Ford 1997 Aerostar, 1997 Ranger Workshop Manual

Clean the valve covers and mating surfaces.

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Valve Cover and Gasket

NOTE: The rocker covers installed on the 3.0L engine incorporate integral (built-in) gaskets which
should last the life of the vehicle. Be sure to adhere to the following steps when removing and
replacing rocker covers. Replacement gaskets are available if required.

Removal

1. Disconnect battery ground cable (14301) and set aside.

2. Disconnect the crankcase ventilation hose from the air cleaner outlet tube. Disconnect the wiring
connectors from the mass air flow (MAF) sensor, intake air temperature (IAT) sensor, and the
harness locator from the outlet tube. Loosen the clamps at the throttle body and air cleaner and
remove the outlet tube.

3. Remove air cleaner outlet tube.

4. Disconnect the canister purge hose from the canister purge valve at the LH frame rail and the locator
from the accelerator control bracket. Remove the accelerator control splash shield.

5. Disconnect the throttle cable (09A758A) and speed control cable (9A825) from the throttle body and
the locator at the top of the intake manifold. Remove the cable bracket retaining bolts and remove
bracket with cables attached. Position the bracket and cables out of the way.

6. Disconnect the wiring connectors from the coil connector, radio noise suppressor, the EVR and left
side spark plug wires from coil. Disconnect right side spark plug wires from the locators and wires
from the spark plugs. Disconnect the vacuum hose from the EVR and heater control tee. Remove the
brace from the coil bracket and the exhaust manifold. Remove the coil assembly.

7. Disconnect the right side valve cover harness locators. Disconnect the IAT harness locator from the
generator bracket. Remove the right side valve cover and gasket.

8. Disconnect the DPFE vacuum hoses and the wiring connector. Remove the EGR valve tube from the
valve and exhaust manifold.

9. Disconnect the vacuum hoses from the brake booster, EGR, and the engine vacuum harness from
upper intake and position the harness out of the way.

10. Disconnec the wiring connectors from the throttle position sensor (TPS) and idle air control (IAC).
Disconnect the 42-pin connector from the bracket at the rear of intake manifold. Remove the positive
crankcase ventilation (PCV) valve from the valve cover.

11. Remove the upper intake manifold and gasket. Tape the lower intake openings closed.

12. Disconnect the left side spark plug wire locators and wires from the spark plugs. Remove the left side
valve cover and gasket.

13. NOTE: Do not clean the valve cover gasket with solvent. Damage to the valve cover gasket
may occur.

14. Clean upper intake manifold and mating surfaces.

symptoms may occur while the powertrain control module (PCM) (12A650) relearns its

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Installation

1. NOTE: Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford
specification WSE-M4G323-A6.

Apply sealant and install the left valve cover and a new gasket. Tighten the bolts to 14 Nm (10 lb-ft).

2. NOTE: Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford
specification WSE-M4G323-A6.

Apply sealant and install the right valve cover and a new gasket. Tighten the bolts to 14 Nm (10 lb-ft).

3. Route the left side spark plug wires and connect the wires to the locators on the valve cover and to
the spark plugs.

4. NOTE: Tighten the bolts in sequence in two steps.

Remove the tape from the lower intake manifold and install a new gasket. Install upper intake
manifold, and the three bolts and the three stud bolts. Tighten the bolts in two steps. Tighten to 20
Nm (14 (lb-ft) then tighten to 25 Nm (18 lb-ft). Route and connect the PCV valve and hose.

5. Connect the brake booster vacuum, EGR valve and the engine vacuum harness to the upper intake
manifold.

6. Install the coil and bracket assembly to the upper intake manifold. Install the coil bracket brace to the
bracket and exhaust manifold. Tighten the retainers to 18 Nm (13 lb-ft).

7. Connect the wiring connectors to the coil connector, radio noise suppressor, EVR vacuum and
electrical connectors, left side spark plug wires to the coil and right side spark plug wires to the spark
plugs.

8. Connect the right side valve cover harness locators. Connect the heater control vacuum hose source
to the engine vacuum harness. Connect the IAT harness locator to the generator bracket.

9. Install the EGR valve tube. Tighten the tube nut to 20 Nm (15 lb-ft). Tighten the bolt to 16 Nm (11 lb­ft). Connect the DPFE vacuum hoses and electrical connector.

10. Connect the throttle cable (09A758A) and speed control cable (9A825) to the throttle body and
locator. Install the bracket with cables attached to the throttle body. Tighten the bolts to 10 Nm (89 lb­in).

11. Connect the canister purge hose to the valve and the locator to the accelerator control bracket. Install
the accelerator control splash shield.

12. Connect the wiring connectors to the TPS and IAC and the 42-pin connector to the bracket at the rear
of the intake manifold.

13. Install the outlet tube and tighten the clamps securely. Connect the crankcase ventilation hose to the
air cleaner outlet tube. Connect the wiring connectors to the MAF sensor, IAT sensor, and the
harness locator to the outlet tube.

14. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the

Item

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strategy.

Connect battery ground cable .

Valve Cover Installation, Ranger

Part Number Description

1 6582 Valve Cover (RH)
2 N803298-S Screw and Washer
3 N803262-S Stud
4 6582 Valve Cover (LH)
5 ESE-

M4G195-B
6 9424 Intake Manifold
7 6049 Cylinder Head
8 6584 Valve Cover Gasket
9 6049 Cylinder Head
10 — Intersection of Head and Intake Manifold Must Be

A — Tighten to 10-14 Nm

Sealer

Flush to Within ± 1mm
(0.04 In.). Gasket Must Not Protrude Above Highest
Surface.

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(7-10 Lb-Ft)

B — 4-6mm (.15-.23 In.)

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Rocker Arm

Refer to Valve Tappet, Hydraulic In-Vehicle Service for removal and installation of the rocker arms. Perform
only the steps necessary to remove the rocker arms.

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Valve Tappet, Hydraulic

NOTE: Before replacing a tappet for noisy operation,

make sure the noise is not caused by improper

valve-to-rocker arm clearance or by worn rocker arms or push rods. Refer to Section 03-00 .

Removal

1. NOTE: On 3.0L Aerostar it is necessary to remove the engine (6007) from the vehicle to

perform this procedure. Refer to Engine Assembly, Aerostar , Removal and Installation, in this
section.

Disconnect ground cable at battery and set aside.

2. Drain engine cooling system.

3. Remove PCV closure hose from valve cover (6582) and air cleaner outlet tube.

4. Remove air cleaner outlet tube from throttle body (9E926) and engine air cleaner (ACL) (9600).

5. WARNING: COVER THE VALVE WITH A SHOP RAG TO PREVENT ACCIDENTAL FUEL
SPRAY INTO THE EYES.

Carefully relieve fuel pressure at fuel supply manifold fuel pressure relief valve as outlined in Section

03-04B .

