a tight assembly.
3. After coating each push rod with Oil Conditioner (D9AZ-19579-C), install push rods in their original position. Position rocker arms over push rods and install rocker arms. For each valve rotate crankshaft until tappet rests on heel of camshaft lobe. Check that rocker arms are fully seated in cylinder head and that push rods are seated in rocker arm sockets. Tighten rocker arm attaching nuts.
4. Install exhaust manifolds and apply a thin bead of sealer to rocker arm cover flange. Make sure sealer fills the channel in cover flange. Install rocker arm covers and retaining bolts. Reverse removal procedure to complete installation.

Note. It is not necessary to re-tighten head bolts after extended engine operation when proper tightening sequence is followed.

Cylinder Head Tightening Sequence. Scheme 11

Valve Arrangement

E-I-E-I-E-I (Left side, front-to-rear).

I-E-I-E-I-E (Right side, front-to-rear).

VALVE GUIDE SERVICING

To ream guides for installation of valves with oversize stems, always use reamers in sequence. Reface valve seat after valve guide has been reamed. Reamers are available in .003" oversize with standard diameter pilot; .015" oversize; and .030" oversize.

VALVE STEM OIL SEALS

Cup type seals are used on all valves. Install cupped side down, below upper spring retainer.

1. With cylinder head removed, remove fulcrum attaching bolts and rocker arms. Remove exhaust manifolds (if necessary).
2. Compress valve spring with a spring compressor and remove valve keepers. Release spring compressor and remove spring retainer and spring. Remove valve stem oil seal from valves.

1. Using a square and feeler gauge, check springs for squareness. Spring ends must be square within .078" (1.98 mm). Check valve springs in a valve spring tester and replace as necessary. Install valve stem oil seals.
2. Install valve spring over valve and then install spring retainer. Compress spring and install retainer locks. Check assembled height of valve spring. See «VALVE SPRING INSTALLED HEIGHT»(/ford/thunderbird/ix-1983-1988/remont/mechanical/#38l-v6-vin-3__valve-spring-installed-height) .
3. After checking valve spring installed height, position rocker arms and fulcrums on cylinder head and install fulcrum attaching bolt. DO NOT tighten bolts. The bolts must be loose enough to allow rocker arm to be rotated to the side.

VALVE SPRING INSTALLED HEIGHT

Installed height of valve spring must not exceed specifications. Measure height from surface of cylinder head pad, to underside of spring retainer. (Scheme 12) If height is greater than specified, install.030" (.76 mm) spacer on head under spring to bring height within limits.

Measuring Valve Spring Installed Height. Scheme 12

HYDRAULIC VALVE LIFTER ASSEMBLY

Lifter parts are not interchangeable and are serviced as assemblies. Mark location of each lifter, so when engine is assembled, lifter may be installed in its original position. After cleaning and reassembling lifters, they should be tested for leak-down rate. Leak-down rate is 20-200 seconds measured at .125" (3.18 mm) plunger travel under 50 lb. (23 kg) load.

Exploded View of Valve Lifter Assembly. Scheme 13

COLLAPSED LIFTER CLEARANCE

OIL PAN

1. Disconnect negative battery cable. Remove air cleaner assembly including intake duct assembly. Remove fan shroud attaching bolts and position shroud over fan. Remove engine oil dipstick.
2. Remove electrical connector and retainer clip at low oil level sensor, if equipped. Raise and support vehicle and remove exhaust pipe-to-exhaust manifold attaching nuts. Drain crankcase and remove oil filter. Remove shift linkage bracket from transmission converter housing.
3. Disconnect transmission cooler lines at radiator. Remove flywheel access cover. On LTD/Marquis and Cougar/Thunderbird models, disconnect steering flex coupling. Remove bolts attaching steering gear to main crossmember. Rest steering gear on frame away from oil pan.
4. On all models, remove front insulator-to-chassis nut and washer assembly. Raise engine 2-3". Do not allow transmission dipstick tube and thermactor downstream air tube to contact each other. Place support blocks between engine mounts and frame.
5. Remove oil pan bolts and oil pan. On models requiring additional clearance, lower engine and remove dipstick tube and downstream air tube. (Manual Clamp Cutter T78P-9481-A or equivalent is needed to disconnect air tube from catalyst.)
6. Raise engine up to 5" to obtain adequate clearance. Remove oil pan bolts, loosen oil pan and lower onto crossmember. Remove pickup tube and tube support bracket nut. Lower pickup tube assembly into pan and remove pan through front of vehicle.

