General Information; Disassembly - Ford Ranger Maintaince And Repair Manual

GENERAL INFORMATION

A thorough overhaul or rebuild of an engine block would include replacing the pistons, rings, bearings, timing
belt/chain assembly and oil pump. For OHV engines also include a new camshaft and lifters. The block would
then have the cylinders bored and honed oversize (or if using removable cylinder sleeves, new sleeves
installed) and the crankshaft would be cut undersize to provide new wearing surfaces and perfect clearances.
However, your particular engine may not have everything worn out. What if only the piston rings have worn
out and the clearances on everything else are still within factory specifications? Well, you could just replace
the rings and put it back together, but this would be a very rare example. Chances are, if one component in
your engine is worn, other components are sure to follow, and soon. At the very least, you should always
replace the rings, bearings and oil pump. This is what is commonly called a "freshen up".
Cylinder Ridge Removal
Because the top piston ring does not travel to the very top of the cylinder, a ridge is built up between the end
of the travel and the top of the cylinder bore.
Pushing the piston and connecting rod assembly past the ridge can be difficult, and damage to the piston ring
lands could occur. If the ridge is not removed before installing a new piston or not removed at all, piston ring
breakage and piston damage may occur.
It is always recommended that you remove any cylinder ridges before removing the piston and
connecting rod assemblies. If you know that new pistons are going to be installed and the engine block
will be bored oversize, you may be able to forego this step. However, some ridges may actually prevent
the assemblies from being removed, necessitating its removal.
There are several different types of ridge reamers on the market, none of which are inexpensive. Unless a
great deal of engine rebuilding is anticipated, borrow or rent a reamer.
1. Turn the crankshaft until the piston is at the bottom of its travel.
2. Cover the head of the piston with a rag.
3. Follow the tool manufacturers instructions and cut away the ridge, exercising extreme care to avoid
cutting too deeply.
4. Remove the ridge reamer, the rag and as many of the cuttings as possible. Continue until all of the
cylinder ridges have been removed.

DISASSEMBLY

The engine disassembly instructions following assume that you have the engine mounted on an engine stand.
If not, it is easiest to disassemble the engine on a bench or the floor with it resting on the bell housing or
transmission mounting surface. You must be able to access the connecting rod fasteners and turn the
crankshaft during disassembly. Also, all engine covers (timing, front, side, oil pan, whatever) should have
already been removed. Engines which are seized or locked up may not be able to be completely disassembled,
and a core (salvage yard) engine should be purchased.
Except the 2.3L, 2.5L and 4.0L SOHC (VIN E) Engines
If not done during the cylinder head removal, remove the pushrods and lifters, keeping them in order for
assembly. Remove the timing gears and/or timing chain assembly, then remove the oil pump drive assembly
and withdraw the camshaft from the engine block. Remove the oil pick−up and pump assembly. If equipped,
remove any balance or auxiliary shafts. If necessary, remove the cylinder ridge from the top of the bore. See
the cylinder ridge removal procedure earlier in this section.
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GENERAL INFORMATION