Ford Aerostar 1997 Workshop Manual page 129

1997 Aerostar/Ranger
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.
2. Attach Rotunda Engine Lifting Sling 014-00036 or equivalent and hoist to lifting brackets at exhaust
manifolds. Remove engine from work stand.
3. Lower the engine carefully into the engine compartment. Make sure exhaust manifolds are properly
aligned with the exhaust inlet pipes.
4. Remove transmission jack and lifting equipment from engine.
5. Install transmission-to-engine bolts finger-tight and remove guide studs and install those two bolts
finger-tight.
6. Position transmission-to-engine bracket and finish installing transmission-to-engine bolts and tighten
to 38-51 Nm (28-38 lb-ft).
7. Install flexplate-to-torque converter nuts and tighten to 45-61 Nm (33-45 lb-ft).
8. Install starter motor and tighten bolts to 20-27 Nm (15-20 lb-ft). Install starter bracket and tighten to
specifications.
9. Route and connect battery cable.
10. Connect the muffler inlet pipes at the exhaust manifolds. Tighten bolts to 37-50 Nm (27-37 lb-ft).
11. Install transmission line bracket bolts and tighten to 16-24 Nm (12-18 lb-ft).
12. Install battery cable bracket bolt and tighten.
13. Install the engine front support nuts and washer to the crossmember or through-bolts.
14. Lower the vehicle.
15. Install ground wires to cylinder block.
16. Route wiring harness through intake manifold.
17. For Ranger, connect the engine wiring harness connector to the CID sensor.
18. Connect air conditioner manifold tube assembly to condenser A/C condenser core and suction
accumulator/drier and install bolt attaching it to upper intake manifold.
19. Install vacuum hoses, PCV hose, and tie strap.
20. Uncap and connect fuel lines as outlined in
file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C41.HTM~gen~ref.HTM
Section 03-04C .
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2011-04-27