6. Remove fuel tube clips. Disconnect fuel lines as outlined in Section 03-04B .

7. Mark location of vacuum lines and remove.

8. Disconnect electrical connectors of:

 Intake air temperature sensor (IAT sensor) (12A697)
 Idle air control valve (IAC valve) (9F715)
 Engine coolant temperature sensor (ECT sensor) (12A648)
 Camshaft position sensor (12A112)
 Ignition coil
 Radio ignition interference capacitor (18801)
 Water temperature indicator sender unit (10884)
 EGR pressure sensor, if equipped
 EGR vacuum regulator control, if equipped

9. Disconnect upper radiator hose from thermostat housing. After loosening hose clamp, use a twisting
motion on hose to loosen from housing.

10. Remove ignition coil and bracket assembly (two nuts) from top of throttle body and pencil brace at

rag in the tappet valley to catch any gasket material. After scraping, carefully lift cloth from tappet

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exhaust manifold.

11. Remove throttle body, refer to Section 03-04B .

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.

nstallation

I

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

valley preventing any particles to enter oil drain holes or cylinder head. Use a suitable solvent to

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remove old rubber sealant.

2. Lubricate valve tappets and bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent
meeting Ford specification ESR-M99C80-A.

Item Part Number Description

1 — Bolt (Part of 6K564)
2 6K564 Tappet Guide Plate and Retainer
3 — Cylinder Block Assembly Tappet Bore

(Part of 6010)
4 — Washer (Part of 6K564)
5 — Cylinder Block Assembly Guide Plate Retainer

(Part of 6010)
6 6500 Valve Tappet
7 6K512 Valve Tappet Guide Plate
A — Tighten to 10-14 Nm

(7-10 Lb-Ft)

3. Install valve tappet into bore.

in rocker arm and lifter sockets prior to final

-

tightening.

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4. NOTE: Install plate with the word "UP" and button visible.

Align valve tappet flats. Install valve tappet guide plate.

5. Install tappet guide plate retainer over valve tappet guide plates. Retainer orientation is not important.
Hand-start two retaining bolts. Tighten bolts to 10-14 Nm (7-10 lb-ft).

6. Apply a 5-6mm drop of Silicone Rubber D6AZ-19562-AA or -BA or equivalent meeting Ford
specification ESB-M4G92-A or ESE-M4G195-A to intersection of cylinder block and cylinder head
assembly at four corners as shown in the illustration under Intake Manifold in this section.

7. Position intake manifold gaskets (9439) onto cylinder heads. Align the intake gasket locking tabs to
the provisions on the cylinder head gaskets as shown in the illustration.

8. Install front and rear intake manifold seals as shown in the illustration under Intake Manifold in this
section. Secure with retaining features.

9. Lower intake manifold into position aligning manifold bolt holes to those in the cylinder head. Use
care to prevent disturbing the rubber sealer which can cause sealing voids. Install bolts 1, 2, 3 and 4
and hand-snug. Install remaining bolts and tighten in a two-step process. Tighten in numerical
sequence to 15 Nm (11 lb-ft), then again to 26-32 Nm (19-24 lb-ft).

10. NOTE: Rocker arm must be fully seated into cylinder head and push rod must be fully seated

Apply ESE-M2C39-F oil to removed push rods and rocker arms. Install push rods. Move rocker arms

adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the

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into position with push rod and snug rocker arm bolts. Rotate crankshaft (6303) to position camshaft
lobe(s) straight down and away from push rods. Tighten rocker arm bolt to 11 Nm (8 lb-ft) to seat
rocker arm into cylinder head. Final-tighten bolt to 26-38 Nm (19-28 lb-ft).

11. Install valve covers as outlined in this section.

12. Install fuel charging wiring to each fuel injector. Secure with standoffs to inboard rocker arm cover
studs.

13. Install throttle body assembly and new intake manifold upper gasket (9H486) as outlined in Section

03-04B . Install ignition coil and bracket assembly (Ranger only). Tighten retaining nuts to 16-20 Nm

(12-15 lb-ft).

14. Install spark plug wire set and bracket RH and/or spark plug wire set LH. Install wire harness
standoffs to rocker arm cover studs and connect wires to spark plugs and ignition coil.

15. Install fuel lines to fuel injection supply manifold as outlined in Section 03-04B .

16. Install fuel tube clips.

17. Install upper radiator hose and heater water hoses. Tighten hose clamps securely.

18. Connect vacuum lines to premarked locations.

19. Connect electrical connections of:

 Intake air temperature sensor
 Idle air control valve (IAC valve)
 Engine coolant temperature sensor
 Distributor
 Ignition coil
 Radio ignition interference capacitor
 Water temperature indicator sender unit
 EGR pressure sensor, if equipped
 EGR vacuum regulator control, if equipped

Refer to Section 18-01 for further information.

20. NOTE: Engine coolant is corrosive to all engine bearing material. Replacing oil after removal
of a coolant carrying component prevents failure later.

Fill and bleed cooling system with specified coolant and proper mixture.

21. Replace crankcase oil and filter.

22. Install air cleaner outlet tube to throttle body and engine air cleaner. Tighten retaining clamps to 1.9
Nm (17 lb-in).

23. Install PCV closure hose to valve cover and air cleaner outlet tube.

24. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

symptoms may occur while the powertrain control module (PCM) (12A650) relearns its

strategy.

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Connect ground cable at battery.

25. Start engine and check for coolant, oil fuel and vacuum leaks.

26. Verify and correct default base initial engine timing to 10 degrees BTDC. Refer to the Powertrain
Control/Emissions Diagnosis Manual.

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Intake Manifold

Upper

Refer to Section 03

-04B for throttle body removal and installation procedures.

Lower

Removal

1. Disconnect ground cable at battery and set aside.

2. Drain engine cooling system.

3. Remove PCV closure hose from valve cover (6582) and air cleaner outlet tube.

4. Remove air cleaner outlet tube from throttle body (9E926) and engine air cleaner (ACL) (9600).

5. CAUTION: Cover the fuel pressure relief valve with a shop rag to prevent accidental fuel
spray into the eyes.

Carefully relieve fuel pressure at fuel pressure relief valve as outlined in Section 03

-04B .

6. Remove fuel tube clips. Disconnect fuel supply and return lines as outlined in Section 03-04B .

7. Mark location of vacuum lines and remove.

8. Disconnect electrical connectors of:

 Intake air temperature sensor (IAT sensor) (12A697)
 Idle air control valve (IAC valve) (9F715)
 Engine coolant temperature sensor (ECT sensor) (12A648)
 Camshaft position sensor (12A112)
 Ignition coil
 Radio ignition interference capacitor (18801)
 Water temperature indicator sender unit (10884)
 EGR pressure sensor, if equipped
 EGR vacuum regulator control, if equipped

Refer to Section 18-01 for further information.

