Ford 1997 Aerostar Workshop Manual
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Ford 1997 Aerostar Workshop Manual

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1997 Aerostar/Ranger
Section 03-01B: Engine, 3.0L V-6
IN-VEHICLE SERVICE
Valve Cover and Gasket
NOTE: The rocker covers installed on the 3.0L engine incorporate integral (built-in) gaskets which
should last the life of the vehicle. Be sure to adhere to the following steps when removing and
replacing rocker covers. Replacement gaskets are available if required.
Removal
1. Disconnect battery ground cable (14301) and set aside.
2. Disconnect the crankcase ventilation hose from the air cleaner outlet tube. Disconnect the wiring
connectors from the mass air flow (MAF) sensor, intake air temperature (IAT) sensor, and the
harness locator from the outlet tube. Loosen the clamps at the throttle body and air cleaner and
remove the outlet tube.
3. Remove air cleaner outlet tube.
4. Disconnect the canister purge hose from the canister purge valve at the LH frame rail and the locator
from the accelerator control bracket. Remove the accelerator control splash shield.
5. Disconnect the throttle cable (09A758A) and speed control cable (9A825) from the throttle body and
the locator at the top of the intake manifold. Remove the cable bracket retaining bolts and remove
bracket with cables attached. Position the bracket and cables out of the way.
6. Disconnect the wiring connectors from the coil connector, radio noise suppressor, the EVR and left
side spark plug wires from coil. Disconnect right side spark plug wires from the locators and wires
from the spark plugs. Disconnect the vacuum hose from the EVR and heater control tee. Remove the
brace from the coil bracket and the exhaust manifold. Remove the coil assembly.
7. Disconnect the right side valve cover harness locators. Disconnect the IAT harness locator from the
generator bracket. Remove the right side valve cover and gasket.
8. Disconnect the DPFE vacuum hoses and the wiring connector. Remove the EGR valve tube from the
valve and exhaust manifold.
9. Disconnect the vacuum hoses from the brake booster, EGR, and the engine vacuum harness from
upper intake and position the harness out of the way.
10. Disconnec the wiring connectors from the throttle position sensor (TPS) and idle air control (IAC).
Disconnect the 42-pin connector from the bracket at the rear of intake manifold. Remove the positive
crankcase ventilation (PCV) valve from the valve cover.
11. Remove the upper intake manifold and gasket. Tape the lower intake openings closed.
12. Disconnect the left side spark plug wire locators and wires from the spark plugs. Remove the left side
valve cover and gasket.
13. NOTE: Do not clean the valve cover gasket with solvent. Damage to the valve cover gasket
may occur.
Clean the valve covers and mating surfaces.
file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B14.HTM~gen~ref.HTM
1997 Aerostar, Ranger Workshop Manual
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Page 1 of 4
2011-04-27

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  • Page 1 1997 Aerostar/Ranger Page 1 of 4 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Valve Cover and Gasket NOTE: The rocker covers installed on the 3.0L engine incorporate integral (built-in) gaskets which should last the life of the vehicle. Be sure to adhere to the following steps when removing and replacing rocker covers.
  • Page 2 14. Clean upper intake manifold and mating surfaces. Installation 1. NOTE: Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. Apply sealant and install the left valve cover and a new gasket. Tighten the bolts to 14 Nm (10 lb-ft).
  • Page 3 1997 Aerostar/Ranger Page 3 of 4 adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect battery ground cable . Valve Cover Installation, Ranger Item Part Number Description 6582 Valve Cover (RH)
  • Page 4 1997 Aerostar/Ranger Page 4 of 4 (7-10 Lb-Ft) — 4-6mm (.15-.23 In.) tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B14.HTM~gen~ref.HTM 2011-04-27...

  • Page 5: Rocker Arm

    1997 Aerostar/Ranger Page 1 of 1 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Rocker Arm Refer to Valve Tappet, Hydraulic In-Vehicle Service for removal and installation of the rocker arms. Perform only the steps necessary to remove the rocker arms.
  • Page 6 1997 Aerostar/Ranger Page 1 of 6 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Valve Tappet, Hydraulic NOTE: Before replacing a tappet for noisy operation, make sure the noise is not caused by improper valve-to-rocker arm clearance or by worn rocker arms or push rods. Refer to...
  • Page 7 1997 Aerostar/Ranger Page 2 of 6 10. Remove ignition coil and bracket assembly (two nuts) from top of throttle body and pencil brace at exhaust manifold. 11. Remove throttle body, refer to Section 03-04B 12. Disconnect fuel injector harness retaining standoffs from inboard rocker arm cover studs. Carefully disconnect electrical connections to each fuel injector and remove fuel charging wiring (9D930) from engine.
  • Page 8 Use a suitable solvent to remove old rubber sealant. 2. Lubricate valve tappets and bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Item Part Number Description —...
  • Page 9 5. Install tappet guide plate retainer over valve tappet guide plates. Retainer orientation is not important. Hand-start two retaining bolts. Tighten bolts to 10-14 Nm (7-10 lb-ft). 6. Apply a 5-6mm drop of Silicone Rubber D6AZ-19562-AA or -BA or equivalent meeting Ford specification ESB-M4G92-A or ESE-M4G195-A to intersection of cylinder block and cylinder head assembly at four corners as shown in the illustration under Intake Manifold in this section.
  • Page 10 1997 Aerostar/Ranger Page 5 of 6 Apply ESE-M2C39-F oil to removed push rods and rocker arms. Install push rods. Move rocker arms into position with push rod and snug rocker arm bolts. Rotate crankshaft (6303) to position camshaft lobe(s) straight down and away from push rods. Tighten rocker arm bolt to 11 Nm (8 lb-ft) to seat rocker arm into cylinder head.
  • Page 11 1997 Aerostar/Ranger Page 6 of 6 strategy. Connect ground cable at battery. 25. Start engine and check for coolant, oil fuel and vacuum leaks. 26. Verify and correct default base initial engine timing to 10 degrees BTDC. Refer to the Powertrain Control/Emissions Diagnosis Manual.

  • Page 12: Intake Manifold

    1997 Aerostar/Ranger Page 1 of 9 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Intake Manifold Upper Refer to Section 03-04B for throttle body removal and installation procedures. Lower Removal 1. Disconnect ground cable at battery and set aside.
  • Page 13 1997 Aerostar/Ranger Page 2 of 9 Item Part Number Description 12A648 Engine Coolant Temperature Sensor(Ranger) 124648 Engine Coolant Temperature Sensor (Aerostar) 9424 Intake Manifold 806344 Heater Elbow 18599 Hot Water Heater Elbow Connection 10884 Water Temperature Indicator Sender Unit —...
  • Page 14 1997 Aerostar/Ranger Page 3 of 9 16. Loosen cylinder No. 3 intake valve rocker arm bolt and rotate rocker arm (6564) off push rod (6565) and away from top of valve stem. Remove push rod. NOTE: Intake manifold (9424) may be removed with fuel injector and fuel injection supply manifolds (9F792) in place.
  • Page 15 Hot water heater elbow connection (18599) by-pass fitting (18599). Coolant temperature sending unit 3. Apply a 5-6mm drop of Silicone Rubber D6AZ-19562-AA or -BA or equivalent meeting Ford specification ESB-M4G92-A or ESE-M4G195-A to intersection of cylinder blocks and cylinder head (6049) at four corners as shown in the illustration.
  • Page 16 1997 Aerostar/Ranger Page 5 of 9 Item Part Number Description 9A424 Seal, Intake Manifold, Rear — Distributor Hole (Part of Cylinder Block) 6049 Cylinder Head ESE-M4G195-B Sealer (4 places) 6010 Cylinder Blocks 9A424 Seal, Intake Manifold, Front 6051 Head Gasket...
  • Page 17 CAUTION: If a new distributor or camshaft position sensor is installed, be sure to add the rest of the pint of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to the engine oil by pouring it through the distributor hole onto the cam drive gear.
  • Page 18 1997 Aerostar/Ranger Page 7 of 9 Item Part Number Description — Nut (Part of 12A310) 9J472 EGR Vacuum Regulator Bracket tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B17.HTM~gen~ref.HTM 2011-04-27...
  • Page 19 1997 Aerostar/Ranger Page 8 of 9 — Nut (Part of 12A310) 12A310 Ignition Coil and Bracket Assembly — Stud (Part of 9E926) 12N004 Ignition Coil Mounting Bracket — Exhaust Manifold Stud (Part of 9430) — Tighten to 8-12 Nm (6-9 Lb-Ft) —...
  • Page 20 1997 Aerostar/Ranger Page 9 of 9 22. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

