Ford Aerostar 1997 Workshop Manual
  1. Manuals
  2. Brands
  3. Ford Manuals
  4. Automobile
  5. 1997 Aerostar
  6. Workshop manual

Ford Aerostar 1997 Workshop Manual

Hide thumbs Also See for Aerostar 1997:
Table of Contents

Advertisement

Quick Links

See also: Manual
1997 Aerostar/Ranger
Section 03-01C: Engine, 4.0L V-6
IN-VEHICLE SERVICE
Valve Cover and Gasket, Ranger
Removal
1. Disconnect negative battery cable.
2. Drain cooling system.
3. Disconnect the wiring connectors and locator from the intake air temperature (IAT) and mass air flow
(MAF) sensors. Remove the breather hose from the RH valve cover and remove the air cleaner tube.
4. Remove the accelerator control splash shield. Disconnect the accelerator and speed control cables
from the throttle body. Remove the accelerator control bracket with cables attached and position
aside.
5. Disconnect the idle air control (IAC), differential pressure feedback EGR (DPFE) transducer, throttle
position sensor (TPS), EGR vacuum regulator (EVR) solenoid electrical connectors and vacuum
hoses.
6. Disconnect the brake booster vacuum hose, vacuum connectors from the upper intake manifold and
the positive crankcase ventilation (PCV) valve from the LH valve cover.
7. Disconnect the 42-pin connector and the powertrain control module (PCM) harness locator from the
bracket mounted to the under side of intake manifold.
8. Disconnect the ignition coil electrical connector, locator, and the noise suppressor electrical
connector. Disconnect the ignition wires from the spark plugs.
9. Disconnect the vent line from under the throttle body.
10. Disconnect the spark plug wires from the seven retaining clips. Remove the two ignition coil bolts
from the upper intake manifold and one bolt from RH exhaust manifold. Remove the coil pack with
ignition wires as an assembly.
11. Disconnect the vacuum hose from the EGR valve. Disconnect the EGR tube flange nut from the EGR
valve. Remove the EGR valve and gasket. Discard the gasket.
12. Remove the oil level indicator tube bracket nut and remove the oil level indicator tube and indicator.
13. Remove the stud retaining the EGR outlet tube bracket to the exhaust manifold. Remove the upper
intake manifold and gasket. Discard the gasket. Tape the lower intake manifold openings.
14. Disconnect the wiring connector from the oil pressure-sending unit and locators. Position harness
aside.
15. Disconnect the upper radiator hose from the thermostat housing. Disconnect the heater hose from the
intake manifold. Position the hoses aside.
16. Remove the LH valve cover (with gasket). Discard the gasket.
file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C12.HTM~gen~ref.HTM
1997 Aerostar, Ranger Workshop Manual
tomsn048@gmail.com
Page 1 of 3
2011-04-27

Advertisement

Table of Contents
loading

Related Manuals for Ford Aerostar 1997

Summary of Contents for Ford Aerostar 1997

  • Page 1 1997 Aerostar/Ranger Page 1 of 3 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Valve Cover and Gasket, Ranger Removal 1. Disconnect negative battery cable. 2. Drain cooling system. 3. Disconnect the wiring connectors and locator from the intake air temperature (IAT) and mass air flow (MAF) sensors.
  • Page 2 17. Remove the RH valve cover (with gasket). Discard the gasket. 18. Clean both valve covers. Installation 1. NOTE: Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specifications WSE-M4G323-A6 to the intake manifold-to-cylinder head parting seams. Install the LH and RH valve cover gaskets.
  • Page 3 1997 Aerostar/Ranger Page 3 of 3 the electrical connectors to the IAT and MAF sensors. 19. Connect the negative battery cable. 20. Fill the cooling system. 21. Start the engine and check for leaks. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C12.HTM~gen~ref.HTM 2011-04-27...
  • Page 4 3. NOTE: Since silicone rubber will set up within 15 minutes, if you are installing both covers, apply only to one side at a time. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A, to left intake manifold-to-cylinder head parting seam.
  • Page 5 6. Snap spark plug wires into clips on valve cover. 7. Install upper intake manifold as described in this section. 8. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to right intake manifold-to-cylinder head parting seam.
  • Page 6 1997 Aerostar/Ranger Page 3 of 3 13. Install air cleaner outlet tube and shield. 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. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

  • Page 7: Rocker Arm

    Installation 1. Lubricate all rocker arm assemblies with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. 2. Install the rocker arm shaft assemblies and draw the shaft support bolts down evenly, two turns at a time, until the rocker shaft assemblies are fully down. Tighten shaft support bolts to 32 Nm (24 lb-ft).
  • Page 8 1997 Aerostar/Ranger Page 2 of 3 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C14.HTM~gen~ref.HTM 2011-04-27...
  • Page 9 1997 Aerostar/Ranger Page 3 of 3 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C14.HTM~gen~ref.HTM 2011-04-27...
  • Page 10 Installation 1. Lubricate a new valve stem seal with engine oil XO-5W30-QSP or equivalent meeting Ford specification WSE-M2903-A1 or SAE 5W-30 Service SG and install on valve stem using Valve Stem Seal Replacer T90T-6571-A.
  • Page 11 T86L-6565-A, compress the valve spring and install the valve spring retainer keys. 3. Apply SAE 50 Service SG oil or equivalent meeting Ford specification ESE-M2C39-F to both ends of the push rods, the valve tips and both ends of the rocker arms (6564). Install the valve tappets, making sure the lower end of the rod is positioned in the tappet push rod cup.
  • Page 12 1997 Aerostar/Ranger Page 3 of 3 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C15.HTM~gen~ref.HTM 2011-04-27...
  • Page 13 Lubricate each tappet and bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A or engine oil SAE 50 Service SG ESE-M2C39-F. 2. Install each valve tappet in the bore from which it was removed with the alignment tab in the locating groove of the bore.
  • Page 14 1997 Aerostar/Ranger Page 2 of 2 3. Install cylinder head assembly as outlined in this section. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C16.HTM~gen~ref.HTM 2011-04-27...

  • Page 15: Intake Manifold, Upper

    1997 Aerostar/Ranger Page 1 of 4 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Intake Manifold, Upper Removal NOTE: The procedure for removal and installation of the upper intake manifold (9424) has been changed. After removing the ignition coil and bracket assembly, the EGR valve (EGR valve) (9D475), the intake manifold to EGR valve tube, and the EGR transducer vacuum lines must be removed.
  • Page 16 1997 Aerostar/Ranger Page 2 of 4 14. Remove the EGR tube retaining bolts and release EGR tube from upper intake. 15. Disconnect the mass air flow (MAF) sensor electrical connector. 16. Disconnect the bulkhead wiring harness, remove pushpin locators and position wiring harness aside. 17.
  • Page 17 1997 Aerostar/Ranger Page 3 of 4 18. Install air cleaner outlet and tighten the two clamps. 19. Connect the IAT electrical connector and crankcase ventilation hose to the air cleaner outlet tube. 20. Connect the ground cable at the battery. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C17.HTM~gen~ref.HTM 2011-04-27...
  • Page 18 1997 Aerostar/Ranger Page 4 of 4 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C17.HTM~gen~ref.HTM 2011-04-27...

  • Page 19: Intake Manifold, Lower

    1. NOTE: Once applied, the silicone sealer will set up in approximately 15 minutes. The intake manifold must be installed immediately after the sealer is applied. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to the block and cylinder head mating surfaces at the four corners shown. Install the intake manifold gasket (9439) and again apply sealer to the four corner locations.
  • Page 20 1997 Aerostar/Ranger Page 2 of 5 Part Item Number Description 6049 Cylinder Head 9439 Intake Manifold Gasket 9424 Intake Manifold — Examine Closely for Erosion, Corrosion, or Pitting on This Surface — Silicone Sealer — 4 Places tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C18.HTM~gen~ref.HTM 2011-04-27...
  • Page 21 1997 Aerostar/Ranger Page 3 of 5 Item Part Number Description W702301S309M Bolt with Captive Washer (8) 12A648 Engine Coolant Temperature Sensor 10884 Water Temperature Indicator Sender Unit 8501 Water Pump — Stud (2) (Part of 9424) 9439 Intake Manifold Gasket 9424 Intake Manifold —...
  • Page 22 15 Nm (11 lb-ft) c. 22 Nm (16 lb-ft) 3. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to the four locations at the joint where the intake manifold and the cylinder heads (6049) meet (as shown).
  • Page 23 1997 Aerostar/Ranger Page 5 of 5 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C18.HTM~gen~ref.HTM 2011-04-27...