15.

Remove valve covers as outlined in this section.

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Item Part Number Description

1 12A648 Engine Coolant Temperature Sensor(Ranger)
2 124648 Engine Coolant Temperature Sensor (Aerostar)
3 9424 Intake Manifold
4 806344 Heater Elbow
5 18599 Hot Water Heater Elbow Connection
6 10884 Water Temperature Indicator Sender Unit
A — Tighten to 16-24 Nm

(12-17 Lb-Ft)

9. Disconnect upper radiator hose from thermostat housing connection. After loosening hose clamp, use
a twisting motion on hose to loosen from housing.

10. Remove ignition coil and bracket assembly (two nuts) from top of throttle body and pencil brace at
exhaust manifold.

11. Remove throttle body as outlined in Section 03

12. Disconnect fuel charging wiring retaining standoffs from inboard rocker arm cover studs. Carefully
disconnect electrical connections to each fuel injector and remove harness from engine.

13. Disconnect heater water hoses.

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.

-04B .

16. Loosen cylinder No. 3 intake valve rocker arm bolt and rotate rocker arm (6564) off push rod (6565)

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and away from top of valve stem. Remove push rod.

NOTE: Intake manifold (9424) may be removed with fuel injector and fuel injection supply manifolds
(9F792) in place.

17. Remove intake manifold retaining bolts using a Torx® head socket. Before attempting to remove
intake manifold, break the seal between the intake manifold and cylinder blocks (6010). Wedge a
large screwdriver or similar heavy-duty tool between the manifold and the block. Pry upward on the
tool using the lug on top of the front cover as a leverage point. Removal of generator (GEN) (10300)
may be required for this step. Use care to prevent damage to machined surfaces.

Fuel Rail and Injectors to Intake Manifold, Installation

Item Part Number Description

1 — Outlet End (Part of 9F593)
2 9F593 Fuel Injector
3 — Inlet End (Part of 9F593)
4 — Black Shipping Cap

(Part of 9F593)

5 — Green Shipping Cap

(Part of 9F593)
6 N802353-S100 Bolt
7 9F792 Fuel Injection Supply Manifold
8 9424 Intake Manifold
A — Tighten to 8-12 Nm

(71-106 Lb-In)

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Installation

NOTE: Lightly oil all retaining bolt and stud threads before installation.

CAUTION: Aluminum components gouge easily which may cause gasket to leak. Always use

care when scraping aluminum gasket surfaces.

1. Clean mating gasket surfaces of intake manifold and cylinder blocks. Lay a clean cloth or shop rag in
the tappet valley to catch any gasket material. After scraping, carefully lift cloth from tappet valley
preventing any particles from entering oil drain holes or cylinder head. Use a suitable solvent to
remove old rubber sealant.

2. If installing new intake manifold, transfer:

 Fuel injectors
 Fuel injection supply manifold
 Engine coolant temperature sensor
 Water thermostat (8575)
 Water thermostat housing
 Hot water heater elbow connection (18599) by-pass fitting (18599).
 Coolant temperature sending unit

3. Apply a 5-6mm drop of Silicone Rubber D6AZ-19562-AA or -BA or equivalent meeting Ford
specification ESB-M4G92-A or ESE-M4G195-A to intersection of cylinder blocks and cylinder head
(6049) at four corners as shown in the illustration.

4. Position intake manifold gaskets (9439) onto cylinder heads. Align the intake gasket locking tabs to
the provisions on the cylinder head gaskets as shown in the illustration.

Intake Manifold Gasket, Installation

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Item Part Number Description

1 9A424 Seal, Intake Manifold, Rear
2 — Distributor Hole

(Part of Cylinder Block)
3 6049 Cylinder Head
4 ESE-M4G195-B Sealer (4 places)
5 6010 Cylinder Blocks
6 9A424 Seal, Intake Manifold, Front
7 6051 Head Gasket
8 9439 Intake Manifold Gasket

5. Install front and rear intake manifold seals as shown in the illustration. Secure with retaining features.

6. Lower intake manifold into position aligning manifold bolt holes to those in the cylinder head. Use
care to prevent disturbing the rubber sealer which can cause sealing voids. Install bolts 1, 2, 3 and 4
and hand-snug. Install remaining bolts and tighten in a two-step process. Tighten in numerical
sequence to 15 Nm (11 lb-ft), then again to 26-32 Nm (19-24 lb-ft).

Intake Manifold Bolt Torquing Sequence

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7. CAUTION: If a new distributor or camshaft position sensor is installed, be sure to add the
rest of the pint of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford
specification ESR-M99C80-A to the engine oil by pouring it through the distributor hole onto
the cam drive gear. Run engine at idle for five minutes before driving vehicle.

Dip entire distributor or camshaft position sensor drive gear in Engine Assembly Lubricant D9AZ­19579-D or equivalent meeting Ford specification ESR-M99C80-A.

8. NOTE: Rocker arm fulcrum must be fully seated into cylinder head and push rod must be fully
seated in rocker arm and lifter sockets prior to final tightening.

Apply Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR­M99C80-A to cylinder No. 3 intake valve push rod and rocker arm. Install push rod. Move rocker arm
into position with push rod and snug rocker arm bolt. Rotate crankshaft (6303) to position camshaft
lobe straight down and away from valve tappet (6500). Tighten retaining bolt to 11 Nm (8 lb-ft) to seat
rocker arm fulcrum into cylinder head. Final-tighten bolt to 26-38 Nm (19-28 lb-ft) in any position.

9. Install valve covers as outlined in this section.

10. Install fuel charging wiring (9D930) to each fuel injector. Secure with standoffs to inboard rocker arm
cover studs.

Ignition Coil Installation

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Item Part Number Description

1 — Nut (Part of 12A310)
2 9J472 EGR Vacuum Regulator Bracket

3 — Nut (Part of 12A310)

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4 12A310 Ignition Coil and Bracket Assembly
5 — Stud (Part of 9E926)
6 12N004 Ignition Coil Mounting Bracket
7 — Exhaust Manifold Stud

(Part of 9430)

A — Tighten to 8-12 Nm

(6-9 Lb-Ft)

B — Tighten to 16-20 Nm

(12-15 Lb-Ft)

11. Installthrottle body and newintake manifold gasketas outlined in Section 03-04B . Install coil and
bracket assembly (Ranger only). Tighten retaining nuts to 16-20 Nm (12-15 lb-ft).