PISTON & ROD ASSEMBLY

Note. Following procedure is with cylinder head, oil pan, oil pump and pick-up tube removed from engine.

1. Rotate crankshaft until piston to be removed is at bottom of stroke and covered with a cloth to collect cuttings. Remove ridge at top of cylinder bore, using ridge reamer. Mark connecting rods and caps for reassembly in original position if necessary.
2. Remove connecting rod cap nuts and cap. Cover connecting rod studs with spark plug boots or rubber hose to protect crankshaft journal. Push piston and rod assembly out top of cylinder block. Install rod caps on mating rods and hold in position with cap nuts.

Note. Take care not to nick crankshaft journals or cylinder walls.

Scheme 14

1. If installing new pistons, check fit of piston in cylinder bore before assembling. Check piston pin fit before assembling piston to rod.
2. Oil piston rings and cylinder walls with a light coat of engine oil. Ensure that ring gaps are properly spaced on piston. (Scheme 14) Install ring compressor. Insert piston and rod assembly into correct cylinder bore, guiding rod over crankshaft journal. (Scheme 14): Piston Ring Gap Spacing NOTE: Notch on piston head must be toward front of engine and connecting rod oil squirt hole should be facing to the right. (Scheme 15)
3. Tap piston into cylinder bore using a wooden handle. Remove spark plug boot from connecting rod stud. Install rod cap and tighten. Repeat procedure for each piston assembly.
4. Be sure bearing inserts and bearing bore are clean. Check rod bearing clearance and rod side play.

Installing Piston & Connecting Rod Assembly. Scheme 15

PISTON SIZE SPECIFICATIONS

PISTON SIZE CODE CHART

Piston pins are replaced using an arbor press and pilot shaft. Pins are a press fit in bore.

Light tap with mallet may be needed to start pin into piston and rod assembly. Using arbor press and pilot, press pin into piston and rod assembly until pin centers in piston. (Scheme 16)

Installing Piston Pin. Scheme 16

CRANKSHAFT MAIN BEARINGS

Note. The following procedure is with cylinder heads, oil pan, oil pump and pick-up tube removed.

1. Before removing main bearing caps, mark caps for reassembly reference so they may be installed in original position. Remove crankshaft sprocket, camshaft sprocket and timing chain.
2. Remove flywheel and rear cover plate. Remove connecting rod caps. Turn crankshaft as necessary to position connecting rod in low point of travel before removing rod cap.
3. Each connecting rod cap should be identified so it can be installed in its original position during reassembly. Remove crankshaft. Remove main bearing inserts from the main bearing caps and engine block.

1. Lightly oil all bolts and stud threads before installation. Make sure all crankshaft bearing surfaces and bearing inserts are clean. Contaminants under a bearing will cause distortion. Contaminants on a bearing surface will cause damage to crankshaft journals.
2. If crankshaft main bearing journals have been refinished to a definite undersize, remove main bearing inserts from cylinder block and main bearing caps. Install new bearings making sure tabs on insert assembly engage slots in cap and block.
3. Make sure seal groove in cylinder block is clean. Carefully lower crankshaft into position in cylinder block. Be careful not to damage thrust bearing. Check main bearing clearance.
4. Silicone rear main bearing cap to cylinder block parting line. When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. Lubricate bearing surfaces with Oil Conditioner (D9AZ-19579-C) or heavy engine oil.
5. Tighten main bearing cap attaching bolts. Wedge a screwdriver between cylinder block web and crankshaft cheek in front of No. 3 main bearing. DO NOT jam screwdriver into position. Carefully tap on screwdriver until it holds crankshaft toward front of engine.
6. Check crankshaft end play as outlined. Install crankshaft rear oil seal. If crankshaft connecting rod journals have been refinished to a definite undersize, remove bearing inserts from connecting rods and rod caps.
7. Install new bearings making sure tabs on insert securely engage slots in cap and rod. Rotate crankshaft as necessary to bring each crankshaft throw to lowest point of travel. Put piston downward until connecting rod seats on crank throw and install rod caps.
8. Install timing chain and front cover/water pump assembly. To complete installation, reverse removal procedure.

Position crankshaft so connecting rod to be checked or serviced is down. Inspect connecting rod caps for cylinder identification so caps can be installed in original position. Remove rod cap and bearing inserts.

Install bearing insert in connecting rod and pull rod down until it seats on crankshaft. Make sure tab on bearing engages slot in rod and that bearing is fully seated in rod. Install bearing insert in rod cap and lubricate with engine oil. Install connecting rod cap and tighten.