  • Page 24: Cylinder Heads

    1997 Aerostar/Ranger Page 1 of 7 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Cylinder Head(s) Removal WARNING: RESIDUAL PRESSURE REMAINS IN FUEL SYSTEM AFTER ENGINE IS SHUT OFF. THIS COULD RESULT IN INJURY OR FIRE WHEN FUEL LINES ARE DISCONNECTED. DISCONNECT INERTIA FUEL SHUTOFF SWITCH AND CRANK ENGINE A MINIMUM OF 15 SECONDS TO DEPRESSURIZE SYSTEM.
  • Page 25 1997 Aerostar/Ranger Page 2 of 7 Installation CAUTION: The 4.0L engine should always be assembled using new cylinder head bolts. NOTE: If cylinder heads were completely disassembled, refer to Cylinder Head Disassembly and Assembly in this section. NOTE: Head gaskets are not interchangeable, they are either right- or left-hand side. NOTE: The cylinder heads and intake manifold installation procedure has changed.
  • Page 26 4. NOTE: Once applied, the silicone sealer will set up in approximately 15 minutes. The intake manifold must be installed immediately after the sealer is applied. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to the block and cylinder head mating surfaces at the four corners shown. Install the intake manifold gasket (9439) and again apply sealer to the four corner locations.
  • Page 27 1997 Aerostar/Ranger Page 4 of 7 Part Item Number Description 6049 Cylinder Head 9439 Intake Manifold Gasket 9424 Intake Manifold — Examine Closely for Erosion, Corrosion, or Pitting on This Surface — Silicone Sealer — 4 Places tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C19.HTM~gen~ref.HTM 2011-04-27...
  • Page 28 1997 Aerostar/Ranger Page 5 of 7 Item Part Number Description W702301S309M Bolt with Captive Washer (8) 12A648 Engine Coolant Temperature Sensor 10884 Water Temperature Indicator Sender Unit 8501 Water Pump — Stud (2) (Part of 9424) 9439 Intake Manifold Gasket 9424 Intake Manifold —...
  • Page 29 6. Install valve tappets. Install rocker arms (6564) as outlined in this section. 7. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to the four locations at the joint where the intake manifold and the cylinder heads meet (as shown).
  • Page 30 1997 Aerostar/Ranger Page 7 of 7 19. Fill and bleed the cooling system as detailed in Section 03-03 20. 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 31 1997 Aerostar/Ranger Page 1 of 3 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Crankshaft Pulley/Damper/Front Oil Seal SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Crankshaft Damper Remover T74P-6316-A Front Cover Aligner T74P-6019-A Removal 1. Lift drive belt tensioner (6B209) by rotating it clockwise. Remove drive belt (8620). 2.
  • Page 32 1997 Aerostar/Ranger Page 2 of 3 Item Part Number Description 6312 Crankshaft Pulley E800611 Crankshaft Pulley Bolt E602164 Screw 6C315 Crankshaft Position Sensor — Lubricate with Engine Oil Installation 1. Inspect engine front cover and shaft seal surface of the crankshaft damper for damage, nicks, burrs or other roughness which may cause the new seal to fail.
  • Page 33 1997 Aerostar/Ranger Page 3 of 3 Lubricate seal lip with clean engine oil XO-5W30-QSP or equivalent meeting Ford specification ESE- M2C153-E or SAE 5W-30 Service SG engine oil and install crankshaft front seal using Front Cover Aligner T74P-6019-A and Crankshaft Front Seal Installer T90T-6701-A.
  • Page 34 1997 Aerostar/Ranger Page 1 of 2 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Front Cover Oil Seal SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Front Cover Aligner T74P-6019-A Front Crank Seal Replacer T90T-6701-A Removal 1. Support the front cover to prevent damage while driving out seal. 2.
  • Page 35 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C21.HTM~gen~ref.HTM 2011-04-27...

  • Page 36: Water Pump

    1997 Aerostar/Ranger Page 1 of 5 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Water Pump Removal SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fan Clutch Holding Tool T84T-6312-C Fan Clutch Nut Wrench T84T-6312-D NOTE: The drive belt routing, drive belt tensioner (6B209), and idler pulley have changed. The following illustration shows current accessory drive configuration.
  • Page 37 1997 Aerostar/Ranger Page 2 of 5 Item Part Number Description 8620 Drive Belt 10300 Generator 8678 Belt Idler Pulley 19703 A/C Compressor 3A733 Power Steering Pump Pulley 8501 Water Pump 6312 Crankshaft Pulley 6B209 Drive Belt Tensioner N806020- A/C Compressor Bolts (4 Req'd) S309 2882 A/C Compressor Mounting Bracket...
  • Page 38 1997 Aerostar/Ranger Page 3 of 5 3A674 Power Steering Pump N606572-S2 A/C Compressor Mounting Bracket Bolts (3 Req'd) N800199- Power Steering Pump Bolts (3 Req'd) S309 N620481-S2 A/C Compressor Mounting Bracket Brace Nuts (2 Req'd) 3C718 A/C Compressor Mounting Bracket Brace N606068-S2 Generator Bolts (3 Req'd) 10153...
  • Page 39 1997 Aerostar/Ranger Page 4 of 5 3. Lift drive belt tensioner by rotating it counterclockwise and remove drive belt (8620). 4. Without disconnecting lines, remove A/C compressor mounting bracket (2882) and brace with assembled A/C compressor (19703) and power steering pump (3A674) and set to one side. 5.
  • Page 40 1997 Aerostar/Ranger Page 5 of 5 3. Install water pump pulley. Tighten bolts to 22-28 Nm (16-20 lb-ft). 4. Install generator mounting bracket with assembled generator. Tighten bracket-to-cylinder head bolts to 40-55 Nm (30-40 lb-ft). 5. Install drive belt tensioner. Tighten bolts to 40-55 Nm (30-40 lb-ft). 6.
  • Page 41 1997 Aerostar/Ranger Page 1 of 5 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Engine Front Cover Removal SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fan Clutch Holding Tool T84T-6312-C Fan Clutch Nut Wrench T84T-6312-D Crankshaft Damper Remover T74P-6316-A Crankshaft Front Seal Replacer T90T-6701-A 1.
  • Page 42 8. Install crankshaft position sensor. 9. Install oil pan as outlined in this section. 10. Lubricate seal lip with clean engine oil X0-5W30-QSP or equivalent meeting Ford specification ESE- M2C153-E or SAE 5W-30 Service SG engine oil and install crankshaft front seal using Crankshaft Front Seal Installer T90T-6701-A.
  • Page 43 1997 Aerostar/Ranger Page 3 of 5 16. On Aerostar: a. Install transmission as outlined in Group 07. b. Install lower radiator hose. c. Install water pump pulley. Tighten bolts to 22-28 Nm (17-21 lb-ft). d. Install generator mounting bracket with assembled generator. Tighten bracket-to-cylinder head bolts to 40-50 Nm (30-37 lb-ft).
  • Page 44 1997 Aerostar/Ranger Page 4 of 5 FRONT COVER BOLTS Fastener Location Size Quan. Torque Nm (Lb- Ft) Bolt M8x47 17-21 (13-15) Bolt M8x25 17-21 (13-15) Stud 17-21 (13-15) 47-19 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C23.HTM~gen~ref.HTM 2011-04-27...
  • Page 45 1997 Aerostar/Ranger Page 5 of 5 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C23.HTM~gen~ref.HTM 2011-04-27...
  • Page 46 1997 Aerostar/Ranger Page 1 of 4 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Timing Chain, Sprockets, Tensioners and Guides Removal NOTE: It is necessary to replace oil pan gasket (6710) when removing and installing engine front cover (6019).
  • Page 47 1997 Aerostar/Ranger Page 2 of 4 Item Part Number Description E804389- Torx® Screw S200 6256 Camshaft Sprocket 6250 Camshaft E804358- Torx® Bolt 6K297 Timing Chain Guide 6268 Timing Chain/Belt 6K254 Timing Chain/Belt Tensioner E600112-S Bolt 6269 Camshaft Thrust Plate — Tighten to 60-68 Nm (40-50 Lb-Ft) —...
  • Page 48 1997 Aerostar/Ranger Page 3 of 4 (7-8 Lb-Ft) Installation 1. Install the timing chain guide to the cylinder blocks (6010) with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 lb-ft). 2.
  • Page 49 1997 Aerostar/Ranger Page 4 of 4 6256 Camshaft Sprocket — Camshaft Timing Mark (Part of 6256) 6K297 Timing Chain Guide — Crankshaft Timing Mark (Part of 6306) 6306 Crankshaft Sprocket 6K254 Timing Chain/Belt Tensioner 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 lb-ft). 6.
  • Page 50 1997 Aerostar/Ranger Page 1 of 12 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Camshaft SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Sensor Adjusting Wrench T94T-12270- A NOTE: 4.0L OHV engines are equipped with a camshaft position sensor (CMP sensor) (12A112) mounted on the camshaft synchronizer (12A362).
  • Page 51 1997 Aerostar/Ranger Page 2 of 12 Item Part Number Description 6256 Camshaft Sprocket — Camshaft Timing Mark (Part of 6256) 6K297 Timing Chain Guide — Crankshaft Timing Mark (Part of 6306) 6306 Crankshaft Sprocket 6K254 Timing Chain/Belt Tensioner 11. Remove the camshaft sprocket attaching bolt and remove the camshaft sprocket (6256) from the camshaft.
  • Page 52 1. Oil the camshaft journals and cam lobes with SAE 50 Service SG engine oil or equivalent meeting Ford specification ESE-M2C39-F. Insert the camshaft key. 2. Install the camshaft in the cylinder blocks, being careful to avoid damaging the bearing surfaces.
  • Page 53 6. Position the valve tappets in their original locations as outlined. Apply SAE 50 Service SG or equivalent oil meeting Ford specification ESE-M2C39-F to both ends of the push rods. Install the push rods in the same locations as removed.
  • Page 54 1997 Aerostar/Ranger Page 5 of 12 9. Install the valve covers as outlined. 10. Install the engine front cover as an assembly. Refer to Engine Front Cover , Installation, in this section. 11. Install the oil pump drive, hold-down clamp and screw. 12.
  • Page 55 1997 Aerostar/Ranger Page 6 of 12 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. Connect the battery ground cable (14301) to the battery. 20.
  • Page 56 1997 Aerostar/Ranger Page 7 of 12 Item Part Number Description 12K073 CID Sensor E853103-S O-Ring 6846 Oil Pump Drive Assembly 6007 Engine 12270 Hold-Down Clamp E602550 Screw tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C25.HTM~gen~ref.HTM 2011-04-27...
  • Page 57 1997 Aerostar/Ranger Page 8 of 12 — Tighten to 17-21 Nm (13-15 Lb-Ft) — Maximum Level for Pre-Oiling Drive Gear — Minimum Level for Pre-Oiling Drive Gear 4. NOTE: Normal CID sensor rotation is clockwise viewed from top of CID sensor. Align the CID sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window.
  • Page 58 1997 Aerostar/Ranger Page 9 of 12 7. Rotate the CID sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CID Testing Wiring Harness T94T-50-B to the CID Sensor. 9.
  • Page 59 1997 Aerostar/Ranger Page 10 of 12 a. Red harness wire to battery positive terminal. b. Black harness wire to battery negative terminal. c. Voltmeter positive lead to harnesses white lead. d. Voltmeter negative lead to battery negative terminal. Item Part Number Description T94T-50-B CID Testing Wiring Harness...
  • Page 60 1997 Aerostar/Ranger Page 11 of 12 007-00407 Rotunda Digital Volt-Ohmmeter or Equivalent — Black Lead (Part of 007-00407) — Negative Terminal (Part of 10655) — Black Lead (Part of T94T-50-B) — Connector (Part of T94T-50-B) (Attaches to CID Sensor) 10. Rotate engine two revolutions to take up slack in timing chain and return No. 1 cylinder to its compression stroke.
  • Page 61 1997 Aerostar/Ranger Page 12 of 12 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C25.HTM~gen~ref.HTM 2011-04-27...

