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Ford 1997 Aerostar Workshop Manual
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Ford 1997 Aerostar Workshop Manual

Ford 1997 Aerostar Workshop Manual

Gasoline engines
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1997 Aerostar/Ranger
Section 10-01: Fuel Tank, Filters, Lines and
Electric Fuel Pump
DESCRIPTION AND OPERATION
Fuel Injected Engines
WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO, OR OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL
INJURY.
The multiport fuel injection system (MFI) is classified as a multi-point, pulse time, speed density control, fuel
injection system. Fuel is metered into each intake port in a sequential firing order. Fuel injectors pulse to
follow engine firing order in accordance with engine demand through fuel injectors mounted on a tuned
lower intake manifold.
The powertrain control module (PCM) (12A650) accepts inputs from various engine sensors to compute the
required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire engine
operational range. The powertrain control module then outputs a command to the fuel injector nozzle tips
(9E527) to meter the appropriate quantity of fuel.
The powertrain control module also determines and compensates for the age of the vehicle and its
uniqueness. The powertrain control module will automatically sense and compensate for changes in altitude
(i.e., from sea level to mountains) and will also permit push-starting the vehicle should it become necessary
(manual transmission only).
file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1001.HTM~gen~ref.HTM
1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L
tomsn048@gmail.com
Gasoline Engines Workshop Manual
Page 1 of 1
2011-04-29

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Summary of Contents for Ford 1997 Aerostar

  • Page 1 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual DESCRIPTION AND OPERATION Fuel Injected Engines WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO, OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT.
  • Page 2 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual DESCRIPTION AND OPERATION Fuel Tank and Fuel Tank Filler Pipe Fuel tanks (9002) are designed and fabricated of either non-corrosive metal or polyethylene molded plastic.
  • Page 3 DESCRIPTION AND OPERATION Fuel Tank Filler Cap NOTE: Use of an aftermarket fuel tank filler cap (9030) other than an authorized Ford/Motorcraft service part could result in damage to the fuel system or improper system operation if not properly designed/manufactured for pressure vacuum relief. Customer warranty is void for fuel tank and/or fuel system damage resulting from the use of such fuel tank filler caps.
  • Page 4 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual DESCRIPTION AND OPERATION Fuel Filter Fuel is filtered at two locations on Aerostar and Ranger vehicles.
  • Page 5 1997 Aerostar/Ranger Page 1 of 2 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual DESCRIPTION AND OPERATION Fuel Vapor Valve, Aerostar All fuel tank evaporative emission valves (9B593) make use of a small orifice that tends to allow only vapor and not liquid fuel to pass into the line running forward to the evaporative emissions canister (EVAP canister) (9D653).
  • Page 6 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1005.HTM~gen~ref.HTM 2011-04-29...
  • Page 7 1997 Aerostar/Ranger Page 1 of 2 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual DESCRIPTION AND OPERATION Fuel Vapor Valve, Ranger The evaporative emission valve (9B593) makes use of a small orifice that tends to allow only vapor and not liquid fuel to pass into the line running forward to the fuel vapor canister.
  • Page 8 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1006.HTM~gen~ref.HTM 2011-04-29...
  • Page 9 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual DESCRIPTION AND OPERATION Fuel Tank Pressure Transducer The fuel tank pressure (FTP) transducer is used to monitor the fuel tank pressure or vacuum during the OBD II purge monitor test of the Evaporative Emission System.
  • Page 10 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual DESCRIPTION AND OPERATION Fuel Lines MFI engines use Teflon® stainless steel for fuel supply and return lines and carbon steel for vapor line in the engine compartment.
  • Page 11 1997 Aerostar/Ranger Page 1 of 3 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual DESCRIPTION AND OPERATION Fuel Pump, Electric — Ranger The multiport fuel injection (MFI) system uses a fuel tank (9002) and a fuel pump and sender assembly. The fuel tank has an internal pump cavity where the fuel pump and sender assembly rest.