12. Install wire harness standoffs to rocker arm cover studs and connect wires to spark plug and ignition
coil.

13. Install fuel supply and return lines to fuel injection supply manifold as outlined in Section 03-04B .

14. Install fuel tube clips.

15. Install upper radiator hose and heater water hoses. Tighten hose clamps securely.

16. Connect vacuum lines to premarked locations.

17. Connect electrical connections of:

 Radio ignition interference capacitor
 Idle air control valve
 Engine coolant temperature sensor
 Distributor
 Ignition coil
 Radio ignition interference capacitor
 Water temperature indicator sender unit
 EGR pressure sensor, if equipped
 EGR vacuum regulator control, if equipped

Refer to Section 18-01 for further information.

18. NOTE: Engine coolant is corrosive to all engine bearing material. Replacing oil after removal
of a coolant carrying component prevents failure later.

Fill and bleed cooling system with specified coolant and proper mixture.

19. Replace crankcase oil and oil filter.

20. Install air cleaner outlet tube to throttle body and MAF sensor (12B579). Tighten retaining clamps to

1.9 Nm (17 lb-in).

21. Install closure hose to valve cover and air cleaner outlet tube.

22. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

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symptoms may occur while the powertrain control module (PCM) (12A650) relearns its
adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the
strategy.

Connect ground cable at battery.

23. Start engine (6007) and check for coolant, oil, fuel and vacuum leaks.

24. Verify and correct default base initial engine timing to 10 degrees BTDC. Refer to the Powertrain
Control/Emissions Diagnosis Manual. Tighten retaining bolt to 19-30 Nm (14-22 lb-ft).

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Cylinder Head(s)

Removal

1. NOTE: On 3.0L Aerostar it is necessary to remove the engine (6007) from the vehicle to

perform this procedure. Refer to Engine Assembly, Aerostar
section.

Disconnect ground cable at battery and set aside.

2. Drain cooling system. Refer to Section 03-03 .

3. Remove:

 Engine air cleaner outlet tube
 Engine air cleaner
 PCV closure hose

, Removal and Installation, in this

4. Remove throttle body (9E926) as outlined in Section 03-04B .

5. Remove engine oil filler adapter (Aerostar only).

6. Disconnect fuel lines as outlined in Section 03

-04B .

7. Mark vacuum line location and remove lines.

8. Disconnect upper radiator hose and heater water hoses and move out of the way.

9. Disconnect spark plug wires from spark plugs with a turning motion and remove spark plug wire
separators from valve cover retaining pins.

10. Remove ignition coil and bracket from top of throttle body and pencil at exhaust manifold.

11. Remove spark plugs (12405) and bring number one piston to top dead center of the compression
stroke.

12. Remove intake manifold (9424) as outlined.

13. Remove engine accessory drive belt (8620).

14. On Ranger only:

a. Recover refrigerant from A/C system. Refer to Section 12

-00 .

b. Disconnect liquid line at condenser and suction hose from accumulator.
c. Plug or cap all openings in the air conditioning system to keep dirt, foreign material and excess

moisture out of the system.

d. Remove 4 bolts securing A/C compressor to power steering pump support bracket and remove

A/C compressor and hoses assembly from vehicle.

15. If left cylinder head is being removed, perform the following:

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a. Remove fuel line retaining bracket from stud bolt on left side of power steering pump support

bracket and remove stud bolt.

b. Loosen lower bolt on left side of power steering pump support bracket two or three turns, but

DO NOT REMOVE.

c. Remove three bolts securing power steering pump support bracket to front of left cylinder head

and carefully allow power steering pump and bracket to tilt forward.

d. Remove engine oil level indicator tube attaching nut from exhaust manifold stud. Remove oil

level indicator tube from exhaust manifold.

16. If right cylinder head (6049) is being removed, perform the following:

a. Disconnect wiring from generator.
b. Remove three generator bracket and adjusting arm retaining bolts. Remove generator/bracket

assembly from vehicle.

17. Remove exhaust inlet pipe or pipes and exhaust manifolds (9430) and exhaust manifold.

18. Loosen rocker arm bolts and remove rocker arm assemblies. Identify the location of each assembly.
The rocker arm assemblies must be installed in their original location during reassembly.

19. Remove push rods (6565). Identify the position of each rod. The push rods should be installed in their
original position during reassembly.

20. Remove cylinder head retaining bolts.

21. Remove cylinder heads.

22. Remove head gaskets (6051) and discard.

nstallation

I

NOTE: Lightly oil all bolt and threads before installation. Always use new bolts when installing a
cylinder head.

1. CAUTION: Aluminum components gouge easily. Gouges in aluminum components will
cause gaskets to leak.

Lay a clean shop rag in lifter valley to catch any gasket particles. Clean cylinder head, intake manifold
and cylinder head to block gasket surfaces. After scraping, lift cloth so no gasket material falls into
lifter valley. If the cylinder head was removed for a head gasket replacement, check the flatness of
the cylinder head and block gasket surfaces. Refer to Section 03-00 .

2. NOTE: Replace alignment dowels if damaged.

Position head gaskets on cylinder blocks (6010) using the dowels for alignment. Make sure gasket is
aligned as shown in the illustration.

be checked for tightness if desired.

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3. Carefully position cylinder heads on cylinder blocks.

4. Install new cylinder head retaining bolts and hand tighten.

5. Tighten retaining bolts in sequence as illustrated to 80 Nm (59 lb-ft).

6. Back off all bolts a minimum of one full turn (360 degrees).

7. NOTE: When the cylinder head retaining bolts have been tightened using this procedure, it is

not necessary to retighten the bolts after extended engine operation. However, the bolts can

Retighten the cylinder head retaining bolts in sequence in two tightening steps as follows:

required.

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 45-55 Nm (33-41 lb-ft)
 85-99 Nm (63-73 lb-ft)

Cylinder Head Assembly, Installation

8. Install intake manifold as outlined in this section.

9. Dip each push rod Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford
specification ESR-M99C80-A heavy engine oil. Install push rods in their original positions and
orientation.

10. Loosely install rocker arm assemblies in original locations. Apply Engine Assembly Lubricant D9AZ­19579-D or equivalent meeting Ford specification ESR-M99C80-A heavy engine oil. Tighten rocker
arm fulcrum bolts to 10-12 Nm (8-10 lb/ft) while lifter is on base circle of corresponding cam lobe.
Final tighten rocker arm fulcrum bolts to 26-38 Nm (20-28 lb/ft).

11. CAUTION: Rocker arm fulcrum must be fully seated into cylinder head and push rods

must be fully seated in lifter and rocker arm sockets during final tightening.

NOTE: With number one piston at top dead center (TDC) of the exhaust stroke, you can tighten
intake rockers of cylinder numbers 1 and 4, and exhaust rockers of cylinder 2 and 5. With the
crankshaft rotated so number one piston is 135 degs. after top dead center (ATDC) of the
exhaust stroke, you can tighten intake rockers of cylinder numbers 2, 3, 5 and 6, and exhaust
rockers of cylinder numbers 1, 3, 4 and 6.

