Ford Aerostar 1997 Workshop Manual page 191

1997 Aerostar/Ranger
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.
4. Check the end gap of all piston rings. It must be within specification:
Compression (Top) 0.38-0.58mm (0.015-0.023 in.)
Compression (Bottom) 0.38-0.58mm (0.015-0.023 in.)
Oil Ring (Steel Rail) 0.38-1.39mm (0.015-0.055 in.)
5. Follow the instructions contained on the piston ring package and install the piston rings.
6. Check the ring side clearance of the compression rings with Feeler Gauge D81L-4201-A or
equivalent by inserting it between the ring and its lower land. The gauge should slide freely around
the entire ring circumference without binding. Any wear that occurs will form a step at the inner
portion of the lower land. If the lower lands have high steps, the piston should be replaced.
7. Make sure bearing inserts and the bearing bore in the connecting rod and cap are clean. Foreign
material under the inserts will distort the bearing and cause a failure. Install the connecting rod
bearings in the connecting rod and cap with the tangs fitting in the slots provided.
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2011-04-27