  • Page 12 1997 Aerostar/Ranger Page 2 of 3 Part Item Number Description — Fuel Supply Tube (Part of 9H307) — Electrical Connector (Part of 9H307) — Flange (Part of 9H307) — Fuel Gauge Sender to Electrical Connector-Spade Connection (Part of 9H307) 9350 Fuel Pump —...
  • Page 13 1997 Aerostar/Ranger Page 3 of 3 — Fuel Gauge Sender Assembly (Part of 9H307) — Fuel Return Tube (Part of 9H307) tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1009.HTM~gen~ref.HTM 2011-04-29...
  • Page 14 1997 Aerostar/Ranger Page 1 of 2 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual DESCRIPTION AND OPERATION Fuel Pressure Regulator The fuel pressure regulator (9C968) is attached to the fuel supply manifold assembly downstream of the fuel injectors.
  • Page 15 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1010.HTM~gen~ref.HTM 2011-04-29...

  • Page 16: Inertia Fuel Shutoff Switch

    1997 Aerostar/Ranger Page 1 of 2 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual DESCRIPTION AND OPERATION Inertia Fuel Shutoff Switch WARNING: IF YOU SEE OR SMELL GASOLINE AT ANY TIME OTHER THAN DURING FUELING, DO NOT RESET THE INERTIA FUEL SHUTOFF SWITCH (IFS SWITCH) (9341).
  • Page 17 1997 Aerostar/Ranger Page 2 of 2 Item Part Number Description 9341 Inertia Fuel Shutoff Switch — Reset Button (Part of 9341) 20124 Door RH Side 02018 Cowl Panel RH Side 01610 Dash Panel RH Side tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1012.HTM~gen~ref.HTM 2011-04-29...
  • Page 18 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Fuel Draining Use appropriate adapter to connect Rotunda Fuel Storage Tanker 034-00002 or equivalent suction pump to the fuel hose (at the fuel pump-to-fuel tube connection) and drain the fuel tank (9002).
  • Page 19 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Fuel Filling The fuel filler nozzle openings for the fuel tanks (9002) on vehicles with gasoline engines (6007) have been made smaller to prevent accidental filling with other than unleaded fuel.
  • Page 20 1997 Aerostar/Ranger Page 1 of 6 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Fuel Tanks Steel Midship, Aerostar Removal and Installation 1.
  • Page 21 1997 Aerostar/Ranger Page 2 of 6 Item Part Number Description N802810-S36 U-Nut 383526-S Clamp 9034 Fuel Tank Filler Pipe 9030 Fuel Tank Filler Cap 42127-S2 Screw and Washer 383526-S Clamp 9047 Fuel Tank to Filler Pipe Hose 9002 Fuel Tank...
  • Page 22 1997 Aerostar/Ranger Page 3 of 6 9092 Fuel Tank Support Strap N620480-S36 9A032 Fuel Tank Heat Shield N802253-S36 Bolt 9240 Insulator, Fuel Tank N801107-S36 U-Nut 9A307 Fuel Tank Sending Unit Locking Retainer Ring 9323 Tube Assembly, Fuel Tank to Filter...
  • Page 23 1997 Aerostar/Ranger Page 4 of 6 8. Lower fuel tank. 9. Remove fuel supply hose at sender push connector. To disconnect push connect fittings, refer to Push Connect Fittings in this section. 10. Remove fuel return hose at sender unit push connector. To disconnect push connect fittings, refer to Push Connect Fittings in this section.
  • Page 24 1997 Aerostar/Ranger Page 5 of 6 Item Part Number Description 9002 Fuel Tank 9054 Fuel Tank Support Strap, Front 9092 Fuel Tank Support Strap, Rear N801107-S426 Nut, U-Lock 5030 Crossmember, No. 4 9A147 Skid Plate Assembly (4x4 Only) 9A032 Fuel Tank Heat Shield...
  • Page 25 1997 Aerostar/Ranger Page 6 of 6 9A032 Fuel Tank Heat Shield — Tighten to 34-46 Nm (25-34 Lb-Ft) tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1016.HTM~gen~ref.HTM 2011-04-29...
  • Page 26 1997 Aerostar/Ranger Page 1 of 2 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Fuel Tank Filler Pipe, Aerostar Lower Fill Hose Removal and Installation 1.