  • Page 21: Cylinder Heads

    1997 Aerostar/Ranger Page 1 of 8 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Cylinder Head(s) Removal 1. NOTE: On 3.0L Aerostar it is necessary to remove the engine (6007) from the vehicle to perform this procedure. Refer to...
  • Page 22 1997 Aerostar/Ranger Page 2 of 8 15. If left cylinder head is being removed, perform the following: a. Remove fuel line retaining bracket from stud bolt on left side of power steering pump support bracket and remove stud bolt. b. Loosen lower bolt on left side of power steering pump support bracket two or three turns, but DO NOT REMOVE.
  • Page 23 1997 Aerostar/Ranger Page 3 of 8 3. Carefully position cylinder heads on cylinder blocks. 4. Install new cylinder head retaining bolts and hand tighten. 5. Tighten retaining bolts in sequence as illustrated to 80 Nm (59 lb-ft). 6. Back off all bolts a minimum of one full turn (360 degrees).
  • Page 24 Cylinder Head Assembly, Installation 8. Install intake manifold as outlined in this section. 9. Dip each push rod Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A heavy engine oil. Install push rods in their original positions and orientation.
  • Page 25 Install inlet pipe retaining nuts, tighten to 39-42 Nm (30-32 lb/ft). 14. Apply Cup Plug Sealer meeting Ford specification ESE-M4621-A or equivalent to cylinder block. Install oil level indicator tube into cylinder block. Oil level indicator tube must bottom out as illustrated.
  • Page 26 1997 Aerostar/Ranger Page 6 of 8 15. Install fuel charging wiring (9D930) to fuel injectors and inboard rocker arm cover studs. Connect fuel charging wiring to engine control sensor wiring (12A581) and secure with retaining features. 16. Install throttle body and new intake manifold gasket (9439) as outlined. Refer to Section 03-04B 17.
  • Page 27 1997 Aerostar/Ranger Page 7 of 8 (30-46 lb/ft). c. Install fuel line retaining bracket to stud bolt on left side of power steering pump support bracket and secure with nut. Tighten nut to 16-20 Nm (12-15 lb/ft). 18. If right cylinder head was removed, perform the following: a.
  • Page 28 1997 Aerostar/Ranger Page 8 of 8 Connect ground cable at battery. 31. Start engine and check for coolant, fuel, oil, vacuum and exhaust leaks. 32. Verify base ignition timing as outlined. 33. Check and, if necessary, adjust speed control linkage.
  • Page 29 1997 Aerostar/Ranger Page 1 of 3 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Crankshaft Pulley/Vibration Damper/Crankshaft Front Seal SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Front Cover Seal Replacer T70P-6B070- A Crankshaft Damper Remover T58P-6316-D...
  • Page 30 Seal Replacer T82L-6316-A and Front Cover Seal Replacer T70P-6B070-A. 3. Coat crankshaft damper sealing surface with clean engine oil. Apply RTV F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 using Rotunda Gasket Gun with Regulator 071-R0001 or equivalent to keyway of damper prior to installation. Install crankshaft vibration damper using Vibration Damper and Seal Replacer T82L-6316-A.
  • Page 31 1997 Aerostar/Ranger Page 3 of 3 Connect ground cable at battery. 8. Start engine and check for oil leaks. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B19.HTM~gen~ref.HTM 2011-04-27...

