Pistons And Connecting Rods - Ford Aerostar 1997 Workshop Manual

1997 Aerostar/Ranger
Section 03-01C: Engine, 4.0L V-6
IN-VEHICLE SERVICE

Pistons and Connecting Rods

Removal
1. NOTE: On the Ranger, it is necessary to remove the engine to remove the oil pan and perform
this procedure.
Drain engine cooling system.
2. Remove intake manifold as outlined in this section.
3. Remove cylinder head (6049) as outlined in this section.
4. Remove oil pan (6675) and crankshaft oil windage baffle (6L680).
5. Remove oil pump (6600) and oil pump intermediate shaft (6A618).
6. Inspect the top of each cylinder bore before removing the piston (6108). If a ridge has formed at the
top of the cylinder it must be removed before piston removal. Remove ridge as follows:
a. Turn crankshaft (6303) until the piston to be removed is at the bottom of the cylinder bore.
b. Place a clean shop cloth over the piston head to collect cuttings.
c. Remove ridge using a suitable ridge reamer following the instructions of manufacturer. Never
cut into the ring travel area more than 0.794mm (1/32 inch) when removing the ridge.
7. NOTE: The cylinder number is stamped on the top of the piston. Matched letters are stamped
on the sides of corresponding rod and cap.
Turn crankshaft until the piston to be removed is at the high point of its travel. If more than one piston
is being removed, identify the pistons and connecting rod ca ps. Each component should be installed
in its original position during assembly.
8. Remove connecting rod cap attaching nuts and cap.
9. Install spark plug boots over connecting rod cap studs and push piston out through top of the cylinder
bore. Use care to prevent damage to bearing surfaces.
10. Install connecting rod cap and hold in position with cap attaching nuts.
11. If piston is to be disassembled, refer to
12. Inspect cylinder bore. If new piston rings are to be installed on the piston, a visible cross-hatch
pattern should be obvious on cylinder bore wall.
If honing is required, remove glaze from cylinder wall using spring-loaded hone. Follow
manufacturer's instructions when using this type of equipment.
file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C31.HTM~gen~ref.HTM
1997 Aerostar, Ranger Workshop Manual
Piston Disassembly in this section.
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2011-04-27