THRUST BEARING ALIGNMENT

Install all bearing caps except thrust bearing cap and tighten. Install thrust bearing cap with bolts finger tight. Pry crankshaft to front of engine and pry thrust bearing cap to rear of engine. While holding crankshaft forward, tighten thrust bearing cap bolts. Check crankshaft end play.

Using sharp awl, punch hole into seal metal surface between lip and block. Screw in threaded end of Slide Hammer (T77L-9533-B). Remove seal. Avoid damaging oil seal mating surface.

Apply sealer to mating edges. Position seal on Seal Installer (T82L-6701-A). Position seal and tool on rear of engine. Tighten bolts alternately, to seat seal properly. Rear face of seal must be within .005" (.127 mm) of rear face of block.

Rear Main Bearing Oil Seal Installation. Scheme 17

1. Drain cooling system and disconnect negative battery cable. Remove air cleaner assembly and heat tube. Remove fan shroud and fan clutch attaching bolts. Remove shroud and fan clutch assembly.
2. Loosen accessory drive belt idler. Remove drive belt and water pump pulley. If equipped, remove power steering pump mounting bracket bolts and move pump to one side.
3. If equipped, remove air compressor front support bracket. Disconnect coolant by-pass and heater hoses at water pump. Remove upper radiator hose at thermostat housing.
4. Disconnect coil wire from distributor cap and remove cap with wires attached. Remove distributor hold-down clamp and remove distributor. If equipped with tripminder, remove fuel flow meter support bracket. Raise vehicle.
5. Using Crankshaft Damper Remover (T58P-6316-D and T82L-6316-B), remove crankshaft damper. Remove fuel pump crash shield and disconnect fuel line at pump. Remove oil filter. Disconnect lower radiator hose at water pump. Remove oil pan bolts and let oil pan drop down.
6. Remove front cover attaching bolt behind oil filter adapter. Remove remaining front cover attaching bolts. Remove ignition timing indicator. Remove front cover and water pump as an assembly.

Clean all gasket surfaces. Apply sealer to gasket and position on cylinder block. Install front cover and water pump and tighten attaching bolts. Reverse removal procedure to complete installation.

FRONT COVER OIL SEAL

1. Remove fan shroud and fan clutch assembly bolts. Remove shroud and fan clutch assembly. Loosen accessory drive belt idler.
2. Raise vehicle. Disengage accessory drive belt. Using a puller, remove crankshaft damper. Using a screwdriver, remove front cover oil seal.
3. Lubricate new oil seal with engine oil. Install damper seal using damper seal installer. Reverse removal procedure to complete installation.

Inspection

1. Turn crankshaft clockwise until No. 1 piston is at TDC. The damper pulley timing mark should point to TDC on the timing indicator. Remove the right valve cover. Loosen No. 3 exhaust rocker arm and rotate to one side.
2. Install a dial indicator to cylinder head and position it on push rod. Zero indicator and slowly turn crankshaft counterclockwise until slightest movement is seen on indicator.
3. Observe damper timing mark for number of degrees of travel from TDC. If reading exceeds 6 degrees, replace timing chain and sprockets.

With No. 1 cylinder at TDC and front cover removed, remove camshaft thrust button and spring from front of camshaft sprocket, crankshaft sprocket, and timing chain.

Install timing chain on sprockets with timing marks aligned. (Scheme 18) Slide both sprockets and timing chain onto engine. Tighten camshaft sprocket attaching bolts. Install camshaft thrust button and spring.

Timing Chain Sprocket Alignment. Scheme 18

1. Drain cooling system and remove radiator. If equipped with air conditioning, remove condenser.
2. Remove grille. Remove intake manifold and valve covers. Loosen rocker arms. Remove push rods and lifters. Remove drive belts and pulley. Remove front cover and water pump as an assembly.
3. Remove camshaft thrust button, spring, timing chain, and sprocket. Remove camshaft attaching bolts and camshaft (through front of engine).

Note. Front engine cover cannot be removed without lowering oil pan.

Lubricate cam lobes and bearing surfaces with oil conditioner. Install camshaft being careful not to damage bearing surfaces while sliding camshaft into position. Reverse removal procedure to complete installation.

1. Remove engine from vehicle. Remove flywheel and rear cover plate. Remove camshaft and rear bearing bore plug.
2. Remove crankshaft and push piston to top of cylinder bore. Select proper size expanding collet and back-up nut and assemble on expanding mandrel from Bearing Removal and Installation Set (T65L-6250-A).
3. With expanding collet collapsed, install collet assembly in camshaft bearing and tighten back-up nut on expanding mandrel until collet fits camshaft bearing.
4. Assemble puller screw and extension (if necessary) and install on expanding mandrel. Wrap a cloth around threads of puller screw to protect front bearing or journal.
5. Tighten pulling nut against thrust bearing and pulling plate to remove camshaft bearing. Be sure to hold a wrench on end of puller screw to prevent it from turning. Repeat this procedure for each bearing. To remove front bearing, install puller screw from rear of cylinder block.

