Ford 1997 Aerostar Workshop Manual page 87

1997 Aerostar/Ranger
Tap cap with a plastic mallet to separate from connecting rod. Carefully remove cap from crankshaft.
If lower bearing remained on crankshaft, carefully grasp both sides of connecting rod bearing (6211)
and pull straight down away from crankshaft (oil acts as an adhesive between two precision fitted
components).
13. NOTE: If crankshaft journal inhibits safe removal of piston assembly, rotate crankshaft out of
the way once protective caps are clear of journal.
NOTE: Protective caps may be made from rubber fuel hose.
Install protective rubber caps onto connecting rod bolts to protect crankshaft journal contact from bolt
threads.
14. NOTE: If connecting rod bearing remained on crankshaft journal, carefully rotate bearing
around journal and remove as lower bearing.
Push piston and connecting rod assembly up slightly using wooden end of hammer or similar device
while guiding connecting rod from crankshaft journal. Remove upper connecting rod bearing from
connecting rod.
15. CAUTION: Do not push piston assembly out of bore too fast as damage to piston, pin
and ring, cylinder bore, or crankshaft journal can result from contact to connecting rod.
Push connecting rod bearing and connecting rod up out of bore by tapping with wooden end of
hammer or similar device while guiding connecting rod from crankshaft journal.
16. Install cap to connecting rod in original position and secure with retaining nuts.
17. Refer to Piston Disassembly in this section if piston, pin and ring is to be disassembled.
Installation
NOTE: Lightly oil all retaining bolts and stud threads before installation.
1. CAUTION: When honing or cleaning cylinder wall(s), make sure crankshaft journals are
protected by wrapping a clean shop cloth around the machined surfaces.
Inspect cylinder bore for excessive scratches. If new piston rings are to be installed, the cylinder wall
should be honed to exhibit a visible cross-hatch pattern for proper ring seating. If honing is required,
follow manufacturer's instructions. After honing, thoroughly clean cylinder bore using a detergent and
water solution.
2. Install protective rubber caps on the connecting rod bolts.
3. Lubricate piston, pin and ring and cylinder walls with Engine Assembly Lubricant D9AZ-19579-D or
equivalent meeting Ford specification ESR-M99C80-A.
4. Rotate crankshaft journal to bottom of its travel (if moved).
5. Arrange piston rings alternately around piston to prevent ring end gaps from aligning to each other.
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2011-04-27