  • Page 32: Water Pump

    1997 Aerostar/Ranger Page 1 of 11 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Water Pump SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fan Clutch Holding Tool T84T-6312-C Fan Clutch Nut Wrench T84T-6312-D Removal 1. Disconnect ground cable at battery and set aside.
  • Page 33 1997 Aerostar/Ranger Page 2 of 11 Item Part Number Description N606068-S2 Bolt 10300 Generator 10153 Generator Mounting Bracket N806020-S2 Bolt 19703 A/C Compressor 6312 Crankshaft Pulley 3A674 Power Steering Pump N807551-S100 Bolt N807123-S2 Stud N605805-S2 Bolt 2882 A/C Compressor Mounting Bracket tomsn048@gmail.com...
  • Page 34 1997 Aerostar/Ranger Page 3 of 11 N800199-S8M Bolt 3A733 Power Steering Pump Pulley 6B209 Drive Belt Tensioner N60608-S2 Bolt N807124-S2 Bolt 3F671 Belt Adjuster N802096-S2 Bolt 8509 Water Pump Pulley — Tighten to 40-55 Nm (30-41 Lb-Ft) — Tighten to 21-29 Nm (15-21 Lb-Ft) —...
  • Page 35 2. Position a new gasket on water pump sealing surface using Gasket and Trim Adhesive D7AZ- 19B508-B or equivalent meeting Ford specification ESE-M2G52-A to hold gasket in position. 3. Install water pump on engine front cover and hand-tighten 12 attaching bolts. Refer to...
  • Page 36 1997 Aerostar/Ranger Page 5 of 11 S309 3F671 Power Steering Belt Idler Support — Tighten to 40-55 Nm (30-41 Lb-Ft) — Pulley with Pull-Off Groove Facing Front, Flush with End of Shaft + /- .25mm (0.018 Inch) — Tighten to 30-50 Nm (22-37 Lb-Ft) Power Steering Support Bracket —...
  • Page 37 1997 Aerostar/Ranger Page 6 of 11 N602098-S2 Screw and Washer 8509 Water Pump Pulley 6312 Crankshaft Pulley — Tighten to 40-55 Nm (30-41 Lb-Ft) — Tighten to 53-72 Nm (39-53 Lb-Ft) — Tighten to 21-29 Nm (16-21 Lb-Ft) 6. Reinstall engine accessory drive belt tensioner and torque to 35-45 Nm (27-33 lb-ft).
  • Page 38 1997 Aerostar/Ranger Page 7 of 11 Item Part Number Description 6049 Cylinder Head (RH) N606068-S309 Bolt N806209-S309 Stud 10A313 Generator Bracket 10300 Generator N802827-S309 N606706-S309 Bolt N606070-S309 Bolt 3F671 Power Steering Belt Idler Support 8680 Belt Idler Bracket — A/C Compressor Bracket (Part of 19703)
  • Page 39 1997 Aerostar/Ranger Page 8 of 11 Item Part Number Description N606068-S2 Bolt 10300 Generator 10A313 Generator Bracket N606065-S2 Bolt 6049 Cylinder Head (RH) — Tighten to 40-55 Nm (30-41 Lb-Ft) 13. Reconnect 3 wiring connectors in generator. 14. Install oil fill tube bracket over stud at generator and torque retaining nut to 42-50 Nm (32-37 lb-ft).
  • Page 40 1997 Aerostar/Ranger Page 9 of 11 Item Part Number Description 3F671 Power Steering Belt Idler Support 3A733 Power Steering Pump Pulley 6B209 Drive Belt Tensioner 8620 Drive Belt 6312 Crankshaft Pulley 8509 Water Pump Pulley — Idler (Part of 8A620)
  • Page 41 1997 Aerostar/Ranger Page 10 of 11 Item Part Number Description 19703 A/C Compressor 3A733 Power Steering Pump Pulley 6B209 Drive Belt Tensioner 8620 Drive Belt 6312 Crankshaft Pulley 8509 Water Pump Pulley 10300 Generator 3F671 Power Steering Belt Idler Support 17.
  • Page 42 1997 Aerostar/Ranger Page 11 of 11 of fan shroud should locate in clips at bottom of radiator. Secure top of fan shroud with 2 screws and torque to 6-8 Nm (53-71 lb-in). CAUTION: Fan clutch has left-hand threads so nut must be turned clockwise to remove.
  • Page 43 1997 Aerostar/Ranger Page 1 of 10 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Engine Front Cover SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fan Clutch Holding Tool T84T-6312-C Fan Clutch Nut Wrench T84T-6312-D Vibration Damper and Seal Replacer T82L-6316-A...
  • Page 44 1997 Aerostar/Ranger Page 2 of 10 Item Part Number Description N606068-S2 Bolt 10300 Generator 10153 Generator Mounting Bracket N806020-S2 Bolt 19703 A/C Compressor 6312 Crankshaft Pulley 3A674 Power Steering Pump N807551-S100 Bolt N807123-S2 Stud N605805-S2 Bolt 2882 A/C Compressor Mounting Bracket tomsn048@gmail.com...
  • Page 45 1997 Aerostar/Ranger Page 3 of 10 N800199-S8M Bolt 3A733 Power Steering Pump Pulley 6B209 Drive Belt Tensioner N60608-S2 Bolt N807124-S2 Bolt 3F671 Belt Adjuster N802096-S2 Bolt 8509 Water Pump Pulley — Tighten to 40-55 Nm (30-41 Lb-Ft) — Tighten to 21-29 Nm (15-21 Lb-Ft) —...
  • Page 46 1997 Aerostar/Ranger Page 4 of 10 10300 Generator N802827-S309 N606706-S309 Bolt N606070-S309 Bolt 3F671 Power Steering Belt Idler Support 8680 Belt Idler Bracket — A/C Compressor Bracket (Part of 19703) N605801-S309 Bolt 19703 A/C Compressor N806020-S309 Bolt — Tighten to 40-55 Nm (30-41 Lb-Ft) —...
  • Page 47 1997 Aerostar/Ranger Page 5 of 10 S309 3A733 Power Steering Pump Pulley 6B209 Drive Belt Tensioner N606068- Bolt S309 3F671 Power Steering Belt Idler Support — Tighten to 40-55 Nm (30-41 Lb-Ft) — Pulley with Pull-Off Groove Facing Front, Flush with End of Shaft + /- .25mm...
  • Page 48 1997 Aerostar/Ranger Page 6 of 10 Fasteners Fastener and Hole No. Part No. Size Lb- Ft N804215 M8 x 1.25 x 72.25 20- 30 15- 22 N804215 M8 x 1.25 x 72.25 20- 30 15- 22 N804811- S8 M8 x 1.25 x 73.0 20- 30 15- 22 N804811- S8 M8 x 1.25 x 73.0 20- 30 15- 22...
  • Page 49 M6 x 1.0 x 28.5 8-12 Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specifications WSK- M2G350-AZ and ESR-M18P7-A to fastener threads. 12. Remove remaining bolts in engine front cover and remove cover. Discard old engine front cover gasket (6020).
  • Page 50 1997 Aerostar/Ranger Page 8 of 10 3. Align new engine front cover gasket on cylinder blocks dowel pins. Note bolts that require pipe sealant on accompanying chart. Fasteners Fastener and Hole No. Part No. Size Lb- Ft N804215 M8 x 1.25 x 72.25 20- 30 15- 22 N804215 M8 x 1.25 x 72.25 20- 30 15- 22...
  • Page 51 M6 x 1.0 x 28.5 8-12 Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specifications WSK- M2G350-AZ and ESR-M18P7-A to fastener threads. 4. Install engine front cover and attaching bolts. Refer to the previous illustration. Tighten bolts 1 through 10 to 20-30 Nm (15-22 lb-ft) and bolts 11 through 15 to 8-12 Nm (6-8 lb-ft).
  • Page 52 1997 Aerostar/Ranger Page 10 of 10 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B21.HTM~gen~ref.HTM 2011-04-27...
  • Page 53 1997 Aerostar/Ranger Page 1 of 3 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Timing Chain, Sprockets, Tensioners and Guides Removal 1. Disconnect ground cable at battery and set aside. 2. Remove engine front cover (6019) as outlined in this section.
  • Page 54 1997 Aerostar/Ranger Page 2 of 3 Nm (41-52 lb-ft). Lubricate chain and sprockets with engine oil. Item Part Number Description 6279 Camshaft Sprocket Bolt 6256 Camshaft Sprocket 6306 Crankshaft Sprocket 6268 Timing Chain/Belt 6278 Camshaft Sprocket Washer — Tighten to 55-70 Nm (41-52 Lb-Ft) 4.
  • Page 55 1997 Aerostar/Ranger Page 3 of 3 11. Install front end accessory drive components as outlined. Refer to Section 03-05 for routing and tension of drive belt. 12. Fill crankcase with the correct viscosity and weight engine oil. CAUTION: This engine has aluminum components and requires a special corrosion- inhibiting coolant formulation to avoid radiator damage.
  • Page 56 1997 Aerostar/Ranger Page 1 of 10 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Camshaft Removal 1. NOTE: On 3.0L Aerostar it is necessary to remove the engine (6007) from the vehicle to perform this procedure. Refer to...
  • Page 57 5. Slide camshaft through bearings into cylinder blocks (6010) remembering to keep camshaft perfectly in line with front bearing. 6. Lubricate camshaft thrust plate with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install with two retaining bolts. Tighten bolts to 8-12 Nm (6-8 lb-ft). tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B23.HTM~gen~ref.HTM...
  • Page 58 Hand-start two retaining bolts. Tighten bolts to 10-14 Nm (7-10 lb-ft). 13. Apply a 5-6mm drop of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A or ESE-M4G195-A to intersection of cylinder block and cylinder head assembly at four corners.
  • Page 59 CAUTION: If a new camshaft is installed, always add the rest of the pint of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to the engine oil by pouring it through the distributor hole onto the camshaft drive gear. Run engine at idle for five minutes before driving vehicle.
  • Page 60 22. Rotate engine so camshaft is in Position B, as shown, with camshaft sprocket timing mark at two o'clock position and crankshaft sprocket timing mark at 4:30 position. 23. NOTE: Lubricate each push rod, rocker arm, and rocker arm fulcrum with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before installing. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B23.HTM~gen~ref.HTM...
  • Page 61 1997 Aerostar/Ranger Page 6 of 10 Install push rod, rocker arm, rocker arm seat (6A528), and rocker arm bolt for valves: Cylinder No. 1 Exhaust Cylinder No. 2 Intake Cylinder No. 3 Exhaust Cylinder No. 3 Intake Cylinder No. 4 Exhaust Cylinder No.
  • Page 62 1997 Aerostar/Ranger Page 7 of 10 CAUTION: Rocker arm fulcrum must be fully seated into cylinder head and push rod must be fully seated into lifter sockets before final tightening. Final-tighten allrocker arm bolts (6A527) to 26-38 Nm (19-28 lb-ft) with camshaft in any position.
  • Page 63 1997 Aerostar/Ranger Page 8 of 10 36. Connect two pressure differential hoses from the EGR pressure sensor to the EGR tube. EGR Tube — Ranger Item Part Number Description — Throttle Body — Transducer Hose — EGR Valve — Bolt & Washer —...
  • Page 64 1997 Aerostar/Ranger Page 9 of 10 38. Install fuel line safety clips. 39. Connect vacuum lines to premarked locations. 40. Connect electrical connections of: Intake air temperature sensor (IAT sensor) (12A697) Idle air control valve (IAC valve) (9F715) Engine coolant temperature sensor (ECT sensor) (12A648)
  • Page 65 1997 Aerostar/Ranger Page 10 of 10 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B23.HTM~gen~ref.HTM 2011-04-27...