1. Camshaft bearings are available pre-finished to size for standard and .015" (.38 mm) undersize journal diameters. Bearings are not interchangeable from one bore to another.
2. Position new bearings at bearing bores with oil holes aligned with holes in block. Press bearings in place. Be sure to center pulling plate and puller screw to avoid damage to bearing.
3. Failure to use correct expanding collet can cause severe bearing damage. Be sure front bearing is installed specified distance below front face of cylinder block. To complete installation, reverse removal procedure.

Remove transmission and flywheel. Remove engine rear cover plate. Using a sharp chisel or punch and hammer, cut a hole in center of plug. Remove plug using slide hammer. Plug can also be pried from bore using large punch. Use care to prevent damage to plug bore.

1. Prior to installing a core plug, plug bore should be inspected for any damage that would interfere with proper sealing. If bore is damaged it will be necessary to true surface by boring for next specified oversize plug. Oversize plugs are identified by "OS" stamped in flat located on cup side of plug.
2. Install bore plug using a driver. Apply a light coating of Perfect Seal Sealing Compound (B5A-19554-A) to sealing edge of plug bore before installation. To complete installation, reverse removal procedure.

CAMSHAFT END THRUST

The V6 engine has no camshaft end play because camshaft has a spring loaded thrust button, not a thrust plate.

CAM LOBE LIFT

With rocker arms removed, check lift of each lobe in consecutive order. Using a dial indicator, position point to end of push rod, in the same plane as push rod movement. Rotate crankshaft until lifter and push rod are at lowest position. Zero indicator. Rotate crankshaft slowly until push rod is in fully raised position. Ensure that total lift recorded is within specifications. If lift on any lobe is below specifications, camshaft and valve lifters must be replaced.

ENGINE OILING SYSTEM

Engine lubrication system is of force-feed type in which oil is supplied under full pressure to crankshaft, connecting rods, valve lifters, and camshaft. From lifters, a controlled flow of oil is supplied to rocker arms by hollow push rods. All other moving parts are lubricated by gravity flow or splash oiling. Oil pump shaft is driven by distributor shaft through an intermediate shaft.

Crankcase Capacity

Crankcase capacity is 4 Qts. (3.8 L) without filter change. Add 1 qt. (.9L) with filter change.

Normal Oil Pressure (Hot)

Normal oil pressure is 54-59 psi (3.7-4.1 kg/cm 2 ) at 2500 RPM.

Oil Filter

Oil filter is full-flow type mounted externally on front engine cover. Filter has integral by-pass valve and anti-drain back diaphragm.

Removal & Disassembly

1. Remove oil filter and oil pump cover attaching bolts. Remove cover and lift pump gears out of pocket in front cover. Discard gasket. (Scheme 19)
2. To remove pressure relief valve, drill a small hole in front cover and insert self-threading sheet metal screw into oil pressure relief valve chamber cap. Pull or pry plug, spring and valve from valve body.

Reassembly & Installation

Clean gasket surfaces. Measure pump gear end clearance, side clearance, and check pump cover for flatness using a straightedge. Pack gears with petroleum jelly and install in cover pocket making sure petroleum jelly fills all voids between gears and pocket. Position cover and gasket. Install cover attaching bolts and tighten.

Exploded View of Oil Pump. Scheme 19

OIL PUMP SPECIFICATIONS

1. Drain cooling system. Remove air cleaner and heater tube. Remove fan shroud and fan clutch attaching bolts. Remove shroud and fan clutch assembly. Loosen accessory drive belt idler. Remove drive belt and water pump pulley.
2. If equipped with power steering, remove pump mounting bracket bolts and move pump aside. If equipped with air conditioning, remove compressor front support bracket and leave compressor in place.
3. Disconnect by-pass and heater hose at water pump. If equipped with tripminder, remove fuel flow sensor support bracket. Remove water pump attaching bolts and remove pump.

Clean all gasket surfaces. Reverse removal procedure to complete installation.

Note. For further information on cooling system capacities and other cooling system components, see ENGINE COOLING SYSTEMS article in this section.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

VALVE SPRING SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• VALVE SPRING INSTALLED HEIGHT