Ford Aerostar 1997 Workshop Manual page 137

1997 Aerostar/Ranger
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.
1. WARNING: DO NOT OPERATE ENGINE WITH HOOD OPEN UNTIL FAN HAS BEEN FIRST
CHECKED FOR POSSIBLE CRACKS AND SEPARATION.
Position the engine in the vehicle and remove the engine lifting brackets.
2. Connect the fuel charging wiring main connectors.
3. Install the throttle body and upper intake manifold.
4. Install the ignition coil and ignition coil mounting strap, and connect the spark plug wires and the coil
assembly wiring connector.
5. Connect the electrical connector for the throttle position sensor.
6. Connect the upper and lower heater water hoses.
7. Connect the engine vacuum lines to the evaporative emissions canister, lower intake manifold and
the upper intake manifold vacuum outlet fitting and cap.
8. Connect the accelerator cable and accelerator cable bracket.
9. Connect the fuel supply and return lines where engine supply and return tubes connect to the chassis
fuel lines to the left of the engine near the frame.
10. Install the left front engine support insulator.
11. Install the converter housing to engine bolts. Connect the transmission electrical connectors.
12. Install the engine mount to frame bolts (left and right sides).
13. Install the transmission oil cooler line bracket retaining bolt.
file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31C42.HTM~gen~ref.HTM
tomsn048@gmail.com
Page 6 of 10
2011-04-27