  • Page 66: Exhaust Manifolds

    1997 Aerostar/Ranger Page 1 of 3 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Exhaust Manifolds Removal WARNING: ALLOW ENGINE (6007) TO COOL SUFFICIENTLY BEFORE REMOVING MANIFOLDS. SERIOUS INJURY WILL RESULT FROM CONTACT WITH HOT EXHAUST MANIFOLDS.
  • Page 67 1997 Aerostar/Ranger Page 2 of 3 Item Part Number Description 9430 Exhaust Manifold, Right N804468-S Stud N804465-S2 Screw and Washer — Bolt N805702-S2 Hex Flange Stud, M8 x 1.25 x 90 9430 Exhaust Manifold, Left — Screw and Washer —...
  • Page 68 1997 Aerostar/Ranger Page 3 of 3 4. Install spark plugs. Tighten to 11 Nm (8 lb-ft). 5. Install EGR tube flare nut into exhaust manifold connector (9F485) (Aerostar) finger tight. 6. Install EGR tube flare nut into EGR valve finger-tight.
  • Page 69 1997 Aerostar/Ranger Page 1 of 4 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Oil Pan, Ranger SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Engine Lifting Sling 014-00036 Removal 1. Disconnect battery ground cable. For additional information, refer to Section 14-01 2.
  • Page 70 Apply a 4.0-6.0 mm (1/5 inch) bead of Silicone Rubber D6AZ-19562-AA or -BA (or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A) to junction of rear main bearing cap and cylinder block and to junction of front cover assembly and cylinder block. Position oil pan gasket to cylinder block and secure it with Gasket and Trim Adhesive D7AZ-19B508-B (or equivalent meeting Ford specifications ESR-M11P17-A and ESE-M2G52-A).
  • Page 71 1997 Aerostar/Ranger Page 3 of 4 15. NOTE: When battery has been disconnected and reconnected, some abnormal drive symptoms can occur while powertrain control module (PCM) (12A650) relearns its adaptive strategy. Vehicle may need to be driven 16 km (10 miles) or more to relearn strategy.
  • Page 72 1997 Aerostar/Ranger Page 4 of 4 — Tighten to 10-14 Nm (7-10 Lb-Ft) D6AZ-19562-BA Silicone Sealer — 4 Places — Stop Bead 3mm from Timing Chain Cavity tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B25.HTM~gen~ref.HTM 2011-04-27...
  • Page 73 Apply a 4.0-6.0mm (1/5-inch) bead of Silicone Sealer D6AZ-19562-AA or -BA or equivalent meeting Ford specification ESB-M4G9Z-A to the junction of the rear main bearing cap and cylinder block and junction of the front cover assembly and cylinder block. See following illustration.
  • Page 74 1997 Aerostar/Ranger Page 2 of 3 9. Lower vehicle. 10. Replace oil level dipstick. 11. Fill crankcase with correct viscosity and amount of engine oil. 12. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy.
  • Page 75 1997 Aerostar/Ranger Page 3 of 3 6734 Oil Pan Drain Plug Gasket 6730 Oil Pan Drain Plug 6C624 Low Oil Level Sensor 6C626 Low Oil Level Sensor Washer 6019 Engine Front Cover — Rear Main Bearing Cap (Part of 6010) —...

  • Page 76: Oil Pump

    1997 Aerostar/Ranger Page 1 of 1 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Oil Pump Removal 1. Remove oil pan (6675) as outlined. 2. Remove retaining bolt and remove oil pump and intermediate shaft. Installation 1.
  • Page 77 1997 Aerostar/Ranger Page 1 of 5 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Crankshaft Removal 1. Remove engine (6007) from vehicle as outlined in this section, remove flywheel and engine rear plate, and install on a work stand.
  • Page 78 1997 Aerostar/Ranger Page 2 of 5 15. Lift crankshaft straight up from cylinder blocks (6010). Make sure crankshaft bearing surfaces are not scratched or damaged by contact with cylinder block. 16. NOTE: If crankshaft main bearings (6333) are to be reused, they should be identified to make sure that they are installed in their original positions.
  • Page 79 After bearings have been fitted, apply a light coat of heavy engine oil, SAE 50, to the journal's bearings and rear seal surface. Install all bearing caps. Apply a 6mm (1/4-inch) dot of Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSK-M2G348-A4 between rear cap and cylinder block (two places). Refer to the procedure in this section.
  • Page 80 1997 Aerostar/Ranger Page 4 of 5 the crankshaft forward against the thrust surface of the upper half of the bearing. Hold the crankshaft cap to the rear. This will align the thrust surfaces of both halves of the bearing. Retain the forward pressure on the crankshaft.
  • Page 81 1997 Aerostar/Ranger Page 5 of 5 19. Position flywheel (6375) on the crankshaft. Tighten to specification. 20. Install crankshaft pulley. Install and adjust drive belt to specification. Refer to Section 03-05 21. Remove engine from the work stand and install in vehicle.

  • Page 82: Crankshaft Main Bearings

    5. If bearing insert clearance is to be checked, refer to Section 03-00 6. If No. 1 or No. 2 crankshaft main bearing was removed, lubricate the bearing surface with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B29.HTM~gen~ref.HTM...
  • Page 83 1997 Aerostar/Ranger Page 2 of 4 main cap. Tighten attaching bolts to 80 Nm (60 lb-ft). Crankshaft and Bearings Part Item Number Description E1FZ- Sealer 19562-A 6337 Crankshaft Thrust Main Bearing 6333 Crankshaft Main Bearing, Rear Upper 6303 Crankshaft 6337...
  • Page 84 Remove all traces of sealant from the main bearing cap to cylinder block parting line. b. Apply a 6mm (1/4-inch) dot of Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSKM2G348-A4 between rear cap and cylinder blocks (two places). (See illustration.)
  • Page 85 1997 Aerostar/Ranger Page 4 of 4 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B29.HTM~gen~ref.HTM 2011-04-27...