  • Page 62: Exhaust Manifold, Rh

    1997 Aerostar/Ranger Page 1 of 2 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Exhaust Manifold, RH Removal 1. Remove heater hose support bracket. 2. Disconnect heater water hoses (18472). 3. Remove manifold-to-exhaust inlet pipe attaching nuts. 4.
  • Page 63 1997 Aerostar/Ranger Page 2 of 2 1. NOTE: Lightly oil all bolt and stud threads before installation. Clean mating surfaces on the exhaust manifold, cylinder head (6049) and exhaust inlet pipe (5246). 2. Position exhaust manifold on the cylinder head and install manifold attaching bolts. Tighten to 25 Nm (18 lb-ft).

  • Page 64: Exhaust Manifold, Lh

    1997 Aerostar/Ranger Page 1 of 4 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Exhaust Manifold, LH LH Exhaust Manifold — Ranger Item Part Number Description 9430 Exhaust Manifold (LH) N806170-S100 Exhaust Manifold Bolts (2 Req'd) N806171-S100 Exhaust Manifold Bolts (4 Req'd) —...
  • Page 65 1997 Aerostar/Ranger Page 2 of 4 LH Exhaust Manifold — Aerostar Removal 1. Remove oil level indicator tube support bracket. 2. Disconnect the EGR transducer vacuum hoses. 3. Loosen and remove the EGR valve to exhaust manifold tube. 4. Remove EGR valve bolts and EGR valve. 5.
  • Page 66 1997 Aerostar/Ranger Page 3 of 4 6. Remove power steering pressure hose (3A719) and power steering return hose (3A713) if necessary. 7. Remove exhaust pipe to manifold nuts. 8. Remove exhaust manifold bolts and exhaust manifold (9430). Installation 1. NOTE: Lightly oil all bolt and stud threads before installation. Clean mating surfaces on the exhaust manifold, cylinder head (6049) and exhaust pipe.
  • Page 67 1997 Aerostar/Ranger Page 4 of 4 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C27.HTM~gen~ref.HTM 2011-04-27...
  • Page 68 Carefully lift the rear outside corners of the oil pan gasket and use a suitable sharp instrument to cut off the soft rubber wedge seal tabs. 13. Thoroughly clean all sealing surfaces with Ford Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A.
  • Page 69 4. After all parts have been thoroughly cleaned and washed, it is necessary and extremely important that they be wiped down with Extra Strength Spot and Stain Remover B7A-19521-AA meeting Ford specification ESR-M5B197-A or denatured alcohol. 5. Thoroughly clean the transmission bell-housing area and the rear of the cylinder blocks. Oil removal should be verified with an ultraviolet lamp ("black light").
  • Page 70 1997 Aerostar/Ranger Page 3 of 6 Item Part Number Description E804579-S72 Stud 6C629 Oil Pan Spacer 6734 Oil Pan Drain Plug Gasket 6730 Oil Pan Drain Plug E804587-S72 Torx® Bolt E802185-S72 Bolt tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C28.HTM~gen~ref.HTM 2011-04-27...
  • Page 71 8. Use a suitable sharp instrument to cleanly cut the rubber wedge seal tabs off of new oil pan gasket (6710). 9. Apply a bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 on each of the gasket tabs remaining between the rear main cap and cylinder blocks, on the sealing rail at the front cover to block joint, and on the corners of the radius of the front cover.
  • Page 72 1997 Aerostar/Ranger Page 5 of 6 17. On E-4WD vehicles, perform the following steps: a. Raise front carrier assembly into place. b. Install front carrier assembly to front drive axle crossmember bolts and tighten to 95-108 Nm (70-80 lb-ft). c. Install rear pivot cross member and tighten bolts. d.
  • Page 73 1997 Aerostar/Ranger Page 6 of 6 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C28.HTM~gen~ref.HTM 2011-04-27...

  • Page 74: Oil Pump

    1997 Aerostar/Ranger Page 1 of 3 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Oil Pump NOTE: The oil pump (6600) is only serviced as an assembly. Refer to Section 03-00 for disassembly and cleaning instructions. Removal 1.
  • Page 75 1997 Aerostar/Ranger Page 2 of 3 Item Part Number Description 6622 Oil Pump Screen Cover and Tube 6600 Oil Pump E804387 Screw E804553 Screw 6A618 Oil Pump Intermediate Shaft 6629 Oil Pump Intermediate Shaft Retaining Ring 6626 Oil Pump Inlet Tube Gasket —...
  • Page 76 1. Prime the oil pump by filling either the inlet or outlet port with engine oil XO-5W30-QSP or equivalent meeting Ford specification WSE-M2903-A1 or SAE 5W-30 Service SG engine oil. Rotate the pump shaft to distribute the oil within the pump body.