  • Page 27 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1017.HTM~gen~ref.HTM 2011-04-29...
  • Page 28 1997 Aerostar/Ranger Page 1 of 2 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Fuel Tank Filler Pipe, Ranger Removal 1. Loosen screw clamp attaching fuel tank to filler pipe hose (9047) to fuel tank (9002).
  • Page 29 1997 Aerostar/Ranger Page 2 of 2 Item Part Number Description 9417 Fuel Pump Mounting Gasket 9C385 Ring, Sender (SuperCab Only) 9C291 Fuel Tube Shield 9A307 Fuel Tank Sending Unit Locking Retainer Ring 9H307 Fuel Pump and Sender Assembly 9002 Fuel Tank...
  • Page 30 1997 Aerostar/Ranger Page 1 of 3 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Fuel Filters NOTE: Ignition switch (11572) must be in OFF position before removing the filter.
  • Page 31 1997 Aerostar/Ranger Page 2 of 3 Remove filter from bracket by loosening filter retaining clamp enough to allow filter to pass through. Installation 1. Install filter in bracket, ensuring proper direction of flow as noted by arrow. Tighten clamp to 1.7-2.8 Nm (15-25 lb-in).
  • Page 32 1997 Aerostar/Ranger Page 3 of 3 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1019.HTM~gen~ref.HTM 2011-04-29...
  • Page 33 1. Clean the fuel pump mounting flange and the fuel tank mounting surface and groove in fuel tank sending unit locking retainer ring. 2. Put a light coating of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B on a new fuel pump mounting gasket to hold it in place during assembly and install it in the fuel ring groove.
  • Page 34 1997 Aerostar/Ranger Page 2 of 7 a. For Ranger and Aerostar, tighten the fuel tank sending unit locking retainer ring to 55-74 Nm (40-55 lb-ft). b. For Ranger SuperCab, tighten fuel tank sending unit locking retainer ring clockwise until stop.
  • Page 35 1997 Aerostar/Ranger Page 3 of 7 — Sender Float (Part of 9H307) — Inlet Filter Sock (Part of 9H307) — Fuel Pump (Part of 9H307) — Fuel Gauge Sender to Electrical Connector-Spade Connection (Part of 9H307) — Flange (Part of 9H307) —...
  • Page 36 1997 Aerostar/Ranger Page 4 of 7 — Fuel Supply Tube (Part of 9H307) — Electrical Connector (Part of 9H307) — Flange (Part of 9H307) — Fuel Gauge Sender to Electrical Connector-Spade Connection (Part of 9H307) — Fuel Pump (Part of 9H307) —...
  • Page 37 1997 Aerostar/Ranger Page 5 of 7 Part Item Number Description — Electrical Connector (Part of 9H307) — Fuel Return Tube (Part of 9H307) — Flange (Part of 9H307) — Fuel Gauge Sender Assembly (Part of 9H307) — Sender Float (Part of 9H307) —...
  • Page 38 1997 Aerostar/Ranger Page 6 of 7 Inertia Fuel Shutoff Switch WARNING: IF YOU SEE OR SMELL GASOLINE AT ANY TIME OTHER THAN DURING FUELING, DO NOT RESET THE INERTIA FUEL SHUTOFF SWITCH. To Reset Switch 1. Turn ignition switch (11572) to OFF.
  • Page 39 1997 Aerostar/Ranger Page 7 of 7 Item Part Number Description 9341 Inertia Fuel Shutoff Switch — Reset Button (Part of 9341) 20124 Door RH Side 02018 Cowl Panel RH Side 01610 Dash Panel RH Side tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1020.HTM~gen~ref.HTM 2011-04-29...
  • Page 40 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Fuel Vapor Valve The evaporative emission valve (9B593) is not repairable. It must be replaced as a complete assembly. To...
  • Page 41 Fuel and Vapor Return Tubes Plastic CAUTION: Ford-approved nylon fuel tubing is made from material which has been tested and proven to be acceptable for use with commercially available fuels. It is also resistant to most environmental conditions. Avoid using alternate tubing materials. Use of non-approved tubing could pose a hazard in service.