  • Page 86: Pistons And Connecting Rods

    1997 Aerostar/Ranger Page 1 of 8 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Pistons and Connecting Rods Removal NOTE: If more than one piston (6108) is being removed, identify the piston and connecting rod cap to the cylinder number.
  • Page 87 2. Install protective rubber caps on the connecting rod bolts. 3. Lubricate piston, pin and ring and cylinder walls with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. 4. Rotate crankshaft journal to bottom of its travel (if moved).
  • Page 88 1997 Aerostar/Ranger Page 3 of 8 6. Install piston ring compressor D81L-6002-C or equivalent to piston. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B30.HTM~gen~ref.HTM 2011-04-27...
  • Page 89 1997 Aerostar/Ranger Page 4 of 8 Item Part Number Description 6212 Connecting Rod Nut 6210 Rod Cap tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B30.HTM~gen~ref.HTM 2011-04-27...
  • Page 90 7. Install clean, dry upper connecting rod bearing. 8. Lubricate bearing surfaces and crankshaft journal with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A engine oil, if clearances are within specification. 9. Carefully align piston to cylinder bore making sure piston dome notch and button on connecting rod face the front of engine.
  • Page 91 1997 Aerostar/Ranger Page 6 of 8 Item Part Number Description — Bolt (Part of 6600) 6600 Oil Pump 6629 Oil Pump Intermediate Shaft Retaining Ring 6A618 Oil Pump Intermediate Shaft 6010 Cylinder Blocks — Tighten to 40-55 Nm (30-41 Lb-Ft) tomsn048@gmail.com...
  • Page 92 Dip entire distributor or camshaft position sensor drive gear in Engine Assembly Lubricant D9AZ- 19579-D or equivalent meeting Ford specification ESR-M99C80-A. 15. Pour the rest of the pint of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A through distributor hole onto cam drive gear.
  • Page 93 1997 Aerostar/Ranger Page 8 of 8 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B30.HTM~gen~ref.HTM 2011-04-27...

  • Page 94: Connecting Rod Bearings

    1997 Aerostar/Ranger Page 1 of 4 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Connecting Rod Bearings The connecting rod bearings are a selective fit to provide for necessary operational clearances and oil pressure. Refer to Section 03-00 to measure bearing clearances and selection of the proper bearing insert.
  • Page 95 1997 Aerostar/Ranger Page 2 of 4 Item Part Number Description 6102 Piston, Pin and Ring 6200 Connecting Rod tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B31.HTM~gen~ref.HTM 2011-04-27...
  • Page 96 2. Clean crankshaft journal and lubricate with Engine Assembly Lubricant D9AZ-19579-B or equivalent meeting Ford specification ESR-M99C80-A. Make sure the entire journal is well lubricated. 3. Install upper connecting rod bearing in the connecting rod. Align locating tab with relief in connecting rod and seat fully into the rod.
  • Page 97 1997 Aerostar/Ranger Page 4 of 4 12. Install spark plugs. Tighten to 9-20 Nm (7-15 lb-ft). 13. Add correct amount and viscosity engine oil. 14. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy.
  • Page 98 1997 Aerostar/Ranger Page 1 of 2 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Flywheel Removal 1. Remove transmission as outlined in the appropriate section in Group 07. 2. NOTE: The engine rear plate can be removed.
  • Page 99 1997 Aerostar/Ranger Page 2 of 2 6375 Flywheel — Dowel (3 Req'd) (Part of 6375) — Alignment Tool — Tighten to 73-87 Nm (54-64 Lb-Ft) — Dowel Must Be Bottomed in Flywheel tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B32.HTM~gen~ref.HTM 2011-04-27...

  • Page 100: Crankshaft Rear Oil Seal

    1. Lubricate the outer lips and the inner seal on the crankshaft rear oil seal with Super Premium SAE 5W-30 Motor Oil XO-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 2. Using the special tool, install the crankshaft rear oil seal. Alternate bolt tightening to correctly seat the crankshaft rear oil seal.
  • Page 101 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B33.HTM~gen~ref.HTM 2011-04-27...
  • Page 102 Oversize plugs are identified by the "OS" stamped in the flat located on the cup side of the plug. NOTE: Apply a light coating of Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSK-M2G348-A4 to the sealing edge of the plug before installation.
  • Page 103 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B34.HTM~gen~ref.HTM 2011-04-27...
  • Page 104 1997 Aerostar/Ranger Page 1 of 2 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Oil Filter and/or Adapter Removal 1. Raise vehicle on hoist. Refer to Section 00-02 2. Position drain pan beneath engine oil pan (6675).
  • Page 105 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B35.HTM~gen~ref.HTM 2011-04-27...
  • Page 106 1. NOTE: Using solvent, clean oil level indicator tube and cylinder block sealing surfaces before applying silicone sealer. Apply a 3mm (1/8-inch) bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A or ESE-M4G-195-A to oil level indicator tube where oil level indicator tube mates with cylinder blocks.
  • Page 107 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B36.HTM~gen~ref.HTM 2011-04-27...