  • Page 77: Crankshaft Main Bearings

    1997 Aerostar/Ranger Page 1 of 4 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Crankshaft Main Bearings The main and connecting rod bearing inserts are selective fit. Do not file or lap bearing caps or use shims to obtain the proper bearing clearance.
  • Page 78 Remove the bearing tool. 4. For bearings number one, two, and three, coat the bearing insert and journal with SAE 50 Service SG meeting Ford specification ESE-M2C39-F and install the bearing cap. Tighten the cap to 90-104 Nm (66-77 lb-ft).
  • Page 79 1997 Aerostar/Ranger Page 3 of 4 Cylinder Block Sealer Application 6. For rear main bearing: tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C30.HTM~gen~ref.HTM 2011-04-27...
  • Page 80 1997 Aerostar/Ranger Page 4 of 4 a. Clean all oil off rear main bearing cap and block mating surface using Ford Extra Strength Spot and Stain Remover B7A-19521-AA meeting Ford specification ESR-M5B197-A. b. Place a bead of Ford Gasket Eliminator E1FZ-19562-A meeting Ford specification WSK- M2G348-A4 or Loctite 515®...

  • Page 81: Pistons And Connecting Rods

    1997 Aerostar/Ranger Page 1 of 8 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual 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.
  • Page 82 1997 Aerostar/Ranger Page 2 of 8 13. After honing, thoroughly clean cylinder bore using a detergent and water solution. Part Item Number Description D81L-6002- Piston Ring Compressor 6212 Connecting Rod Nut 6211 Connecting Rod Bearing — Connecting Rod Bearing Cap (Part of 6200_ —...
  • Page 83 1997 Aerostar/Ranger Page 3 of 8 engine (6007) and the oil squirt holes are oriented toward the RH side of the engine (toward the RH cylinders). NOTE: Connecting rod and cap are not identified from the factory as to cylinder position. Lightly oil all attaching bolt and stud threads before installation except those specifying special sealant.
  • Page 84 Page 4 of 8 1. Lubricate cylinder wall and piston with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A or SAE 50 Service SG or equivalent oil meeting Ford specification ESE-M2C39-F. 2. Remove connecting rod cap and install spark plug boots on the connecting rod studs.
  • Page 85 1997 Aerostar/Ranger Page 5 of 8 8. If necessary, check connecting rod side clearance as outlined. Refer to Section 03-00 9. Check the piston installed height if any of the following repair procedures have been performed: New pistons were installed. New connecting rods were installed.
  • Page 86 1997 Aerostar/Ranger Page 6 of 8 10. NOTE: Each piston to be positioned at TDC. Dimension "Z" is the average of two readings measured from top of cylinder block to piston dome face. NOTE: Both measurements must be taken parallel to crankshaft and a straight line through the measuring points must pass through the true center of the cylinder.
  • Page 87 1997 Aerostar/Ranger Page 7 of 8 d. Take a reading at the front "A" and rear "B" of the piston, in line with the piston pin (6135). e. Compare readings with specifications. f. If the difference between the two readings ("A" and "B") is excessive, the piston or connecting rod is damaged or out of specification.
  • Page 88 1997 Aerostar/Ranger Page 8 of 8 20. Start engine and check for oil, exhaust and coolant leaks. 21. Check and, if necessary, adjust transmission throttle linkage and speed control. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C31.HTM~gen~ref.HTM 2011-04-27...

  • Page 89: Connecting Rod Bearings

    6. Select fit the bearing following procedures in Section 03-00 7. Clean and apply a light coat of engine oil XO-5W30-QSP meeting Ford specification ESE-M2C153-E or equivalent SAE 5W-30 Service SG to the journal and bearings. Install the connecting rod cap.
  • Page 90 1997 Aerostar/Ranger Page 2 of 2 11. Fill the crankcase to the correct level with the specified oil. Start the engine and check for leaks. tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C32.HTM~gen~ref.HTM 2011-04-27...
  • Page 91 1997 Aerostar/Ranger Page 1 of 3 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Flywheel Removal 1. Remove transmission as outlined in Group 07. 2. If equipped with manual transmission, remove clutch assembly as outlined in Section 08-01 3.
  • Page 92 1997 Aerostar/Ranger Page 2 of 3 Item Part Number Description N606062-S2 Bolt, M10 x 50mm N802662-S2 Bolt, M10 x 40mm 7003 Transmission (Automatic) 6379 Flywheel-To-Crankshaft Bolt 6375 Flexplate (Automatic Transmission) 6434 Flywheel Crankshaft Spacer 7007 Engine Rear Plate 6007 Engine N606062-S2 Bolt, M10 x 50mm N802662-S2...
  • Page 93 1997 Aerostar/Ranger Page 3 of 3 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C33.HTM~gen~ref.HTM 2011-04-27...

  • Page 94: Crankshaft Rear Oil Seal

    1997 Aerostar/Ranger Page 1 of 6 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Crankshaft Rear Oil Seal SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Rear Crankshaft Seal Replacer T95T-6701-A Rear Crankshaft Seal Replacer T97T-6701-A NOTE: Use dye and black light as outlined in Section 03-00 to determine if oil leak is from oil pan gasket (6710) or crankshaft rear oil seal.
  • Page 95 1997 Aerostar/Ranger Page 2 of 6 Installation Crankshaft rear oil seals used for service applications can come either with or without a metallic crankshaft sleeve. Special Service Tool T95T-6701-A and T97T-6701-A Rear Crankshaft Seal Replacer, is used for both applications. The rear crankshaft seal adapter and two mounting screws attach to the crankshaft.
  • Page 96 1997 Aerostar/Ranger Page 3 of 6 Item Part Number Description — Bolt (Part of T95T-6701-A) T95T-6701-A2 Rear Crankshaft Seal Replacer T95T-6701-A1 Rear Crankshaft Seal Protector T95T-6701-A4 Bolts T95T-6701-A3 Rear Crankshaft Adapter 6701 Crankshaft Rear Oil Seal Seal Installation With Metal Sleeve 1.
  • Page 97 1997 Aerostar/Ranger Page 4 of 6 3. Apply a very light film of clean engine oil on the inner diameter of the sleeve and outer diameter of seal. 4. Slide the seal/sleeve over the rear crankshaft seal adapter with flange to the rear of the engine. 5.
  • Page 98 1997 Aerostar/Ranger Page 5 of 6 Part Item Number Description 6701 Crankshaft Rear Oil Seal 6303 Crankshaft — 10.5 + 0.2-0.3mm (0.413 + 0.008-0.012 Inch) — Installation Dimension from Rear Face of Cylinder Block to Oil Seal — After Installation This Surface Must Be Square with Centerline of Crankshaft Within 0.38mm (0.015 Inch) —...
  • Page 99 1997 Aerostar/Ranger Page 6 of 6 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C34.HTM~gen~ref.HTM 2011-04-27...
  • Page 100 1997 Aerostar/Ranger Page 1 of 3 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Camshaft Rear Bearing Cover SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Slide Impact Hammer T59L-100-B Slide Impact Hammer T50T-100-A Removal 1. Remove transmission. Refer to the applicable section in Group 07. 2.
  • Page 101 Oversize (OS) plugs are identified by the OS stamped in the flat located on the cup side of the plug. 1. Apply a light coating of Perfect-Seal Sealing Compound B5A-19554-A meeting Ford specifications ESR-M18P2-A and ESE-M4G115-A or equivalent to the sealing edge of the camshaft rear bearing cover before installation.
  • Page 102 1997 Aerostar/Ranger Page 3 of 3 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C35.HTM~gen~ref.HTM 2011-04-27...

  • Page 103: Oil Filter

    1997 Aerostar/Ranger Page 1 of 3 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Oil Filter Removal 1. NOTE: It may be necessary to pull the battery cables forward and out of the way in order to access the oil filter.
  • Page 104 1997 Aerostar/Ranger Page 2 of 3 Item Part Number Description 6894 Oil Filter Adapter Mounting Bolt 6L621 O-Ring tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C36.HTM~gen~ref.HTM 2011-04-27...
  • Page 105 1997 Aerostar/Ranger Page 3 of 3 6881 Oil Filter Adapter 6890 Oil Filter Mounting Insert 6714 Oil Bypass Filter E843188-S O-Ring — Tighten to 35-40 Nm (26-30 Lb-Ft) — Tighten to 35-48 Nm (26-35 Lb-Ft) Installation 1. Coat the gasket on the replacement oil bypass filter with clean oil. Position the oil bypass filter on the oil filter mounting insert.