  • Page 42 1997 Aerostar/Ranger Page 2 of 10 1. Securely grip component with one hand, and hose with the other hand as close as possible to connection. 2. Sharply twist hose along its axis to "break" the temporary bond between hose and component. (No adhesive is used to make hose connections during vehicle assembly, but natural aging of the connections causes a temporary bond to exist.)
  • Page 43 1997 Aerostar/Ranger Page 3 of 10 Item Part Number Description 9B593 Evaporative Emission Valve 9B033 Tube Assembly — Fuel Tank Vapor Outlet 14A163 Clip N802769-S Clip — Double N802769-S Clip — Double 9002 Fuel Tank 9323 Tube Assembly — Fuel Tank to Filter N802769-S Brake Line Clip —...
  • Page 44 1997 Aerostar/Ranger Page 4 of 10 9H334 Tube Assembly — Front N805528- Clip S190 N805526- Clip S190 9J338 Tube Assembly — Engine Supply and Return (3.0L Only) 9B072 Fuel Filter and Base 9A317 Fuel Tube Clip 9B324 Rear Fuel Tube N802693-S36 Rivet, 4.8 x 11.5...
  • Page 45 1997 Aerostar/Ranger Page 5 of 10 Part Item Number Description N805528- Clip, 1/2 S190 9S286 Front Fuel Supply Return and Vapor Tube 5005 Frame 9B262 Filter N620481- Nut, M8-1.25 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1022.HTM~gen~ref.HTM 2011-04-29...
  • Page 46 1997 Aerostar/Ranger Page 6 of 10 9D653 Evaporative Emissions Canister N803640-S Clip 390617-S Clip N805526- Clip, 3/8 S190 N611192- Screw, M8-1.25 x 12 Hex Washer Tap N620481- Nut, M8-1.25 9J279 Fuel and Vapor Return Tube — For Continuation (Fuel Supply Manifold) See...
  • Page 47 1997 Aerostar/Ranger Page 7 of 10 Part Item Number Description 9J338 Tube Fuel Front N805528- Clip, 1/2 S190 N620481-S2 Nut, M8-1.25 N805526- Clip, 3/8 S190 N611192-S2 Screw, M8-1.25 x 12 Hex Washer Tap tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1022.HTM~gen~ref.HTM 2011-04-29...
  • Page 48 1997 Aerostar/Ranger Page 8 of 10 9S286 Front Fuel Supply Return and Vapor Tube 5005 Frame 9J279 Fuel and Vapor Return Tube N620481-S2 Nut, M8-1.25 N803640-S Clip 9D653 Evaporative Emissions Canister N805528- Clip, 1/2 S190 N805526- Clip, 3/8 S190 —...
  • Page 49 1997 Aerostar/Ranger Page 9 of 10 Part Item Number Description 9B593 Fuel Vapor Valve 9J279 Fuel and Vapor Return Tube 9002 Fuel Tank N803640- Clip — For Continuation See: Fuel Line System, Front Lines, Ranger, 2.3L and 4.0L Engines, or Fuel Line System, tomsn048@gmail.com...
  • Page 50 1997 Aerostar/Ranger Page 10 of 10 Front Lines, Ranger, 3.0L Engines in This Section. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1022.HTM~gen~ref.HTM 2011-04-29...
  • Page 51 1997 Aerostar/Ranger Page 1 of 6 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Push Connect Fittings The fittings used on 7.9mm (5/16-inch) nominal diameter nylon tubing use a hairpin clip. Clips should be replaced whenever a connector is removed.
  • Page 52 1997 Aerostar/Ranger Page 2 of 6 Removal 1. Inspect visible internal portion of fitting for dirt accumulation. If more than a light coating of dust is present, clean the fitting before disassembly. CAUTION: Do not use any tools. Some adhesion between the seals in the fitting and the tubing will occur with time. To separate, twist the fitting on the tube, then push and pull the fitting until it moves freely on the tube.
  • Page 53 1997 Aerostar/Ranger Page 3 of 6 Steel SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Quick Disconnect Tool (5/16- Inch) T90T-9550-B (Part of T90T-9550-S) Quick Disconnect Tool (3/8-Inch) T90T-9550-C (Part of T90T-9550-S) tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1023.HTM~gen~ref.HTM 2011-04-29...