NOTE: If the original valve train components are being reused, a valve clearance check is not

You must check rocker arm to valve tip clearance if a cam, lifters, push rods, rocker arms, rocker arm

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fulcrums or valves are replaced, or valves are ground.

12. Install valve covers as outlined in this section.

13. Install exhaust manifolds as outlined in this section. Tighten retaining bolts to 20-30 Nm (15-22 lb/ft).
Install inlet pipe retaining nuts, tighten to 39-42 Nm (30-32 lb/ft).

14. Apply Cup Plug Sealer meeting Ford specification ESE-M4621-A or equivalent to cylinder block.
Install oil level indicator tube into cylinder block. Oil level indicator tube must bottom out as illustrated.
Tighten oil level indicator tube retaining nut at exhaust manifold stud bolt to 16-20 Nm (12-14 lb/ft).

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15. Install fuel charging wiring (9D930) to fuel injectors and inboard rocker arm cover studs. Connect fuel
charging wiring to engine control sensor wiring (12A581) and secure with retaining features.

16. Install throttle body and new intake manifold gasket (9439) as outlined. Refer to Section 03-04B .

17. If left cylinder head was removed, perform the following:

a. Install three bolts securing power steering pump support bracket to front of left cylinder head,

finger tight only.

b. Install stud bolt at left side of power steering pump support bracket. Tighten all five bolts

securing power steering pump support bracket to engine block and cylinder head to 40-62 Nm

(30-46 lb/ft).

strategy.

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c. Install fuel line retaining bracket to stud bolt on left side of power steering pump support

bracket and secure with nut. Tighten nut to 16-20 Nm (12-15 lb/ft).

18. If right cylinder head was removed, perform the following:

a. Install generator (GEN) (10300) and generator bracket assembly. Tighten three retaining bolts

to 48 Nm (35 lb-ft).
b. Install generator brace and tighten nuts to 26-35 Nm (20-25 lb-ft).
c. Connect generator voltage regulator wiring.

19. On Ranger only:

a. Position A/C compressor and hose assembly on power steering pump support bracket. Install

4 bolts securing A/C compressor to power steering pump support bracket and tighten four

fasteners to 21-29 Nm (15-21 lb/ft).
b. Remove plugs and caps from all openings in the air conditioning system.
c. Connect liquid line at condenser and suction hose to accumulator.
d. Evacuate and recharge A/C system. Refer to Section 12

20. Install engine accessory drive belt.

21. Install ignition coil and bracket assembly to throttle body stud bolts and pencil brace at exhaust
manifold. Tighten three nuts to 16-20 Nm (12-14 lb/ft).

-00 .

22. Connect fuel lines to fuel injection supply manifold (9F792) as outlined in Section 03-04A . Install fuel
tube clips.

23. Connect upper radiator hose and heater water hoses. Tighten hose clamps securely. Refer to Section

03-03 .

24. Connect vacuum lines to premarked locations.

25. Install engine oil filler adapter (Aerostar only).

26. NOTE: Engine coolant is corrosive to all engine bearing material. Replacing engine oil after
removal of a coolant-carrying component prevents failure later.

Drain and change engine oil.

27. Install air cleaner outlet tube to throttle body and engine air cleaner (ACL) (9600). Tighten clamps
securely. Refer to Section 03-12 .

28. Install closure hose at air cleaner outlet tube and valve cover (6582).

29. CAUTION: This engine has aluminum components and requires a special corrosion-

inhibiting coolant formulation to avoid radiator damage. Refer to Section 03-03 for coolant
specifications.

Fill and bleed cooling system.

30. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

symptoms may occur while the powertrain control module (PCM) (12A650) relearns its
adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the

Connect ground cable at battery.

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31. Start engine and check for coolant, fuel, oil, vacuum and exhaust leaks.

32. Verify base ignition timing as outlined.

33. Check and, if necessary, adjust speed control linkage.

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

A

Vibration Damper and Seal Replacer

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IN-VEHICLE SERVICE

Crankshaft Pulley/Vibration Damper/Crankshaft Front Seal

SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number

Front Cover Seal Replacer T70P-6B070­Crankshaft Damper Remover T58P-6316-D
Vibration Damper Remover Adapter T82L-6316-B

T82L-6316-A

Removal

1. Disconnect ground cable at battery and set aside.

2. Remove air cleaner outlet tube assembly.

3. Remove drive belts.

4. Remove four pulley-to-damper retaining bolts.

5. Remove crankshaft pulley (6312).

6. Remove crankshaft vibration damper bolt and crankshaft vibration damper washer.

7. Remove crankshaft vibration damper from crankshaft (6303) using Crankshaft Damper Remover
T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B.

8. Pry crankshaft front seal (6700) from engine front cover (6019) with a flat-bladed screwdriver or other
similar tool. Use care to prevent damage to engine front cover and crankshaft.

strategy.

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Installation

1. Inspect front cover and shaft seal surface of the crankshaft damper for damage, nicks, burrs or other
roughness which may cause the new seal to fail. Service or replace components as necessary.

2. Lubricate seal lip with clean engine oil and install crankshaft front seal using Vibration Damper and
Seal Replacer T82L-6316-A and Front Cover Seal Replacer T70P-6B070-A.

3. Coat crankshaft damper sealing surface with clean engine oil. Apply RTV F4AZ-19562-B or
equivalent meeting Ford specification WSE-M4G323-A1 using Rotunda Gasket Gun with Regulator
071-R0001 or equivalent to keyway of damper prior to installation. Install crankshaft vibration damper
using Vibration Damper and Seal Replacer T82L-6316-A. Install crankshaft vibration damper bolt and
crankshaft vibration damper washer and tighten to 125-165 Nm (92-122 lb-ft).

4. Position crankshaft pulley and install attaching bolts. Tighten attaching bolts to 32 Nm (24 lb-ft).

5. Install engine (6007) accessory drive belt (8620) and route as illustrated. Check to ensure drive belt is
riding in ribbed pulley correctly or early failure will result.

6. Install air cleaner outlet tube.

7. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

symptoms may occur while the powertrain control module (PCM) (12A650) relearns its
adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the

Connect ground cable at battery.

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8. Start engine and check for oil leaks.

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

Tool Number

Fan Clutch Holding Tool

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IN-VEHICLE SERVICE

Water Pump

SPECIAL SERVICE TOOL(S)
REQUIRED

Description

T84T-6312-C

Fan Clutch Nut Wrench T84T-6312-D

Removal

1. Disconnect ground cable at battery and set aside.

2. Remove engine air cleaner outlet tube.

3. CAUTION: Fan clutch has left-hand threads so nut must be turned clockwise to remove.

Loosen nut on fan clutch using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Nut Wrench
T84T-6312-D and remove fan blade and clutch assembly from water pump (8501).