  • Page 106: Oil Filter Adapter

    1997 Aerostar/Ranger Page 1 of 5 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Oil Filter Adapter Removal 1. Place a drip pan under the oil bypass filter (6714) and remove oil bypass filter. 2. On Aerostar, remove the small locating bolt securing the oil filter adapter (6881) to the cylinder blocks (6010).
  • Page 107 1997 Aerostar/Ranger Page 2 of 5 Item Part Number Description E853188-S O-Ring E602189 Bolt 6881 Oil Filter Adapter 6890 Oil Filter Mounting Insert 6714 Oil Bypass Filter 6894 Oil Filter Adapter Mounting Bolt — Tighten to 14-21 Nm (10-15 Lb-Ft) —...
  • Page 108 1997 Aerostar/Ranger Page 3 of 5 1. Position the oil filter adapter to the cylinder blocks with a new gasket between the oil filter adapter and the cylinder blocks. Oil Filter and Adapter — Ranger tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C37.HTM~gen~ref.HTM 2011-04-27...
  • Page 109 1997 Aerostar/Ranger Page 4 of 5 Item Part Number Description 6894 Oil Filter Adapter Mounting Bolt 6L621 O-Ring tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C37.HTM~gen~ref.HTM 2011-04-27...
  • Page 110 1997 Aerostar/Ranger Page 5 of 5 6881 Oil Filter Adapter 6890 Oil Filter Mounting Insert 6714 Oil Bypass Filter E843188-S O-Ring — Tighten to 35-40 Nm (26-30 Lb-Ft) — Tighten to 35-48 Nm (26-35 Lb-Ft) 2. Install a new oil filter mounting bolt seal (6749) on the oil filter adapter mounting bolt and install the bolt into the engine block, hand-tight.
  • Page 111 1997 Aerostar/Ranger Page 1 of 4 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual IN-VEHICLE SERVICE Sensors Low Oil Level Sensor Removal 1. With engine off, drain at least 1.9 liters (2 quarts) of oil from engine (6007). 2.
  • Page 112 2. Remove electrical connection to oil pressure sensor (9278) at the front left of the engine block. 3. Remove switch from cylinder blocks (6010). 4. Apply Pipe Sealant with Teflon®, D8AZ-19554-A meeting Ford specifications ESG-M4G-194-A and ESR-M18P7-A or equivalent to new switch unit threads.
  • Page 113 1997 Aerostar/Ranger Page 3 of 4 Item Part Number Description 6010 Cylinder Blocks (LH) 9278 Oil Pressure Sensor 6C624 Low Oil Level Sensor 9D930 Fuel Charging Wiring 9B339 Oil Pressure Sender Fitting — Tighten to 11-16 Nm (8-12 Lb-Ft) tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C38.HTM~gen~ref.HTM 2011-04-27...
  • Page 114 1997 Aerostar/Ranger Page 4 of 4 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C38.HTM~gen~ref.HTM 2011-04-27...

