Ford Aerostar 1997 Workshop Manual page 2

1997 Aerostar/Ranger
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.
2. Install the LH valve cover. Tighten the bolts to 10 Nm (89 lb-in).
3. Install the RH valve cover. Tighten the bolts to 10 Nm (89 lb-in).
4. Position harness, and connect the oil pressure-sending unit and locators.
5. Remove the tape from the lower intake manifold. Install new upper intake manifold seals. Install the
upper intake manifold with the EGR outlet tube attached. Tighten the nuts to 20 Nm (15 lb-ft).
6. Install the EGR outlet tube to exhaust manifold. Tighten stud to 40 Nm (30 lb-ft).
7. Install the oil level indicator tube bracket to EGR bracket stud. Tighten the nut to 20 Nm (15 lb-ft).
Install the oil indicator.
8. Connect the upper radiator hose to the thermostat housing. Connect the heater hose to the intake
manifold.
9. Install the EGR valve with a new gasket to outlet tube bracket. Connect the EGR vacuum line and the
inlet tube from the exhaust manifold. Tighten the EGR valve bolts to 20 Nm (15 lb-ft). Tighten the tube
nut to 34 Nm (25 lb-ft).
10. Install the coil pack with ignition wires as an assembly. Tighten the two ignition coil bolts to the upper
intake manifold and one bolt on right exhaust manifold to 20 Nm (15 lb-ft). Connect the ignition wires
to the seven retaining clips and spark plugs.
11. Connect the ignition coil electrical connector, locator, and the noise suppressor electrical connector.
12. Connect the vent line under the throttle body.
13. Connect the 42-pin connector and the PCM harness locator to the bracket mounted to the under side
of intake manifold.
14. Connect the TPS electrical connector and hoses to the DPFE transducer.
15. Connect the vacuum hoses to the brake booster, upper intake manifold and the PCV valve to the LH
valve cover.
16. Connect the IAC valve, EVR solenoid wiring connectors and vacuum hoses.
17. Install the accelerator control bracket to throttle body. Tighten the bolts to 13 Nm (10 lb-ft). Connect
the accelerator and speed control cables to the throttle body. Install the accelerator splash shield.
18. Install the breather hose to the RH valve cover and to the inlet tube and install the assembly. Connect
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2011-04-27