Thunderbird V6-232 3.8L SC (1989)
Upper Intake Manifold: Service and Repair
Supercharger
REMOVAL
1.
Partially drain coolant.
2.
Remove cowl vent screens.
3.
Remove elbow assembly as outlined.
4.
Remove throttle valve intake air tube.
5.
Disconnect throttle cable.
6.
Disconnect coolant hoses at throttle housing.
7.
Remove throttle cable bracket retaining bolts and position bracket out of the way.
8.
Disconnect PCV tube.
9.
Disconnect vacuum lines, plenum assembly and EGR transducer.
10.
Disconnect electrical connections at throttle position sensor, idle air bypass valve and EGR transducer.
11.
Remove two EGR retaining bolts and pull EGR away from plenum (if equipped).
12.
Remove EGR transducer bracket mounting screw and remove transducer.
13.
Remove four plenum assembly retaining bolts
14.
Loosen bypass hose clamp.
15.
Remove plenum and throttle body assembly as a unit. Remove four throttle body attaching nuts and separate plenum from throttle body.
INSTALLATION
1.
Clean and inspect gasket surfaces.
2.
Install throttle valve assembly to plenum, using new gasket. Tighten nuts to 20-30 Nm (1 5-22 lb-ft).
3.
Apply Loctite 510 or equivalent to plenum mating surface. Slide plenum into bypass hose and install plenum assembly and four retaining bolts.
Tighten to 21-32 Nm (16-24 lb-ft). Tighten clamps to 2.3-3.4 Nm (20-30 lb-in).
4.
Install EGR transducer and bracket. Tighten bolt to 8-11.5 Nm (72-96 lb-in).
5.
Install EGR valve. Tighten bolts to 20-30 Nm (15-22 lb-ft). Ensure new gasket is in place.
6.
Connect electrical connectors at EGR transducer, idle air bypass valve and throttle position sensor.
7.
Connect coolant hoses to throttle housing.
8.
Connect vacuum lines at plenum and EGR transducer. Install PCV tube.
9.
Install throttle cable bracket. Tighten bolts to 20-30 Nm (15-22 lb-ft).
10.
Connect throttle cable.
11.
Install air intake tube.
12.
Install elbow assembly as outlined.
13.
Install cowl vent screens.
14.
Top off coolant.
15.
START engine and check for proper operation and leaks using propane. For procedure See: Supercharger/Testing and Inspection/Component
Tests and General Diagnostics