  • Page 115: Removal And Installation

    1997 Aerostar/Ranger Page 1 of 3 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual REMOVAL AND INSTALLATION Camshaft Bearings Removal 1. Remove engine (6007). Place engine on work stand and remove camshaft (6250), crankshaft (6303) and camshaft rear bearing cover (6266). 2.
  • Page 116 1997 Aerostar/Ranger Page 2 of 3 — Expanding Collet (Part of T65L-6250-A) — Backup Nut (Part of T65L-6250-A) 6262 Bearing, Camshaft (Part Number Given Is for Reference Only) — Puller Screw Extension (Part of T65L-6250-A) — Front Spacer (Part of T65L-6250-A) NOTE: All items except No.
  • Page 117 1997 Aerostar/Ranger Page 3 of 3 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C39.HTM~gen~ref.HTM 2011-04-27...
  • Page 118 6. Thoroughly clean the transmission bell-housing area and the rear of the cylinder blocks (6010). Oil removal should be verified with an ultraviolet lamp ("black light"). 7. Apply a bead of Ford Gasket Eliminator E1FZ-19562-A or Loctite® 515, or equivalent sealer meeting tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C40.HTM~gen~ref.HTM...
  • Page 119 1997 Aerostar/Ranger Page 2 of 9 Ford specification ESE-M4G234-A1, to the cylinder blocks along the corners of the rear main bearing cap joint area, and on the joint face approximately 13mm (1/2 inch) from the rear of the cylinder blocks.
  • Page 120 Fill the cavities on both sides of the rear main cap with Gasket Eliminator E1FZ-19562-A or Loctite 515® or equivalent sealer meeting Ford specification ESE-M4G234-A1. See illustration. Oil Pan Installation tomsn048@gmail.com...
  • Page 121 13. Install the windage tray and tighten to 17-21 Nm (13-15 lb-ft). 14. Place a bead of Ford Silicone Sealer F1AZ-19562-A, Loctite® 598 or equivalent sealer in the oil pan gasket flange at the radius areas at the front and rear of the oil pan.
  • Page 122 Page 5 of 9 16. Place a bead of Ford Silicone Sealer F1AZ-19562-A, or Loctite® 598 or equivalent sealer meeting Ford specification WSE-M4G279, on top of the oil pan gasket at the radius areas at the front and rear of the oil pan.
  • Page 123 1997 Aerostar/Ranger Page 6 of 9 dimension. Determine if oil pan spacers will be required at installation. a. With the oil pan installed on the engine, position straightedge D83L-4201-A or equivalent flat on the rear of the cylinder blocks (as shown) so that it extends over one of the oil pan/transmission bolt mounting pads.
  • Page 124 1997 Aerostar/Ranger Page 7 of 9 Measured Gap Spacer Required Inch Inch Shim Color Code 0.0- 0.0- None None — 0.254 0.010 0.27- 0.011- 0.254 0.010 Yellow 0.51 0.020 0.52- 0.021- 0.508 0.020 Blue 0.76 0.029 0.77- 0.030- 0.762 0.030 Pink 1.00 0.039...
  • Page 125 1997 Aerostar/Ranger Page 8 of 9 Item Part Number Description E804588-S72 Bolt 6C624 Low Oil Level Sensor 6C626 Low Oil Level Sensor Washer 6675 Oil Pan 6710 Oil Pan Gasket E60012-S72 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C40.HTM~gen~ref.HTM 2011-04-27...
  • Page 126 1997 Aerostar/Ranger Page 9 of 9 E804579-S72 Stud 6C629 Oil Pan Spacer 6734 Oil Pan Drain Plug Gasket 6730 Oil Pan Drain Plug E804587-S72 Torx® Bolt — Tighten to 7-10 Nm (5-7 Lb-Ft) — Tighten to 17-21 Nm (13-20 Lb-Ft) —...
  • Page 127 1997 Aerostar/Ranger Page 1 of 5 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual REMOVAL AND INSTALLATION Engine Assembly, Ranger SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fan Clutch Nut Wrench T84T-6312-D Fan Clutch Holding Tool T84T-6312-C WARNING: RESIDUAL PRESSURE REMAINS IN FUEL SYSTEM AFTER ENGINE IS SHUT OFF. THIS COULD RESULT IN INJURY WHEN FUEL LINES ARE DISCONNECTED.
  • Page 128 1997 Aerostar/Ranger Page 2 of 5 12. Disconnect generator (GEN) (10300). Remove bolts and generator mounting bracket with attached generator and set aside. 13. Disconnect the manifold tube assembly at the intake manifold (9424) and water pump (8501). 14. Remove the ground wires from the cylinder block and wire from air conditioning pressure switch. 15.
  • Page 129 1997 Aerostar/Ranger Page 3 of 5 Installation 1. NOTE: To facilitate engine-to-transmission installation and prevent clutch hub damage on manual transmission vehicles, make two guide studs by cutting the heads off two M10 x 70mm bolts and grinding a screwdriver slot in each bolt on the unthreaded end. Install two studs into opposite engine-to-transmission bolt holes in engine to simplify installation.
  • Page 130 1997 Aerostar/Ranger Page 4 of 5 21. Install accelerator cable bracket (9723) and tighten bolts to 21-27 Nm (15-20 lb-ft). 22. Install A/C compressor mounting bracket and brace with assembled power steering pump (3A674) and A/C compressor. Tighten screws to 40-55 Nm (30-40 lb-ft). 23.
  • Page 131 1997 Aerostar/Ranger Page 5 of 5 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C41.HTM~gen~ref.HTM 2011-04-27...
  • Page 132 1997 Aerostar/Ranger Page 1 of 10 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual REMOVAL AND INSTALLATION Engine Assembly, Aerostar Removal 1. NOTE: The engine assembly on Aerostar E4WD vehicles can be removed through the front of the engine compartment without the transmission (7003) attached. WARNING: RESIDUAL PRESSURE REMAINS IN FUEL SYSTEM AFTER ENGINE IS SHUT OFF.
  • Page 133 1997 Aerostar/Ranger Page 2 of 10 18. Disconnect and remove the A/C compressor (if so equipped) as detailed in Section 12-03A 19. Remove the oil fill pipe (6A868). 20. From inside the vehicle, remove the engine cover. 21. Remove the accelerator control splash shield (9E766). 22.
  • Page 134 1997 Aerostar/Ranger Page 3 of 10 24. Remove the transmission oil filler tube (7A228) and fluid level indicator (7A020). 25. Remove the engine oil level dipstick (6750) and oil level indicator tube (6754). 26. Disconnect the dual converter Y pipe (5F250) from the exhaust manifolds (9430). 27.
  • Page 135 1997 Aerostar/Ranger Page 4 of 10 30. Remove the engine mount to frame bolts (left and right sides). 31. Remove the torque converter housing to engine bolts, except the upper bolts. 32. Remove the left front engine support insulator (6038) from the engine. 33.
  • Page 136 1997 Aerostar/Ranger Page 5 of 10 34. Disconnect the transmission and transfer case electrical connectors. 35. Using Disconnect Tools D87L-9280-A and D87L-9280-B, disconnect the fuel supply and return lines where the engine supply and return tubes connect to the chassis fuel lines to the left of the engine near the frame.
  • Page 137 1997 Aerostar/Ranger Page 6 of 10 Installation NOTE: To facilitate engine-to-transmission installation and prevent clutch hub damage on manual transmission vehicles, make two guide studs by cutting the heads off two M10 x 70mm bolts and grinding a screwdriver slot in the end of each bolt on the unthreaded end. WARNING: DO NOT OPERATE ENGINE WITH HOOD OPEN UNTIL FAN HAS BEEN FIRST CHECKED FOR POSSIBLE CRACKS AND SEPARATION.
  • Page 138 1997 Aerostar/Ranger Page 7 of 10 14. Through the starter motor opening in the converter housing, install the converter-to-flywheel bolts. 15. Install the starter motor and connect the starter motor wires. Connect the exhaust system to the manifolds. 16. Install the transmission oil filler tube and fluid level indicator. 17.
  • Page 139 1997 Aerostar/Ranger Page 8 of 10 19. Install the power steering pressure hose and power steering return hose at the power steering pump. 20. Install the accelerator control splash shield. 21. Install the engine oil fill pipe (6763). 22. From inside the vehicle, install the engine cover. 23.
  • Page 140 1997 Aerostar/Ranger Page 9 of 10 25. Install the hood and center hood latch support. 26. Install the right front radiator air deflector. 27. Install drive belt. 28. Install the radiator. 29. Install the radiator fan shroud. 30. Connect the fluid cooler inlet tube and oil cooler outlet tube at the radiator. 31.
  • Page 141 1997 Aerostar/Ranger Page 10 of 10 37. Install the engine air cleaner and air tube. 38. Install the radiator grille and inside engine cover. 39. 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 142 1997 Aerostar/Ranger Page 1 of 7 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual REMOVAL AND INSTALLATION Crankshaft Removal 1. Remove engine (6007) from vehicle and place on a work stand. 2. Remove oil pan (6675) and oil pan gasket (6710) as outlined in this section. 3.
  • Page 143 1997 Aerostar/Ranger Page 2 of 7 Part Item Number Description 6345 Stud, Main Bearing Cap (4 Places) 6345 Bolt, Main Bearing Cap (4 Places) — Main Bearing Cap (Part of 6010) 6306 Crankshaft Sprocket 6026 Oil Gallery Plug 375055- 6333 Crankshaft Main Bearing (No.
  • Page 144 9. NOTE: Make sure that the main bearing caps are installed in their original positions and orientation. Apply a light coat of SAE 50 Service SG meeting Ford specification ESE-M2C39-F oil, to the journals and bearings, and rear seal surface. Install all bearing caps.
  • Page 145 1997 Aerostar/Ranger Page 4 of 7 11. Check crankshaft end play as outlined in Section 03-00 . End play should be 0.05-0.32mm (0.002- 0.0125 inch). 12. If end play exceeds specification, replace upper and lower thrust bearings. If the end play is less than specification, inspect thrust bearing faces for damage, dirt or improper alignment.
  • Page 146 1997 Aerostar/Ranger Page 5 of 7 Cylinder Block Sealer Application tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C43.HTM~gen~ref.HTM 2011-04-27...
  • Page 147 Place a bead of Gasket Eliminator E1FZ-19562-A or Loctite® 515 sealer or equivalent meeting Ford specification WSK-M2G348-A4 to the block along the corners of the rear main bearing cap joint area and on the joint face, approximately 13mm (1/2 inch) from the rear of the cylinder blocks as illustrated.
  • Page 148 22. Clean oil pan, oil pump and oil pump screen cover and tube assembly. 23. Prime oil pump by filling the inlet opening with XO-5W30-QSP meeting Ford specification ESE- M2C153-E or SAE 5W-30 Service SG oil and rotating the pump shaft until oil emerges from the outlet opening.
  • Page 149 1997 Aerostar/Ranger Page 1 of 1 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual REMOVAL AND INSTALLATION Engine Removal and Installation NOTE: 4.0L OHV engines are equipped with a camshaft position sensor (CMP sensor) (12A112) mounted on the camshaft synchronizer (12A362). The camshaft synchronizer replaces the oil pump drive assembly.