  • Page 108: Oil Pressure Switch

    3. Disconnect the wire at the switch unit terminal 4. Remove the oil pressure sensor (9278) from its mounting. 5. Apply Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specification WSK- M2G350-A2 to new switch unit threads. For installation follow removal procedures in reverse order. Tighten switch to 11-24 Nm (8-18 lb-ft).
  • Page 109 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B38.HTM~gen~ref.HTM 2011-04-27...
  • Page 110 1997 Aerostar/Ranger Page 1 of 18 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual REMOVAL AND INSTALLATION Engine Assembly, Aerostar SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fan Clutch Holding Tool T84T-6312-C Fan Clutch Nut Wrench T84T-6312-D Clutch Coupling Tool...
  • Page 111 1997 Aerostar/Ranger Page 2 of 18 7. Disconnect power steering pressure switch (PSP switch). 8. Remove power steering pressure hose from clips in fan shroud. 9. Remove two screws holding fan shroud to radiator and pull fan shroud out of lower clips. Rest fan shroud on radiator fan.
  • Page 112 1997 Aerostar/Ranger Page 3 of 18 15. Loosen pinch bolt and disconnect steering column at intermediate shaft. 16. Follow the procedure as outlined in Section 12-00 to recover air conditioning system and recycle refrigerant. 17. NOTE: All openings in the air conditioning system must be capped to keep dirt, foreign material, and excess moisture out of the system.
  • Page 113 1997 Aerostar/Ranger Page 4 of 18 steering pump. The other is located just above where exhaust manifold (9430) and three-way catalytic converter (TWC) connect. 26. Remove nuts and disconnect front stabilizer bar from front suspension lower arms. Discard nuts. 27. Remove disc brake calipers as outlined in Section 06-03 and secure to suspension upper arms.
  • Page 114 1997 Aerostar/Ranger Page 5 of 18 30. Position Powertrain Removal Lift 014-00765 or equivalent under crossmember and engine. 31. Lower vehicle until crossmember rests on removal lift. Place wood blocks under front crossmember and rear of cylinder blocks (6010) to keep engine and crossmember assembly level. Install safety chains around crossmember.
  • Page 115 1997 Aerostar/Ranger Page 6 of 18 33. Lower engine and raise vehicle, making sure A/C compressor and wiring harnesses and hoses do not interfere with the process. 34. When engine and crossmember assembly are clear, roll lift out from under vehicle.
  • Page 116 1997 Aerostar/Ranger Page 7 of 18 CAUTION: The support hook or chain must angle rearward to the rear attaching point. Damage will result if chain runs across throttle cable or throttle valve mechanism. NOTE: When only two support points are used, the engine assembly will hang slightly down at the rear with the transmission attached.
  • Page 117 1997 Aerostar/Ranger Page 8 of 18 1. Install engine lifting eyes on engine, connect with a chain and attach to a floor crane. 2. Remove attaching bolts and remove engine from work stand. 3. NOTE: Place a block of wood between the crossmember and the forward edge of the oil pan sump to keep engine level.
  • Page 118 1997 Aerostar/Ranger Page 9 of 18 maximum: 14.43mm (9/16 inch). If removed, position torque converter to transmission, making sure converter hub is fully engaged in front pump support and gear. CAUTION: Use care while moving transmission with torque converter installed. If transmission is tipped forward, the converter can slide out of the converter housing.
  • Page 119 1997 Aerostar/Ranger Page 10 of 18 15. Connect transmission oil cooler lines to fittings on case and install oil cooler lines. Tighten cooler line flair nuts to 22-30 Nm (16-22 lb-ft). 16. If removed, install rear engine support insulator to transmission. Tighten bolts to 81-108 Nm (60-80 lb-ft).
  • Page 120 1997 Aerostar/Ranger Page 11 of 18 21. Position a 22mm socket and breaker bar on crankshaft damper bolt. Rotate crankshaft (6303) clockwise (as viewed from front) to gain access to each of the torque converter studs. Install a nut on each stud and tighten to 27-46 Nm (20-34 lb-ft).
  • Page 121 1997 Aerostar/Ranger Page 12 of 18 Item Part Number Description — Converter Clutch Solenoid Connect Wires 7A247 Park/Neutral Position Switch 7A187 Kickdown Control Shaft Rod 7E395 Shift Cable and Bracket — Converter Clutch Solenoid and 3-4 Shift Solenoid 7B229 Transmission Shift Cable Bracket 27.
  • Page 122 1997 Aerostar/Ranger Page 13 of 18 29. Connect front stabilizer bar to lower control arms. Install new stabilizer bar link nuts and tighten to 16- 24 Nm (12-18 lb-ft). 30. Reinstall front brake calipers to steering knuckle as outlined in Section 06-03 31.
  • Page 123 1997 Aerostar/Ranger Page 14 of 18 34. Position 2 dash panel ground straps on engine and tighten 2 ground strap bolts. 35. Lower vehicle. 36. Connect oil pressure sensor electrical connector through cab area. 37. Install rear engine compartment cover inside vehicle.
  • Page 124 1997 Aerostar/Ranger Page 15 of 18 43. Connect electrical connector to power steering pressure switch (PSP switch). 44. Reconnect heater water supply and return hoses. CAUTION: Fan clutch nut has left hand thread. Turn counterclockwise to tighten. Install assembled fan blade and clutch and tighten to 41-135 Nm (30-100 lb-ft) using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Nut Wrench T84T-6312-D.
  • Page 125 1997 Aerostar/Ranger Page 16 of 18 Item Number Description N801731-S2 U-Nut N804639-S2 U-Nut N606692-S2 Screw and Washer Assembly N606677-S2 Screw and Washer Assembly 8260 Upper Radiator Hose Install with Stripe at 12:00 O'Clock Position 8592 Water Hose Connection 8501 Water Pump...
  • Page 126 1997 Aerostar/Ranger Page 17 of 18 Item Part Number Description 3F671 Power Steering Belt Idler Support 3A733 Power Steering Pump Pulley 6B209 Drive Belt Tensioner 8620 Drive Belt 6312 Crankshaft Pulley 8509 Water Pump Pulley — Idler (Part of 8A620)
  • Page 127 1997 Aerostar/Ranger Page 18 of 18 54. Connect upper and lower radiator hoses at radiator. 55. Install engine air cleaner outlet tube at throttle body and engine air cleaner. 56. Install PCV closure hose at air cleaner outlet tube and valve cover.
  • Page 128 1997 Aerostar/Ranger Page 1 of 12 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual REMOVAL AND INSTALLATION 3.0L Engine, Ranger SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fan Clutch Holding Tool T84T-6312-C Fan Clutch Nut Wrench T84T-6312-C Clutch Coupling Tool...
  • Page 129 1997 Aerostar/Ranger Page 2 of 12 Item Part Number Description 12B579 Mass Airflow Sensor 9600 Engine Air Cleaner 9B659 Air Cleaner Outlet Tube 6853 Crankcase Ventilation Hose 12A697 Intake Air Temperature Sensor — Clamp (Part of 9B659) 6582 Valve Cover...
  • Page 130 1997 Aerostar/Ranger Page 3 of 12 drive belt over the radiator. Item Part Number Description 3F671 Belt Idler Pulley 19D629 A/C Compressor 3D673 Power Steering Pump Pulley 6B209 Drive Belt Tensioner 6312 Crankshaft Pulley 8A528 Water Pump Pulley 10300 Generator 9.
  • Page 131 1997 Aerostar/Ranger Page 4 of 12 CAUTION: When disconnecting the speed control cable from the ball stud, use a screwdriver (or similar tool) close to the stud and pry slowly. Pulling by hand can damage the cable. Remove the accelerator control splash shield pushpins and the shield. Disconnect the accelerator and speed control cables from the ball stud at the throttle body.
  • Page 132 1997 Aerostar/Ranger Page 5 of 12 18. Remove the fuel line bracket nut from the A/C compressor/power steering bracket stud. Remove the lines and bracket. Position them out of the way. 19. Disconnect the electrical connector from the A/C pressure cutoff switch. Remove the nut retaining the A/C line to the water pump studded bolt.
  • Page 133 1997 Aerostar/Ranger Page 6 of 12 21. Disconnect the electrical connector from the A/C compressor clutch and two wire locators from the rear of the compressor. Remove the bolt retaining the A/C manifold and tube to the compressor. 22. Remove the bolts retaining the compressor to the bracket. Separate the A/C manifold and tube from the compressor and remove the compressor.
  • Page 134 1997 Aerostar/Ranger Page 7 of 12 38. Remove the bolt and nut retaining the oil filter drain funnel. Remove the starter motor bolts and secure the starter out of the way. Remove the drain funnel. 39. Remove the torque converter dust cover retaining bolts and remove the cover.
  • Page 135 1997 Aerostar/Ranger Page 8 of 12 7. NOTE: Use the crankshaft pulley bolt to rotate the converter. Install new torque converter-to-flexplate nuts. Tighten to 40 Nm (30 lb-ft). 8. Install the torque converter dust cover and retaining bolts. Tighten to 14 Nm (10 lb-ft).
  • Page 136 1997 Aerostar/Ranger Page 9 of 12 25. Install the accessory drive belt tensioner and the Torx® retaining bolt. Tighten to 45 Nm (33 lb-ft). 26. NOTE: Inspect the O-ring seals, replace as necessary. Make sure the fuel lines and bracket are positioned between the compressor and A/C line.
  • Page 137 1997 Aerostar/Ranger Page 10 of 12 37. Remove the protective caps and connect the automatic transmission oil cooling lines to the radiator connectors. Tighten to 20 Nm (15 lb-ft). 38. NOTE: The fan clutch has left-hand threads, so it must be turned counterclockwise for installation and tightening.
  • Page 138 1997 Aerostar/Ranger Page 11 of 12 clamps. 42. Position the air cleaner cover assembly. Connect the air cleaner outlet tube to the throttle body and securely tighten the clamp. Snap the air cleaner cover to the air cleaner housing. Connect the electrical connections to the MAF sensor and the IAT sensor.
  • Page 139 1997 Aerostar/Ranger Page 12 of 12 — Tighten to 2-3 Nm (18-27 Lb-In) — Tighten to 1-2 Nm (9-18 Lb-In) 43. Install and align the hood. Tighten to 9 Nm (80 lb-in). Connect the hood light connector and locator pin to the hood. Clip the ground strap to the hood on the right hand side.

