• Ford's 3.8 liter six-cylinder engine was first produced in 1982 and was discontinued at the end of the 2003 model year. In 1995, the engine was used throughout the intermediate model line of vehicles, including the Thunderbird and the Cougar. Because the engine is computer controlled, it can be more challenging to work on than earlier engines. However, many of the same basic rebuilding basics still apply, including following the torque specifications to ensure that the engine's fasteners are not over-tightened.
  
  

Cylinder Head Bolts

• The cylinder head bolts must be tightened in a specific sequence. Tighten one bolt to an initial torque setting of 15 foot-lb. Tighten that bolt again to 30 foot-lb. Finally, tighten that bolt to its final torque setting of 59 foot-lb. Follow the process for the remaining bolts.
  
  

Intake Manifold Bolts

• Tighten each intake manifold bolt to between 13 and 16 foot-lb. of torque. Tighten the bolts at the center of the manifold first and work toward the ends of the manifold.
  
  

Exhaust Manifold Bolts

• Tighten each exhaust manifold bolt to 16 foot-lb. of torque. Tighten the bolts at the center of the manifold first and work toward the ends of the manifold.
  
  

Timing Chain Cover Bolts

• Tighten the timing chain cover's bolts to between 71 and 106 inch-lb. of torque.
  
  

Connecting Rod Bolts

• Tighten the connecting rod bolts to 36 foot-lb. of torque.
  
  

Main Bearing Cap Nuts

• The main bearing cap nuts must be tightened in two steps. Tighten the nut to an initial torque setting of 50 foot-lb. Tighten the nut a second time to its final torque setting of 99 foot-lb.
  
  

Vibration Dampener Bolt

• Tighten the vibration dampener's bolt to between 103 and 133 foot-lb. of torque.