  • Page 150: Disassembly And Assembly

    1997 Aerostar/Ranger Page 1 of 34 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY Engine NOTE: The cylinder head (6049)(s) and intake manifold installation procedure has changed. The cylinder head bolts and intake manifold bolts are tightened alternately and in sequence to ensure correct fit and gasket crush.
  • Page 151 1997 Aerostar/Ranger Page 2 of 34 11. Remove the oil pump, oil pump screen cover and tube (6622), oil pump intermediate shaft (6A618) and crankshaft oil windage baffle (6L680). 12. Remove the crankshaft rear oil seal. 13. Remove the timing chain vibration damper (6284) 14.
  • Page 152 1997 Aerostar/Ranger Page 3 of 34 Part Item Number Description 6345 Stud, Main Bearing Cap (4 Places) 6345 Bolt, Main Bearing Cap (4 Places) — Main Bearing Cap (Part of 6010) 6337 Crankshaft Thrust Main Bearing (No. 3 Main Bearing) 6333 Crankshaft Main Bearing (No.
  • Page 153 After all the parts have been cleaned they must be wiped down with a cleaner that leaves no residue or film such as Ford Extra Strength Spot Remover B7A-19521-AA meeting Ford specification ESR-M5B197-A or denatured alcohol.
  • Page 154 1997 Aerostar/Ranger Page 5 of 34 9. Pry crankshaft forward against thrust surface of upper half of bearing. 10. Hold crankshaft forward and pry thrust bearing cap to the rear. This will align thrust surfaces of both halves of the bearing. 11.
  • Page 155 1997 Aerostar/Ranger Page 6 of 34 17. Install the timing chain guide with the guide pin in to the oil supply hole. Tighten guide bolts to 10-12 Nm (7-9 lb-ft). 18. Install camshaft sprocket, timing chain/belt (6268) and crankshaft sprocket. Position sprockets and timing chain/belt on camshaft and crankshaft simultaneously.
  • Page 156 1997 Aerostar/Ranger Page 7 of 34 Item Part Number Description E804389- Torx® Screw S200 6256 Camshaft Sprocket 6250 Camshaft E804358- Torx® Bolt 6K297 Timing Chain Guide 6268 Timing Chain/Belt 6K254 Timing Chain/Belt Tensioner E600112-5 Bolt 6269 Camshaft Thrust Plate — Tighten to 60-68 Nm (44-50 Lb-Ft) —...
  • Page 157 1997 Aerostar/Ranger Page 8 of 34 (7-8 Lb-Ft) 21. After the sprockets have been installed, insert the crankshaft sprocket key. Make sure timing marks on the sprockets are aligned as shown. Item Part Number Description 6256 Camshaft Sprocket — Camshaft Timing Mark (Part of 6256) 6K297 Timing Chain Guide...
  • Page 158 1997 Aerostar/Ranger Page 9 of 34 24. Make sure the ring gaps are properly spaced around the circumference of the piston. Refer to Piston and Connecting Rod Installation in this section. 25. NOTE: Install piston with indentation notch in the piston head toward front of engine. Install a piston ring compressor on the piston and push piston in with a hammer handle until it is slightly below the top of the cylinder.
  • Page 159 1997 Aerostar/Ranger Page 10 of 34 31. Check the crankshaft and connecting rod bearings for assembled rotational torque. Torque required to rotate the crankshaft assembly with pistons installed is not to exceed 45 Nm (33 lb-ft). tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C45.HTM~gen~ref.HTM 2011-04-27...
  • Page 160 Seal and assemble the rear main cap to the cylinder blocks. a. Place a bead of Ford Gasket Eliminator E1FZ-19562-A meeting Ford specification WSK- M2G348-AA or Loctite® 515 sealer to the block along the corners of the rear main bearing cap joint area and on the joint face, approximately 13mm (1/2 inch) from the rear of the block as shown in illustration.
  • Page 161 Torque the rear main cap bolts to 90-104 Nm (66-77 lb-ft). e. Fill the cavities on both sides of the rear main cap with Ford Gasket Eliminator E1FZ-19562-A meeting Ford specification WSK-M2G348-A4 or Loctite® 515.
  • Page 162 1997 Aerostar/Ranger Page 13 of 34 35. Prime the oil pump with XO-5W30-QSP meeting Ford specification ESE-M2C153-E or equivalent SAE 5W-30 Service SG oil and install oil pump, oil pump intermediate shaft, and oil pump screen cover and tube. Tighten oil pump bolts to 17-21 Nm (13-15 lb-ft).
  • Page 163 1997 Aerostar/Ranger Page 14 of 34 Item Part Number Description 6A618 Oil Pump Intermediate Shaft 6629 Oil Pump Intermediate Shaft Retaining Ring 6622 Oil Pump Screen Cover and Tube 6600 Oil Pump E804387 Screw E804553 Screw 6626 Oil Pump Inlet Tube Gasket —...
  • Page 164 1997 Aerostar/Ranger Page 15 of 34 37. Install crankshaft front seal (6700), gasket, and front cover. Tighten cover bolts to 17-21 Nm (13-15 lb-ft). 38. Install crankshaft vibration damper and pulley as detailed in this section. Tighten bolt to 40-50 Nm (30-37 lb-ft).
  • Page 165 1997 Aerostar/Ranger Page 16 of 34 Item Part Number Description E804588-S72 Bolt, M6 6C624 Low Oil Level Sensor 6C626 Low Oil Level Sensor Washer 6675 Oil Pan 6710 Oil Pan Gasket E60012-S72 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C45.HTM~gen~ref.HTM 2011-04-27...
  • Page 166 Tighten to 4 Nm (35 Lb-In) 41. Install and seal the oil pan: a. Place a bead of Ford Silicone Sealer F1AZ-19562-A meeting Ford specification WSE- M4G320-A2 or Loctite® 598 sealer in the oil pan gasket groove at the radius areas at the front and rear of the oil pan.
  • Page 167 1997 Aerostar/Ranger Page 18 of 34 f. Install the remaining oil pan bolts and torque to 7-10 Nm (62-89 lb-ft). 42. NOTE: Always use a new rear main seal. Refer to Crankshaft Rear Oil Seal Installation in this section. 43. NOTE: The transmission bolts to the engine and oil pan when installed, so it is important to measure the difference between the surface of the rear face of the oil pan (at the spacer locations) and the rear face of the cylinder blocks.
  • Page 168 1997 Aerostar/Ranger Page 19 of 34 CAUTION: Failure to measure the required spacer thickness can result in insufficient, or excessive clearance between the oil pan and transmission when installed in the vehicle. This can lead to oil pan damage, and/or oil leakage. Determine if spacers are needed and if so, what thickness: a.
  • Page 169 1997 Aerostar/Ranger Page 20 of 34 Inch Inch Shim Color Code 0.0- 0.0- None None — 0.254 0.010 0.27- 0.011- 0.254 0.010 Yellow 0.51 0.020 0.52- 0.021- 0.508 0.020 Blue 0.76 0.029 0.77- 0.030- 0.762 0.030 Pink 1.00 0.039 44. Install valve tappets (6500) in their original bores. 45.
  • Page 170 47. NOTE: Once applied, the silicone sealer will set up in approximately 15 minutes. The intake manifold must be installed immediately after the sealer is applied. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to the block and cylinder head mating surfaces at the four corners. Install the intake manifold gasket (9439) and again apply sealer to the four corner locations.
  • Page 171 1997 Aerostar/Ranger Page 22 of 34 Part Item Number Description 6049 Cylinder Head 9439 Intake Manifold Gasket 9424 Intake Manifold — Examine Closely for Erosion, Corrosion, or Pitting on This Surface — Silicone Sealer — 4 Places tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C45.HTM~gen~ref.HTM 2011-04-27...
  • Page 172 1997 Aerostar/Ranger Page 23 of 34 Item Part Number Description W702301S309M Bolt with Captive Washer (8) 12A648 Engine Coolant Temperature Sensor 10884 Water Temperature Indicator Sender Unit 8501 Water Pump — Stud (Part of 9424) 9439 Intake Manifold Gasket 9424 Intake Manifold —...
  • Page 173 1997 Aerostar/Ranger Page 24 of 34 a. 8 Nm (6 lb-ft) b. 15 Nm (11 lb-ft) c. 22 Nm (16 lb-ft) 49. NOTE: Lightly oil bolts with engine oil prior to installation. Do not place any oil in the threads on the cylinder head.
  • Page 174 51. NOTE: Since silicone rubber will set up within 15 minutes, if you are installing both covers, apply only to one side at a time. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to intake manifold-to-cylinder head parting seam.
  • Page 175 1997 Aerostar/Ranger Page 26 of 34 Item Part Number Description 6582 Valve Cover — Aerostar (RH) E800390-S72 Screw, M6x22 Flange Head 6582 Valve Cover (LH) W701041 Stud 9424 Intake Manifold 6049 Cylinder Head (RH) 6584 Valve Cover Gasket 6582 Valve Cover — Ranger (RH) 6049 Cylinder Head (LH) 6010...
  • Page 176 1997 Aerostar/Ranger Page 27 of 34 55. Install wiring harnesses, emission control system, fuel system, ignition system and front end accessory drive components, by referring to procedures in the specific sections. Assembly, Ranger 1. After performing Steps 1-55 above, rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC).
  • Page 177 1997 Aerostar/Ranger Page 28 of 34 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer.) 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CID sensor with SM-2C 1013-A oil.
  • Page 178 1997 Aerostar/Ranger Page 29 of 34 Item Part Number Description 12K073 CID Sensor (California Only) E853103-S O-Ring 6846 Oil Pump Drive Assembly 6007 Engine 12270 Distributor Hold-Down Clamp E602550 Screw tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C45.HTM~gen~ref.HTM 2011-04-27...
  • Page 179 1997 Aerostar/Ranger Page 30 of 34 — Tighten to 17-21 Nm (13-15 Lb-Ft) — Maximum Level for Pre-Oiling Drive Gear — Minimum Level for Pre-Oiling Drive Gear 4. NOTE: Normal CID sensor rotation is clockwise viewed from top of CID sensor. Align the CID sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left hand side of the plastic window.
  • Page 180 1997 Aerostar/Ranger Page 31 of 34 7. Rotate the CID sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. NOTE: For out of vehicle assembly, use loose 12 volt battery or battery in a conveniently located vehicle.
  • Page 181 1997 Aerostar/Ranger Page 32 of 34 9. Connect the CID Testing Wiring Harness leads: a. Red harness wire to battery positive terminal. b. Black harness wire to battery negative terminal. c. Voltmeter positive lead to harnesses white lead. d. Voltmeter negative lead to battery negative terminal. Item Part Number Description...
  • Page 182 1997 Aerostar/Ranger Page 33 of 34 — Red Lead (Part of 007-00407) 007-00407 Rotunda Digital Volt-Ohmmeter or Equivalent — Black Lead (Part of 007-00407) — Negative Terminal (Part of 10655) — Black Lead (Part of T94T-50-B) — Connector (Part of T94T-50-B) (Attaches to CID Sensor) 10.
  • Page 183 1997 Aerostar/Ranger Page 34 of 34 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C45.HTM~gen~ref.HTM 2011-04-27...