  • Page 54 1997 Aerostar/Ranger Page 4 of 6 Removal 1. Release safety clip from fitting. 2. Fit Quick Disconnect Tool T90T-9550-B (5/16-inch) or T90T-9550-C (3/8-inch) to fitting body so the tool can enter the body and release the retaining fingers. 3. Push the tool into the fitting body to release the retaining fingers from the formed male tube end.
  • Page 55 1997 Aerostar/Ranger Page 5 of 6 3. Pull on the fitting to make sure it is fully engaged. 4. Lock assembly with safety clip. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1023.HTM~gen~ref.HTM 2011-04-29...
  • Page 56 1997 Aerostar/Ranger Page 6 of 6 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1023.HTM~gen~ref.HTM 2011-04-29...
  • Page 57 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Spring Lock Connectors Fuel tubes which connect to MFI engines utilize spring lock push connect fittings in the engine compartment instead of the plastic or stainless steel push connect fittings.
  • Page 58 1997 Aerostar/Ranger Page 1 of 6 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Spring Lock Couplings CAUTION: Discharge fuel system before disconnecting coupling.
  • Page 59 1997 Aerostar/Ranger Page 2 of 6 3. Pull the coupling male and female fittings apart. 4. Remove the tool from the disconnected spring lock coupling. Connecting 1. Check for missing or damaged garter spring. If spring is damaged or missing: remove damaged spring with small hooked wire and install a new spring.
  • Page 60 1997 Aerostar/Ranger Page 3 of 6 2. Clean fittings and install new O-rings. Use only specified O-rings supplied in Kit E35Y-19D690-A. Lubricate with clean refrigerant oil and assemble fitting by pushing with a slight twisting motion. 3. Visually check to be sure garter spring is over flared end of female fitting and pull on fitting to ensure full engagement.
  • Page 61 1997 Aerostar/Ranger Page 4 of 6 Spring Lock Coupling Safety Clip Installation 1. Visually check to be sure garter spring is over flared end of female fitting. 2. Pull on connector opposite the direction of installation to verify that the connector is locked in place. If connector is not locked in place, refer to Connecting Spring Lock Connector procedure in this section.
  • Page 62 1997 Aerostar/Ranger Page 5 of 6 Refer to the following illustration. 4. Attach the tether to the fuel line and snap shut. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1025.HTM~gen~ref.HTM 2011-04-29...
  • Page 63 1997 Aerostar/Ranger Page 6 of 6 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1025.HTM~gen~ref.HTM 2011-04-29...
  • Page 64 1997 Aerostar/Ranger Page 1 of 2 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual REMOVAL AND INSTALLATION Fuel Pressure Regulator SPECIAL SERVICE TOOL(S) REQUIRED Description...
  • Page 65 1997 Aerostar/Ranger Page 2 of 2 1. Lubricate new fuel pressure regulator O-rings with light oil meeting Ford Specification ESE-M2C39-F or equivalent. Never use silicone grease. It will clog the injectors. 2. Make sure O-ring surfaces of fuel pressure regulator and fuel injection manifold are clean.
  • Page 66 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual CLEANING AND INSPECTION Fuel Tanks Fuel tanks (9002) do not require special service procedures and may be steam-cleaned and/or serviced using standard procedures.
  • Page 67 1997 Aerostar/Ranger Page 1 of 1 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual SERVICE PROCEDURES Fuel System Pressure Relief SPECIAL SERVICE TOOL(S) REQUIRED Description...
  • Page 68 1997 Aerostar/Ranger Page 1 of 2 Section 10-01: Fuel Tank, Filters, Lines and 1997 Aerostar, Ranger, Equipped with 2.3L, 3.0L, and 4.0L Electric Fuel Pump Gasoline Engines Workshop Manual SPECIFICATIONS SPECIFICATIONS FUEL TANK CAPACITY Vehicle Location Tank Capacity — Liters (Gallons) Ranger Midship —...
  • Page 69 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1029.HTM~gen~ref.HTM 2011-04-29...

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