  • Page 140: Camshaft Bearings

    1997 Aerostar/Ranger Page 1 of 3 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual REMOVAL AND INSTALLATION Camshaft Bearings SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Camshaft Bearing Set T65L-6250-A Removal 1. Remove engine (6007) from vehicle as outlined in this section.
  • Page 141 1997 Aerostar/Ranger Page 2 of 3 Camshaft Bearings, Removal/Installation Part Item Number Description — Pulling Screw (Part of T65L-6250-A) — Pulling Plate (Part of T65L-6250-A) — Expanding Mandrel (Part of T65L-6250-A) — Expanding Collet (Part of T65L-6250-A) — Backup Nut...
  • Page 142 1997 Aerostar/Ranger Page 3 of 3 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B41.HTM~gen~ref.HTM 2011-04-27...
  • Page 143 After this time, the sealer may start to set up, and its sealing effectiveness may be reduced. Apply a 4.0-6.0mm (1/5-inch) bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A or ESE-M4G195-A to the junction of the rear main bearing cap and cylinder blocks (6010) and junction of the front cover assembly and cylinder blocks.
  • Page 144 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B42.HTM~gen~ref.HTM 2011-04-27...
  • Page 145 1997 Aerostar/Ranger Page 1 of 23 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY Engine Disassembly 1. Remove throttle body (9E926) as outlined in Section 03-04B 2. Remove spark plugs (12405). 3. Remove right exhaust manifold (9430) and left exhaust manifold as outlined in this section.
  • Page 146 1997 Aerostar/Ranger Page 2 of 23 large screwdrivers. Use care to prevent damage to finished areas on the crankshaft (6303). Remove timing chain/belt (6268), camshaft sprocket (6256) and camshaft (6250) as an assembly. 17. Remove camshaft thrust plate bolts and camshaft thrust plate (6269).
  • Page 147 Ford specification ESR-M99C80-A heavy engine oil, and carefully lower the crankshaft into place. Use care to prevent damage to bearing surfaces. c. Apply a 6mm (1/4-inch) dot of Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSK-M2G348-A4 between rear cap and cylinder block (two places).
  • Page 148 1997 Aerostar/Ranger Page 4 of 23 Item Part Number Description 6010 Cylinder Blocks 6701 Crankshaft Rear Oil Seal 6303 Crankshaft — Rear Main Bearing Cap (Part of 6010) T88L-6701-A Rear Main Seal Installer — .5mm (.019 Inch) (Do Not Bottom) 4.
  • Page 149 1997 Aerostar/Ranger Page 5 of 23 Item Part Number Description 6102 Piston, Pin and Ring 6200 Connecting Rod tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B43.HTM~gen~ref.HTM 2011-04-27...
  • Page 150 Nm (23-28 lb-ft). 5. Check connecting rod side clearance as outlined. 6. Install camshaft rear bearing cover using a suitable driver. Coat the sealing edge of the plug with Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSK-M2G348-A4 before installation. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B43.HTM~gen~ref.HTM...
  • Page 151 ESR-M99C80-A, and lubricate the camshaft bearings with heavy oil SG. Install camshaft. Use care to prevent damage to bearing surface. 8. Lubricate camshaft thrust plate with Engine Assembly Lubricant D9AZ-19575-D or equivalent meeting Ford specification ESR-M99C80-A and install with two retaining bolts. Tighten bolts to 8-12 Nm (6-8 lb-ft). tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B43.HTM~gen~ref.HTM...
  • Page 152 1997 Aerostar/Ranger Page 8 of 23 9. Lubricate timing chain with clean engine oil. Rotate crankshaft, as necessary, to position the crankshaft sprocket timing mark in the 6 o'clock position with No. 1 piston at top dead center firing. Install camshaft sprocket (with timing mark in the 12 o'clock position), crankshaft sprocket and timing chain.
  • Page 153 M6 x 1.0 x 28.5 8-12 Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specifications WSK- M2G350-AZ and ESR-M18P7-A to fastener threads. 11. Assemble oil pump intermediate shaft retaining ring (6629) on end of oil pump intermediate shaft (6A618) and insert shaft into hole in oil pump until retainer clicks into place.
  • Page 154 1997 Aerostar/Ranger Page 10 of 23 12. Pilot oil pump withoil pump intermediate shaft through hole in rear main bearing cap, position pump over pins. 13. Install oil pump attaching bolts and tighten to 40-55 Nm (30-40 lb-ft). Item Part Number Description —...
  • Page 155 Install oil pan (6675) and tighten attaching bolts to 10-14 Nm (7-10 lb-ft). 15. Lubricate oil filter gasket with engine oil and install oil filter. 16. Lubricate valve tappets with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A or equivalent and install.
  • Page 156 22. NOTE: Lubricate eachpush rod,rocker arm, and rocker arm fulcrum with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before installing. Install push rod, rocker arm, rocker arm fulcrum, and rocker arm bolt for valves: Cylinder No.
  • Page 157 4:30 position. 25. NOTE: Lubricate each push rod, rocker arm, and rocker arm fulcrum with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before installing. Install push rod, rocker arm, rocker arm fulcrum and rocker arm bolt for valves: Cylinder No.
  • Page 158 1997 Aerostar/Ranger Page 14 of 23 Camshaft Position B — Rocker Arm, Push Rod, and Fulcrum Installation Item Part Number Description — Centerline — Camshaft Timing Mark at Two o'Clock Position — Crankshaft Sprocket Timing Mark at 4:30 Position —...
  • Page 159 29. NOTE: The threads of cover attaching bolts must be covered with Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 before installation. Tighten water pump attaching bolts according to accompanying chart.
  • Page 160 32. Apply Silicone Rubber Sealer D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92- A or ESE-M4G195-A to intersection of cylinder blocks and cylinder head at four corners, as shown.
  • Page 161 34. Position intake manifold gaskets (9439) in place and insert locking tabs over tabs on head gaskets as shown. 35. Apply Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A or ESE-M4G195-A over intake manifold gaskets. 36. Carefully lower intake manifold into position on cylinder blocks and cylinder heads to prevent disturbing the silicone sealer and causing gasketing voids.
  • Page 162 1997 Aerostar/Ranger Page 18 of 23 37. Install bolts and tighten, in the numerical sequence shown, to the following specifications in two steps: 15 Nm (11 lb-ft) 26-32 Nm (19-24 lb-ft) Intake Manifold Assembly Bolts, Installation 38. Install water thermostat (8575) into water hose connection. Rotate water thermostat into water outlet in a clockwise direction to secure thermostat to connector.
  • Page 163 40. Clean valve cover and cylinder head sealing surfaces with solvent to remove all gasket material and dirt. 41. Apply Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A or ESE-M4G195-A to intersection of cylinder head and intake manifold. 42. Install valve cover gasket and secure with retaining features.
  • Page 164 1997 Aerostar/Ranger Page 20 of 23 (7-10 lb-ft). Rocker Arm Cover Stud and Bolt Usage Valve Cover Installation tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B43.HTM~gen~ref.HTM 2011-04-27...
  • Page 165 CAUTION: If a new distributor or camshaft position sensor is installed, run engine at idle for five minutes before driving vehicle. Dip entire camshaft position sensor drive gear in Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B43.HTM~gen~ref.HTM...
  • Page 166 Page 22 of 23 45. If a new camshaft position sensor, pour the rest of the pint of Engine Assembly Lubricant D9AZ- 19579-D or equivalent meeting Ford specification ESR-M99C80-A through distributor hole onto cam drive gear. 46. Install camshaft position sensor. Refer to...
  • Page 167 1997 Aerostar/Ranger Page 23 of 23 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B43.HTM~gen~ref.HTM 2011-04-27...

