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post #1 of 5 (permalink) Old 08-06-2003, 08:00 AM Thread Starter
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First Startup Checklist

Here's what I have to do before I can start my Cougar for the first time after the rebuild. Currently, the engine and tranny is bolted in, driveshaft is attached, and all electrical connections, except those noted in list, are complete. Please read the list to insure that I haven't forgotten anything!

Cougar Tasks:

Install power steering pump pulley
Install serpentine belt
Install coolant reservoir
Install upper and lower coolant hoses
Install radiator
Attach transmission lines to radiator
Attach coolant hoses
Attach negative battery cable to block
Attach ground strap on passenger side of engine
Attach wiring harness and positive battery cable to dist. box
Install exhaust system, plugging in O2 sensors, replacing hot O2 sensors with new
Double check all electrical connections
Fill power steering reservoir
Fill transmission with 6 quarts fluid
Fill radiator with 50/50 coolant
Disconnect coil packs
Install and connect battery
Crank engine until oil pump primes
Reconnect coil packs
Connect fuel pump electrical connector (in trunk)
Install Spark Plugs
Start engine, move transmission lever through gears, look for leaks
Shut off engine
Fill transmission with 4 more quarts fluid.
Check all fluid levels, top off if necessary
Start engine, move transmission lever through gears, look for leaks
Shut off engine.
Fill transmission to line on dipstick
Check all fluid levels, top off if necessary
Raise front end of car and bleed power steering pump as outlined with directions that came with pump.
Lower front end and test drive car slowly and carefully. Go to the gas station with an air gauge and fill tires to the proper PSI.
When up to operating temperature, return home and re-torque intake bolts to 10 FT.-LBS.


What do y'all think......I'm close..eh?

Glen "RustyUL" Weldon

94 Thunderbird SC - 5 Speed -- Picture Here
1 of 722 1994 SC 5-speeds made.
Soilid Engine Mounts, B&M Ripper Shifter, Tokico Shocks
95 Thunderbird LX - 4.6
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post #2 of 5 (permalink) Old 08-06-2003, 09:06 AM
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isn't the intake bolt need to retorque to 22 ft. lbs. instead of 10?
at least that's what my haynes and chilton manual says.....

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post #3 of 5 (permalink) Old 08-06-2003, 09:22 AM Thread Starter
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I'll doublecheck the Ford Service Manual...you may be right. Thanks for the heads up!

Glen "RustyUL" Weldon

94 Thunderbird SC - 5 Speed -- Picture Here
1 of 722 1994 SC 5-speeds made.
Soilid Engine Mounts, B&M Ripper Shifter, Tokico Shocks
95 Thunderbird LX - 4.6
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post #4 of 5 (permalink) Old 08-06-2003, 09:34 AM
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Quote:

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Crank engine until oil pump primes
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Install Spark Plugs
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I think I would crank it with the plugs at least loosely installed. My reasoning would be that with the plugs out, there is a big chance to suck something in through the spark plug holes. Especially the way the heads act like a funnel anyway.

Other than that, I can't see anything glaring that you missed. (I'm assuming you have installed the oil filter, oil pressure sending unit, and put oil in the engine...)

Good luck.

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post #5 of 5 (permalink) Old 08-07-2003, 07:36 AM Thread Starter
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Well, I think I'm just going to take my chances with this one. I want the engine to spin as fast as possible in order to prime the oil pump. If I put the plugs in, that will certainly slow down the engine revs, AND drain my battery quicker.

The engine is pretty clean now as is the engine compartment. I suppose if a fly or mosquito happen to land close to the spark plug hole, it would be history, but I don't think that would hurt anything.....

Thanks for the suggestion....

I just have the radiator and exhaust left to hook up.

Glen "RustyUL" Weldon

94 Thunderbird SC - 5 Speed -- Picture Here
1 of 722 1994 SC 5-speeds made.
Soilid Engine Mounts, B&M Ripper Shifter, Tokico Shocks
95 Thunderbird LX - 4.6
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