Ford 1997 Aerostar Workshop Manual page 7

1997 Aerostar/Ranger
10. Remove ignition coil and bracket assembly (two nuts) from top of throttle body and pencil brace at
exhaust manifold.
11. Remove throttle body, refer to
12. Disconnect fuel injector harness retaining standoffs from inboard rocker arm cover studs. Carefully
disconnect electrical connections to each fuel injector and remove fuel charging wiring (9D930) from
engine.
13. Disconnect heater water hoses at engine.
14. Remove spark plug wire set (12281) from spark plugs (12405) by using a twisting motion on the
rubber boot. Remove harness retaining standoffs from rocker arm cover studs.
15. Remove valve covers as outlined in this section.
16. NOTE: Intake manifold (9424) may be removed with fuel injection supply manifold (9F792) and
fuel injectors in place.
Remove intake manifold retaining bolts using a Torx® head socket. Before attempting to remove
intake manifold, break the seal between the manifold and cylinder blocks (6010). Wedge a large
screwdriver or similar heavy-duty tool between the intake manifold and the cylinder blocks. Pry
upward on the tool using the lug on top of the engine front cover (6019) as a leverage point. Removal
of generator (GEN) (10300) may be required for this step. Use care to prevent damage to machined
surfaces.
17. Loosen rocker arm bolt of the valve tappet (6500) to be replaced enough to allow the rocker arm
(6564) to be lifted off the push rod (6565) and rotated to one side.
18. Remove push rods. If more than one is removed, identify each push rod's location. The push rods
should be installed in their original location and position during reassembly.
19. Loosen roller tappet guide plate retainer bolts (2). Remove tappet guide plate retainer from tappet
valley.
20. Remove valve tappet guide plate (6K512) from valve tappets by lifting straight up.
21. NOTE: If the valve tappets are stuck in the bore(s) due to excessive varnish or gum deposits, it
may be necessary to use a claw-type tool to aid removal. Work the valve tappet in and out of
the lifter bore to loosen it from the deposits.
To remove, grasp valve tappet and pull in line with bore.
Installation
NOTE: Lightly oil all bolt and stud threads before installation.
1. CAUTION: Aluminum components gouge easily, which may result in gasket leaks.
Always use care when scraping aluminum gasket surfaces.
Clean mating gasket surfaces of intake manifold and cylinder head (6049). Lay a clean cloth or shop
rag in the tappet valley to catch any gasket material. After scraping, carefully lift cloth from tappet
file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVK31B16.HTM~gen~ref.HTM
Section 03-04B .
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2011-04-27