  • Page 168: Cylinder Head

    5. Clean, inspect and service the cylinder head (6049), as required, or prepare to transfer all usable parts to a new cylinder head. Assembly All valves, valve stems and valve guides are to be lubricated with heavy oil SF. Apply Ford Multi-Purpose Grease D0AZ-19584-AA or equivalent meeting Ford specification ESR-M1C159-A to the valve tips before installation.
  • Page 169 1997 Aerostar/Ranger Page 2 of 3 Part Item Number Description 6518 Valve Spring Retainer Key 6571 Valve Stem Seal 6049 Cylinder Head 6505 Exhaust Valve 6507 Intake Valve 6513 Valve Spring 6514 Valve Spring Retainer — Exhaust Valve Stem Seal Red Band and Intake Valve Seal Silver Band tomsn048@gmail.com...
  • Page 170 1997 Aerostar/Ranger Page 3 of 3 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B44.HTM~gen~ref.HTM 2011-04-27...
  • Page 171 1997 Aerostar/Ranger Page 1 of 4 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Pistons and Connecting Rods Disassembly 1. Remove connecting rod bearing (6211) from connecting rod (6200) and cap. 2. Remove partial piston ring set using a suitable piston ring expander.
  • Page 172 1997 Aerostar/Ranger Page 2 of 4 (Part of T68P-6135-A) — Press Plates (Part of T68P-6135-A) — Pin Pusher (Part of T68P-6135-A) Assembly Check the fit of a new piston, pin and ring (6102) in the cylinder bore before assembling the piston pin...
  • Page 173 1997 Aerostar/Ranger Page 3 of 4 On V-6 engines with one rod per pin, both sides of rod have larger chamfers. 4. NOTE: Make certain piston floats during installation operation. Start the piston pin in the piston and connecting rod (this may require a very light tap with a mallet).
  • Page 174 1997 Aerostar/Ranger Page 4 of 4 5. Check the end gap of all piston rings. It must be within specification. Follow the instructions contained on the piston ring package and install the partial piston ring sets. 6. Make sure connecting rod bearings and the bearing bore in the connecting rod and cap are clean.
  • Page 175 1997 Aerostar/Ranger Page 1 of 3 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Valve Tappet, Hydraulic The internal parts of each hydraulic valve tappet (6500) are matched sets. Do not intermix the parts.
  • Page 176 1997 Aerostar/Ranger Page 2 of 3 Item Part Number Description — Body (Part of 6500) — Plunger Spring (Part of 6500) — Check Ball Retainer (Part of 6500) — Plunger (Part of 6500) — Lock Ring (Part of 6500) —...
  • Page 177 1997 Aerostar/Ranger Page 3 of 3 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B46.HTM~gen~ref.HTM 2011-04-27...

  • Page 178: Cylinder Block Assembly

    1997 Aerostar/Ranger Page 1 of 1 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Block Assembly Disassembly 1. Mount the engine (6007) in a work stand and remove all parts not furnished with the new cylinder...
  • Page 179 1997 Aerostar/Ranger Page 1 of 1 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Block, Bare Before replacing a cylinder blocks (6010), determine if it is serviceable. If so, make the necessary service.

  • Page 180: Valve Clearance

    1997 Aerostar/Ranger Page 1 of 1 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual ADJUSTMENTS Valve Clearance 1. With No. 1 piston on TDC at the end of compression stroke (Position No. 1 in the illustration) check the following valves: Position 1 No.

  • Page 181: Specifications

    1997 Aerostar/Ranger Page 1 of 10 Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual SPECIFICATIONS SPECIFICATIONS Torque Specifications Torque Specifications — Except When Another Value Is Specified for That Particular Part Thread Size — Plug Cast Iron Aluminum Thread Size —...
  • Page 182 1997 Aerostar/Ranger Page 2 of 10 Intake 47.072mm (1.8532 In.) Min. Exhaust 39.730mm (1.5645 In.) Max. Gasket Surface Flatness 0.08mm (0.003 In.) over 152.0mm (6.00 In.) Valve Stem to Guide Clearance Intake 0.026-0.068mm (.001-0.0027 In.) Exhaust 0.038-0.081mm (0.0015-0.0032 In.) Valve Head Diameter Intake 40.0mm (1.57 In.)
  • Page 183 1997 Aerostar/Ranger Page 3 of 10 Collapsed Tappet Gap (Nominal) Intake 2.23-4.77mm (0.088-0.189 In.) Exhaust 2.23-4.77mm (0.088-0.189 In.) Distributor Shaft Bearing Bore Diameter 22.268-22.230mm Tappet Bore Diameter (0.08767-0.8752 In.) Camshaft Bore Inside Diameter No. 1 54.688-54.713mm (2.1531-2.1541 In.) No. 2 54.188-54.213mm...
  • Page 184 1997 Aerostar/Ranger Page 4 of 10 Item Specification Head Gasket 0.08mm (0.003 In.) Surface Flatness in 152.0mm (6.00 In.) Head Gasket Surface 1.0-3.3 Micrometers Finish (RMS) Cylinder Bore Diameter 89.00mm (3.504 In.) Surface Finish (RMS) 0.45-0.96 Out-of-Round Limit 0.025mm (0.001 In.) Out-of- Round Service Limit 0.050mm (0.002 In.)
  • Page 185 1997 Aerostar/Ranger Page 5 of 10 Runout Limit 0.025mm (0.001 In.) Flywheel Ring Gear Lateral Runout (T.I.R.) Automatic Transmission 1.778mm (0.07 In.) Crankshaft End Play 0.10-0.20mm (0.004-0.008 In.) Connecting Rod Bearings Clearance to Crankshaft Desired 0.025-0.035mm (0.001-0.0014 In.) Allowable 0.020-0.066mm (0.00086-0.0027 In.)
  • Page 186 1997 Aerostar/Ranger Page 6 of 10 Service Limit 0.36mm Max. (0.014 In. Max.) Piston Specifications Item Specification Diameter Coded Red 88.962-88.978mm (3.5024-3.5031 In.) Coded Blue 88.988-89.004mm (3.5035-3.5041 In.) Coded Yellow 89.014-89.030mm (3.5045-3.5051 In.) Piston-to-Bore Clearance 0.030-0.056mm (0.0012-0.0022 In.) Service Limit 0.081mm Max.
  • Page 187 1997 Aerostar/Ranger Page 7 of 10 (0.0575-0.0587 In.) Oil Ring Side Seal — Snug Fit Service Limit Side Clearance 0.15mm Max. (0.0006 In. Max.) Ring Gap Compression (Top) 0.25-0.50mm (in Gauge) (0.01-0.02 In.) Compression (Bottom) 0.25-0.50mm (in Gauge) (0.01-0.02 In.) Oil Ring (Steel Rail) 0.25-1.25mm...
  • Page 188 1997 Aerostar/Ranger Page 8 of 10 Service, and install the indicated service piston. (1) Runout of journals II and III to journals I and IV. (2) Runout of adjacent journals to each other. * Engine packages equipped with Tripminder: Return line must be closed when checking pressure.
  • Page 189 1997 Aerostar/Ranger Page 9 of 10 Rocker Arm Fulcrum to Cylinder Head 26-38 19-28 — Intake Manifold — Bolts — Tighten in Two Steps, 15 Nm (11 Lb-Ft) Then to 26-32 — — — Nm (19-24 Lb-Ft) Exhaust Manifold to Cylinder Head — Bolts/Studs...
  • Page 190 1997 Aerostar/Ranger Page 10 of 10 Bolt Front Brace to Engine Brace A/C 41-61 30-45 — Support A/C Comp. Mounting Bolt to Bracket Assembly 41-61 30-45 — (2 Places) Bolt A/C Comp. Mounting 41-61 30-45 — (5 Places) Front A/C Comp. Plate to Lower A/C Mounting Bracket Bolt...

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