4. Remove 2 screws holding fan shroud to radiator (8005). Remove fan blade and clutch assembly and
fan shroud together.

5. Drain cooling system.

6. Loosen, do not remove, 4 water pump pulley (8509) retaining screws.

7. Rotate engine drive belt tensioner clockwise and remove engine drive belt (8620).

8. Remove 4 water pump pulley retaining screws and water pump pulley.

9. Remove 3 electrical connectors at generator (GEN) (10300).

10. On Aerostar only, remove oil fill tube retaining nut at generator stud and lift tube from stud.

11. Remove 3 bolts retaining generator bracket to cylinder head (6049) and remove generator and
bracket as an assembly.

Engine Accessory Installation, 3.0L, Ranger

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Item Part Number Description

1 N606068-S2 Bolt
2 10300 Generator
3 10153 Generator Mounting Bracket
4 N806020-S2 Bolt
5 19703 A/C Compressor
6 6312 Crankshaft Pulley
7 3A674 Power Steering Pump
8 N807551-S100 Bolt
9 N807123-S2 Stud
10 N605805-S2 Bolt
11 2882 A/C Compressor Mounting Bracket

12 N800199-S8M Bolt

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13 3A733 Power Steering Pump Pulley
14 6B209 Drive Belt Tensioner
15 N60608-S2 Bolt
16 N807124-S2 Bolt
17 3F671 Belt Adjuster
18 N802096-S2 Bolt
19 8509 Water Pump Pulley
A — Tighten to 40-55 Nm

(30-41 Lb-Ft)

B — Tighten to 21-29 Nm

(15-21 Lb-Ft)

C — Tighten to 53-72 Nm

(39-53 Lb-Ft)

12. Disconnect crank position sensor (CKP) wiring.

13. Remove heater water return hose at water pump.

14. Remove bypass hose from fitting at intake manifold (9424).

15. CAUTION: Use care not to damage the throttle linkage or fuel lines.

On Ranger only, remove 3 screws securing A/C compressor to power steering pump support bracket.
Using a piece of wood bridged from the top of the battery to the throttle body (9E926), suspend the
A/C compressor with a wire tie or other suitable material.

16. Using a Torx® 50 driver, remove enginedrive belt tensioner (6B209) assembly.

17. On Aerostar only, if equipped with auxiliary heater, remove screw retaining auxiliary heater tube
bracket at power steering pump support bracket.

18. Remove lower radiator hose at radiator and water pump.

19. Remove 5 screws retaining power steering pump support bracket to the engine (6007) and secure
power steering pump and bracket assembly toward battery tray.

20. Remove 12 water pump retaining bolts and note bolt location.

21. Remove water pump and discard old water pump gasket.

nstallation

I

NOTE: Lightly oil all bolts and stud threads before installation except those requiring special
sealant.

1. Clean gasket surfaces on engine front cover (6019) and water pump carefully. (Use care as

aluminum gouges easily.)

Item

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2. Position a new gasket on water pump sealing surface using Gasket and Trim Adhesive D7AZ­19B508-B or equivalent meeting Ford specification ESE-M2G52-A to hold gasket in position.

3. Install water pump on engine front cover and hand-tighten 12 attaching bolts. Refer to Engine Front

Cover in this section for tightening specifications.

4. Reinstall lower radiator hose at water pump and radiator and tighten clamps.

5. Reinstall power steering pump support bracket to engine and torque to (5 fasteners) (Ranger) 48-61
Nm (35-45 lb-ft) or (3 fasteners) (Aerostar) 40-54 Nm (30-40 lb-ft).

Power Steering Support Bracket — Aerostar

Part

Number Description

1 3A674 Power Steering Pump
2 3C511 Power Steering Pump Support
3 N800199-

S309
4 3A733 Power Steering Pump Pulley
5 6B209 Drive Belt Tensioner
6 N606068- Bolt

Bolt

S309

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7 3F671 Power Steering Belt Idler Support
A — Tighten to 40-55 Nm

(30-41 Lb-Ft)

B — Pulley with Pull-Off Groove Facing Front, Flush with

End of Shaft + /- .25mm
(0.018 Inch)

C — Tighten to 30-50 Nm

(22-37 Lb-Ft)

Power Steering Support Bracket — Ranger

Item Part Number Description

1 6049 Cylinder Head
2 3A674 Power Steering Pump
3 N807123-S2 Stud
4 N605805-S2 Bolt
5 — Power Steering Bracket (Part of 3A674)
6 N800199 Bolt
7 3A733 Power Steering Pump Pulley
8 N606068-S2 Bolt
9 6B209 Drive Belt Tensioner
10 N807124-S2 Bolt
11 3F671 Power Steering Belt Idler Support
12 N807551-S100 Bolt (4 Places)

13 N602098-S2 Screw and Washer

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14 8509 Water Pump Pulley
15 6312 Crankshaft Pulley
A — Tighten to 40-55 Nm

(30-41 Lb-Ft)

B — Tighten to 53-72 Nm

(39-53 Lb-Ft)

C — Tighten to 21-29 Nm

(16-21 Lb-Ft)

6. Reinstall engine accessory drive belt tensioner and torque to 35-45 Nm (27-33 lb-ft).

7. On Ranger only, install A/C compressor to steering pump support bracket with 3 bolts and torque to
22-28 Nm (17-21 lb-ft).

8. Reconnect bypass hose to fitting on intake manifold and tighten clamp.

9. Install heater water return hose at water pump fitting and tighten clamp.

10. On Aerostar only, if equipped with auxiliary heater, reinstall auxiliary heater tube bracket at power
steering pump support bracket and torque to 8-12 Nm (6-8 lb-ft).

11. Connect crank position sensor (CKP) wiring at sensor.

12. Reinstall generator and bracket assembly to right cylinder head with 3 bolts and torque to 40-54 Nm
(30-40 lb-ft).

Front End Accessory Drive, Upper — Aerostar

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Item Part Number Description

1 6049 Cylinder Head (RH)
2 N606068-S309 Bolt
3 N806209-S309 Stud
4 10A313 Generator Bracket
5 10300 Generator
6 N802827-S309 Nut
7 N606706-S309 Bolt
8 N606070-S309 Bolt
9 3F671 Power Steering Belt Idler Support
10 8680 Belt Idler Bracket
11 — A/C Compressor Bracket (Part of 19703)
12 N605801-S309 Bolt
13 19703 A/C Compressor
14 N806020-S309 Bolt
A — Tighten to 40-55 Nm

(30-41 Lb-Ft)

B — Tighten to 21-29 Nm

(16-21 Lb-Ft)

Front End Accessory Drive, Upper — Ranger

Front End Accessory Drive, Drive Belt Routing

— Aerostar

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Item Part Number Description

1 N606068-S2 Bolt
2 10300 Generator
3 10A313 Generator Bracket
4 N606065-S2 Bolt
5 6049 Cylinder Head (RH)
A — Tighten to 40-55 Nm

(30-41 Lb-Ft)

13. Reconnect 3 wiring connectors in generator.

14. Install oil fill tube bracket over stud at generator and torque retaining nut to 42-50 Nm (32-37 lb-ft).

15. Install water pump pulley on water pump hub and tighten bolts finger-tight.

16. Wrap engine accessory drive belt around all pulleys except generator. Rotate belt tensioner clockwise
and when belt clears, slip over alternator pulley.