  • Page 184: Cylinder Head

    1997 Aerostar/Ranger Page 1 of 4 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Head SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Valve Stem Seal Replacer T90T-6571-A Disassembly 1. Remove deposits from the combustion chambers and valve heads with a scraper and a wire brush. Be careful not to scratch the cylinder head gasket surfaces.
  • Page 185 1997 Aerostar/Ranger Page 2 of 4 Item Part Number Description 6518 Valve Spring Retainer Key 6514 Valve Spring Retainer 6513 Valve Spring 6571 Valve Stem Seal 6507 Intake Valve 6505 Exhaust Valve tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C46.HTM~gen~ref.HTM 2011-04-27...
  • Page 186 1997 Aerostar/Ranger Page 3 of 4 — Valve Guide Boss (Part of 6507) — 0.5mm (0.019 Inch) Maximum Gap Assembly 1. Clean, inspect and repair all parts before assembly. 2. Install the left exhaust manifold or right exhaust manifold and spark plugs. Tighten the spark plugs and manifold attaching parts to specifications.
  • Page 187 1997 Aerostar/Ranger Page 4 of 4 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C46.HTM~gen~ref.HTM 2011-04-27...
  • Page 188 1997 Aerostar/Ranger Page 1 of 5 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Pistons, Piston Pins and Rings Disassembly 1. Remove connecting rod bearings (6211) from connecting rod and cap. 2. Remove piston rings using a suitable piston ring expander. 3.
  • Page 189 The piston pin bore of a connecting rod and the diameter of the piston pin must be within specification. 1. Apply a light coat of engine oil XO-5W30-QSP or equivalent meeting Ford specification ESE- M2C153-E or SAE 5W-30 Service SG or SAE 50 Service SG to all parts.
  • Page 190 1997 Aerostar/Ranger Page 3 of 5 Part Item Number Description — Piston Ring Compression, Upper (Part of 6148) — Piston Ring Compression, Second (Part of 6148) — Piston Ring, Oil Control (Part of 6148) 6148 Partial Piston Ring Set 6211 Connecting Rod Bearing 6200 Connecting Rod...
  • Page 191 1997 Aerostar/Ranger Page 4 of 5 3. Start the piston pin in the piston and connecting rod (this may require a very light tap with a mallet). Using an arbor press and Piston Pin Tool D81L-6135-A or equivalent, press the piston pin through the piston until the piston pin is centered in the piston.
  • Page 192 1997 Aerostar/Ranger Page 5 of 5 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C47.HTM~gen~ref.HTM 2011-04-27...

  • Page 193: Cylinder Block Assembly

    1997 Aerostar/Ranger Page 1 of 1 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Block Assembly Disassembly 1. Mount the engine (6007) on a work stand and remove all parts not furnished with the new cylinder assembly.
  • Page 194 1997 Aerostar/Ranger Page 1 of 2 Section 03-01C: Engine, 4.0L 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 repairable. If so, make the necessary repairs following the procedures given in Section 03-00 Disassembly...
  • Page 195 1997 Aerostar/Ranger Page 2 of 2 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C49.HTM~gen~ref.HTM 2011-04-27...

  • Page 196: Rocker Arm Shaft Assembly

    1997 Aerostar/Ranger Page 1 of 2 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Rocker Arm Shaft Assembly Disassembly 1. Remove the spring washer and pin from each end of the rocker arm shaft (6563). 2.
  • Page 197 1997 Aerostar/Ranger Page 2 of 2 6598 Rocker Arm Shaft Washer 6572 Rocker Arm Shaft Plug 6A533 Rocker Arm Shaft Retaining Pin 6563 Rocker Arm Shaft Assembly 1. Use a blunt tool and install a plug, cup side out, in each end of the rocker arm shaft if the plugs were removed from the shaft.

  • Page 198: Valve Clearance

    1997 Aerostar/Ranger Page 1 of 1 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual ADJUSTMENTS Valve Clearance The 4.0L engine uses hydraulic roller tappets and non-adjustable rocker arms (6564). The valve tappets (6500) are not adjustable, and if found to be excessively worn or noisy, should be tested and repaired or replaced as described in Section 03-00 tomsn048@gmail.com...

  • Page 199: Specifications

    1997 Aerostar/Ranger Page 1 of 8 Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual SPECIFICATIONS SPECIFICATIONS Engine Specifications Item Specification Displacement 4.0L (4000 cc) Number of Cylinders Bore and Stroke 100 x 84mm (3.94 x 3.31 inch) Firing Order 1-4-2-5-3-6 Oil Pressure (Hot @ 2000 RPM) 40-60...
  • Page 200 1997 Aerostar/Ranger Page 2 of 8 Valve Face Runout Limit 0.002 Max. Valve Face Angle 44° Valve Stem Diameter (Std.) Intake 0.3159-0.3167 Exhaust 0.3149-0.3156 Valve Stem Diameter (0.008 Oversize) Intake 0.3239-0.3245 Exhaust 0.3228-0.3235 Valve Stem Diameter (0.016 Oversize) Intake 0.3318-0.3324 Exhaust 0.3307-0.3314 Valve Springs...
  • Page 201 1997 Aerostar/Ranger Page 3 of 8 Journal-to-Bearing Clearance 0.001-0.0026 Service Limit 0.006 Bearing Outside Diameter 0.158-0.159 No. 1 49.57-49.59 (1.951-1.952) No. 2 49.21-49.23 (1.937-1.938) No. 3 48.83-48.85 (1.922-1.923) No. 4 48.44-48.46 (1.907-1.908) Runout 0.127 (0.05) Max. T.I.R. Out-of-Round 0.0076 (0.0003) Max. T.I.R. Bearing Inside Diameter No.
  • Page 202 1997 Aerostar/Ranger Page 4 of 8 Pin Bore Diameter 0.9450-0.9452 Ring Groove Width Compression (Top) 0.083-0.0811 Compression (Bottom) 0.1197-0.1205 0.1579-0.1587 Piston Pin Length 2.835-2.866 Diameter 0.9446-0.9448 Blue 0.9448-0.9449 Pin-to-Piston Clearance 0.0003-0.0006 Pin-to-Rod Clearance Interference Fit Piston Rings Ring Width Compression (Top) 0.0778-0.0783 Compression (Bottom) 0.1172-0.1177...
  • Page 203 1997 Aerostar/Ranger Page 5 of 8 Out-of-Round 0.0003 Taper Limit 0.0003 per Inch Surface Finish (RMS) 8.8 Max. Main Bearing Thrust Face Surface Finish 20 Max. Runout (T.I.R.) 0.001 Max. Flywheel Clutch Face Runout 0.0015 Flywheel Ring Gear Lateral Runout (T.I.R.) Standard Transmission 0.015 Automatic Transmission...
  • Page 204 1997 Aerostar/Ranger Page 6 of 8 Standard 0.092-0.268mm (0.0036-0.0106 Inch) Service Limit 0.014 Pin and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at end of an 8 inch bar, 4 inches on each side of rod centerline. Lubricating System Item Specification...
  • Page 205 1997 Aerostar/Ranger Page 7 of 8 Coolant Temperature Sender 4.5-7 — Oil Pan — Bolts and Nuts 7-10 — Oil Pump Pick-Up to Pump Screws 9-13 7-10 — Oil Pump to Engine Block — Screws 17-21 13-15 — Connecting Rod Bearing Cap — Nuts 25-32 18-24 —...
  • Page 206 1997 Aerostar/Ranger Page 8 of 8 tomsn048@gmail.com file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C52.HTM~gen~ref.HTM 2011-04-27...

This manual is also suitable for:

Ranger 1997

Table of Contents