This DIY repair and service manual by Haynes, covers 1989-1997 Ford Thunderbird and Mercury Cougar automobiles, U.S. and Canada models.
Book Excerpt: 1989-1997 Ford Thunderbird, Mercury Cougar Repair Manual
4.6L V8 ENGINE
TIMING CHAIN COVER | REMOVAL AND INSTALLATION
REMOVAL (Refer to illustrations 6.7 and 6.8)
- Disconnect the cable from the negative battery terminal.
- Drain the engine oil and remove the oil filter (see Chapter 1).
- Remove the drivebelt and the water pump pulley. Remove the crankshaft pulley/vibration damper (see Section 5).
- Unplug the electrical connectors from the camshaft sensor and crankshaft sensor. Unplug, unbolt and remove both coil packs from the timing chain cover (see Chapter 5).
- Remove the bolts securing the power steering pump to the engine. Note: The front lower bolt on the power steering pump will not come all the way out. Position the pump aside and secure it out of the way.
Remove the bolts retaining the power steering reservoir to the left coil bracket and set the reservoir aside.
- Remove the drivebelt tensioner from the timing chain cover.
- Remove both valve covers (see Section 4). Remove the timing chain cover-to-block bolts (see illustration). Note: Be sure to remove the four oil pan-to-timing chain cover bolts from underneath.
- Separate the timing chain cover from the block (see illustration). If it's stuck, tap it gently with a soft-face hammer just enough to break the gasket's bond.
CAUTION: DO NOT use excessive force or you may crack the cover. If the cover is difficult to remove, double check to make sure all of the bolts have been removed.
- Apply a 1/8-inch bead of RTV sealant to the junctions of the oil pan, timing chain cover and engine block.
- Lubricate the timing chains and the lip of the front crankshaft oil seal with clean engine oil.
- Install the front cover on the engine. Tighten the cover-to-block bolts to the torque listed in this Chapter's Specifications.
- Install the remaining parts in the reverse order of removal.
REAR BRAKE PADS | REPLACEMENT
(Refer to illustrations 6.2, 6.7a and 6.7b)
- Block the front wheels. Loosen the wheel lug nuts, raise the rear of the vehicle and support it securely on jackstands. Remove the wheel.
- Remove the brake hose bracket screw (see illustration).
- Remove the parking brake cable retaining clip at the caliper. Using a pair of pliers disconnect the cable end from the parking brake lever.
- Hold the hex head portion of the caliper upper slider pin with an open end wrench to prevent it from turning, and then remove the upper pinch bolt.
- Rotate the top of the caliper away from the brake disc to gain access to the brake pads.
- Lift the brake pads from the anchor plate.
- Using a pair of needle-nose pliers, engage the tips of the pliers in the two slots in the caliper piston face. Turn the piston clockwise until it is completely seated in the caliper.
Position the piston in such a way that one of the slots will be aligned with the locating nib on the brake pad when the caliper is installed. (see illustrations).
- Insert the brake pads into the anchor plate.
- Swing the caliper into position, making sure the nib on the pad meshes with a slot in the caliper piston.
- Apply Loctite to the threads of the pinch bolt. Insert the bolt through the caliper and into the slider pin. Tighten both pinch bolts to the torque listed in this Chapter's Specifications.
Subject: 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 Ford Thunderbird, Mercury Cougar service, maintenance, repair. ISBN-10: 1563923114 | ISBN-13: 9781563923111 | Haynes 36086