Front End Accessory Drive, Drive Belt Routing

— Ranger

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Item Part Number Description

1 3F671 Power Steering Belt Idler Support
2 3A733 Power Steering Pump Pulley
3 6B209 Drive Belt Tensioner
4 8620 Drive Belt
5 6312 Crankshaft Pulley
6 8509 Water Pump Pulley
7 — Idler (Part of 8A620)
8 19703 A/C Compressor
9 10300 Generator

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Item Part Number Description

1 19703 A/C Compressor
2 3A733 Power Steering Pump Pulley
3 6B209 Drive Belt Tensioner
4 8620 Drive Belt
5 6312 Crankshaft Pulley
6 8509 Water Pump Pulley
7 10300 Generator
8 3F671 Power Steering Belt Idler Support

17. Torque water pump pulley bolts to 23-32 Nm (18-24 lb-ft).

18. Place radiator fan and clutch assembly in fan shroud and slide fan shroud into position. Lower edge

of fan shroud should locate in clips at bottom of radiator. Secure top of fan shroud with 2 screws and

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torque to 6-8 Nm (53-71 lb-in).

19. CAUTION: Fan clutch has left-hand threads so nut must be turned clockwise to remove.

Install fan clutch on water pump hub and torque to 41-135 Nm (30-100 lb-ft) using Tool T84T-6312-C
and Fan Clutch Nut Wrench T84T-6312-D.

20. Reinstall engine air cleaner outlet tube and tighten clamps.

21. Fill engine cooling system to specified level. Refer to Section 03

22. Reconnect ground cable at battery.

23. Start vehicle and check for leaks. Allow engine to reach operating temperature and verify no fluid
leaks. Shut off engine, check and correct all fluid levels.

-03 .

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

Tool Number

Vibration Damper and Seal Replacer

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IN-VEHICLE SERVICE

Engine Front Cover

SPECIAL SERVICE TOOL(S) REQUIRED

Description

Fan Clutch Holding Tool T84T-6312-C
Fan Clutch Nut Wrench T84T-6312-D

T82L-6316-A
Vibration Damper Remover Adapter T82L-6316-B
Crankshaft Damper Remover T58P-6316-D

Removal

1. Disconnect ground cable at battery and set aside.

2. NOTE: Engine front cover (6019) can be removed with water pump (8501) installed. To perform

this operation, do not remove bolts 11 through 15 in the Fastener Location, Water Pump Front
Cover illustration.

Remove water pump as outlined in this section (if required).

3. Raise vehicle on hoist.

4. On Aerostar only, remove 4 screws holding A/C compressor (19703) to engine bracket and support
compressor to sidemember of engine compartment.

5. On Aerostar only, remove 3 screws securing A/C compressor bracket to cylinder blocks (6010) and 2
nuts in front at timing cover studs.

Engine Accessory Installation, 3.0L — Ranger

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Item Part Number Description

1 N606068-S2 Bolt
2 10300 Generator
3 10153 Generator Mounting Bracket
4 N806020-S2 Bolt
5 19703 A/C Compressor
6 6312 Crankshaft Pulley
7 3A674 Power Steering Pump
8 N807551-S100 Bolt
9 N807123-S2 Stud
10 N605805-S2 Bolt
11 2882 A/C Compressor Mounting Bracket

12 N800199-S8M Bolt

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13 3A733 Power Steering Pump Pulley
14 6B209 Drive Belt Tensioner
15 N60608-S2 Bolt
16 N807124-S2 Bolt
17 3F671 Belt Adjuster
18 N802096-S2 Bolt
19 8509 Water Pump Pulley
A — Tighten to 40-55 Nm

(30-41 Lb-Ft)

B — Tighten to 21-29 Nm

(15-21 Lb-Ft)

C — Tighten to 53-72 Nm

(39-53 Lb-Ft)

Engine Accessory Installation, Upper— Aerostar

Item Part Number Description

1 6049 Cylinder Head (RH)
2 N606068-S309 Bolt
3 N806209-S309 Stud
4 10A313 Generator Bracket

5 10300 Generator

Item

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6 N802827-S309 Nut
7 N606706-S309 Bolt
8 N606070-S309 Bolt
9 3F671 Power Steering Belt Idler Support
10 8680 Belt Idler Bracket
11 — A/C Compressor Bracket (Part of 19703)
12 N605801-S309 Bolt
13 19703 A/C Compressor
14 N806020-S309 Bolt
A — Tighten to 40-55 Nm

(30-41 Lb-Ft)

B — Tighten to 21-29 Nm

(16-21 Lb-Ft)

Engine Accessory Installation, Lower — Aerostar

Part

Number Description

1 3A674 Power Steering Pump
2 3C511 Power Steering Pump Support
3 N800199- Bolt

S309

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4 3A733 Power Steering Pump Pulley
5 6B209 Drive Belt Tensioner
6 N606068-

S309
7 3F671 Power Steering Belt Idler Support
A — Tighten to 40-55 Nm

B — Pulley with Pull-Off Groove Facing Front, Flush with

C — Tighten to 30-50 Nm

6. Remove 4 screws retaining crankshaft pulley (6312) and remove pulley.

7. Remove bolt and washer retaining crankshaft damper to crankshaft.

8. Remove crankshaft vibration damper from crankshaft (6303) using Crankshaft Damper Remover
T58P-6316-D and Damper Remover Adapter T82L-6316-B.

9. Drain engine oil from crankcase.

10. Remove oil pan (6675) as outlined in this section and discard oil pan gasket (6710).

Bolt

(30-41 Lb-Ft)

End of Shaft + /- .25mm
(0.018 Inch)

(22-37 Lb-Ft)

11. Lower vehicle.

Fastener Location, Water Pump Front Cover

Fastener and Hole No.

