< I am still very much a novice with regards to my 1973 XR-7 convertible. My question is whether or not this is something I should even attempt. I'm getting more and more comfortable with things (I've taken off the carb and put it back on), but just wondering if this is something I should try. >
Regardless if you change out your manifold, learning to work on your Cougar and diving into more challenging mods or repairs can be very rewarding. Here are some useful tips to start off with:
1) Invest in the factory shop manual so that you have the proper assembly sequence instructions, torque values, etc.
2) Use your digital camera to take pictures of EVERYTHING before you disassemble. Take pictures as you go. Trust me, you won't remember exactly how things go back together a few days or a week later.
3) "Bag and tag" all your small parts, bolts, clips, clamps, etc. using small Ziplock bags and or masking tape and a Sharpie. Draw a rough sketch of the parts bolt pattern on a piece of cardboard and push the bolts through the carboard in their proper location. For example, the bolt pattern for the waterpump on a 302 has many different sizes and lengths. When you're trying to put all the bolts back in quickly, before your gasket sealent starts to dry, it helps to grab the correct bolt and install them without having to figure out which one goes where.
4) Number or mark all your wiring connectors and hoses with a piece of masking tape and a Sharpie so you can connect them in their proper place.
5) Loosely install all your bolts first before you start the torque down sequence. This will allow the part to float a little bit so you can get all the bolts in. And, always run your bolts or nuts down a few threads by hand before you put a wrench on them to prevent cross threading.
6) Make sure you have ALL the bolts out BEFORE you try to pry a part off with some sort of wedge or screwdriver. Check and double check.
7) Thoroughly clean all gasket surfaces before installing new gaskets. I use a spray on gasket remover (which disolves paper) and a razor blade. I use rubbing alcohol to clean the surfaces afterwards.
Organization and remembering how it all goes back together is really the biggest hurdle. Once you consistantly do that, it's not that difficult.