Ft

M8 x 1.25 x 72.25

30

22

M8 x 1.25 x 72.25

30

22

S8

30

22

S8

30

22

30

22

M8 x 1.25 x 104.3

30

22

S8

30

22

S8

30

22

S8

30

22

S2

30

22

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Fasteners

Part No. Size Nm Lb-

1
2
3

a

a

a

N804215
N804215

N804811-

20­20-

M8 x 1.25 x 73.0 20-

15­15­15-

4 N804811­5 N804811 M8 x 1.25 x 73.0 20­6 N807515
7 N804811­8 N804811­9 N804811-

10 N606543-

M8 x 1.25 x 73.0 20-

20­M8 x 1.25 x 73.0 20­M8 x 1.25 x 73.0 20­M8 x 1.25 x 70.0 20­M8 x 1.25 x 52.0 20-

15­15­15­15­15­15­15-

11 N804576-

S8

S8

S8

S8

S8

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M6 x 1.0 x 28.5 8-12 6-8
12 N804576­13 N804576­14 N804576­15 N804576-

a

Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specifications WSK-

M2G350-AZ and ESR-M18P7-A to fastener threads.

12. Remove remaining bolts in engine front cover and remove cover. Discard old engine front cover
gasket (6020).

13. Pry crankshaft front seal (6700) from engine front cover with a flat-blade screwdriver or similar tool.
Use care to prevent damage to engine front cover.

14. While timing cover is off, inspect timing chain and sprockets to ensure continued service as outlined
in Section 03

Installation

CAUTION: Aluminum components gouge easily, which may result in gasket leaks. Always use

care when servicing aluminum gasket surfaces.

-00 .

M6 x 1.0 x 28.5 8-12 6-8
M6 x 1.0 x 28.5 8-12 6-8
M6 x 1.0 x 28.5 8-12 6-8
M6 x 1.0 x 28.5 8-12 6-8

Engine Front Cover

NOTE: Lightly oil all bolt threads except those requiring special sealants.

1. If crankshaft front seal is to be replaced, follow instructions outlined in this section.

2. Clean gasket surfaces on cylinder blocks and engine front cover.

3. Align new engine front cover gasket on cylinder blocks dowel pins. Note bolts that require pipe

Fastener and Hole No.

Ft

M8 x 1.25 x 72.25

30

22

M8 x 1.25 x 72.25

30

22

S8

30

22

S8

30

22

S8

30

22

M8 x 1.25 x 104.3

30

22

S8

30

22

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sealant on accompanying chart.

Fasteners

Part No. Size Nm Lb-

a

1

a

2

a

3

4 N804811­5 N605909­6 N807515
7 N804811-

N804215
N804215

N804811-

20-

20­M8 x 1.25 x 73.0 20­M8 x 1.25 x 73.0 20-

M8 x 1.25 x 73.0 20-

20­M8 x 1.25 x 73.0 20-

15­15­15­15-

15­15­15-

8 N804811-

S8

30

22

S8

30

22

S2

30

22

S8

S8

S8

S8

S8

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M8 x 1.25 x 73.0 20-

15-

9 N804811­10 N606543­11 N804576­12 N804576­13 N804576­14 N804576­15 N804576-

a

Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specifications WSK-

M2G350-AZ and ESR-M18P7-A to fastener threads.

4. Install engine front cover and attaching bolts. Refer to the previous illustration. Tighten bolts 1 through
10 to 20-30 Nm (15-22 lb-ft) and bolts 11 through 15 to 8-12 Nm (6-8 lb-ft).

5. Raise vehicle.

6. Install oil pan as outlined in this section.

7. Coat crankshaft vibration damper sealing surface with clean engine oil. Apply RTV or equivalent
meeting Ford specification ESE-M4G195-B, using Rotunda RTV Dispenser 021-00031, to keyway of
damper prior to installation. Install damper using Damper/Front Cover Seal Installer T82L-6316-A.
Install crankshaft pulley bolt (6A340) and crankshaft pulley retaining washer (6378) and torque to
125-165 Nm (94-123 lb-ft).

M8 x 1.25 x 70.0 20­M8 x 1.25 x 52.0 20-

M6 x 1.0 x 28.5 8-12 6-8
M6 x 1.0 x 28.5 8-12 6-8
M6 x 1.0 x 28.5 8-12 6-8
M6 x 1.0 x 28.5 8-12 6-8
M6 x 1.0 x 28.5 8-12 6-8

15­15-

8. Install crankshaft pulley and torque 4 screws to 53-70 Nm (40-52 lb-ft).

9. On Aerostar only, position A/C compressor bracket over 2 engine front cover studs and install 2 nuts
on engine front cover studs and 3 screws into engine block bosses. Torque all A/C compressor
bracket retainers to 41-54 Nm (31-40 lb-ft).

10. Detach A/C compressor from sidemember of engine compartment and secure to A/C compressor
bracket with 4 screws. Torque fasteners to 22-28 Nm (17-21 lb-ft).

11. Lower vehicle.

12. Install water pump as outlined in this section (if removed).

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Install timing chain sprocket bolt and crankshaft pulley retaining washer (6378). Tighten bolt to 55

-

70

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Timing Chain, Sprockets, Tensioners and Guides

Removal

1. Disconnect ground cable at battery and set aside.

2. Remove engine front cover (6019) as outlined in this section.

3. Rotate crankshaft (6303) until No. 1 piston (6108) is at top dead center (TDC) and the timing marks
are aligned as illustrated.

4. Check timing chain deflection for excessive wear as outlined in Section 03

5. Slide camshaft sprocket (6256), crankshaft sprocket (6306) and timing chain forward and remove as
an assembly.

6. Clean timing cover and oil pan sealing surfaces of all gasket material and silicone sealer.

-00 .

Installation

1. Clean and inspect all parts before installation.

2. Slide camshaft sprocket, crankshaft sprocket and timing chain on as an assembly with timing marks
aligned as illustrated.

3. NOTE: The timing chain sprocket bolt has a drilled oil passage for timing chain lubrication. If
damaged, do not replace with standard bolt. Clean oil passage with solvent.

Nm (41-52 lb-ft). Lubricate chain and sprockets with engine oil.

10.

Install crankshaft vibration damper and crankshaft pulley as outlined in this section.

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Item Part Number Description

1 6279 Camshaft Sprocket Bolt
2 6256 Camshaft Sprocket
3 6306 Crankshaft Sprocket
4 6268 Timing Chain/Belt
5 6278 Camshaft Sprocket Washer
A — Tighten to 55-70 Nm

(41-52 Lb-Ft)

4. Inspect crankshaft front seal (6700) for burrs or cuts. If required, replace seal using Front Cover Seal
Installer T70P-6B070-A.

5. Position engine front cover gasket (6020) onto cylinder block alignment dowels.

6. Install engine front cover onto cylinder blocks (6010) using caution to not damage crankshaft front
seal.

7. Install retaining bolts and tighten as outlined in this section.

8. Install oil pan (6675) and new oil pan gasket (6710) as outlined in this section.

9. Install water pump (8501) if removed.

11. Install front end accessory drive components as outlined. Refer to Section 03-05 for routing and

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tension of drive belt.

12. Fill crankcase with the correct viscosity and weight engine oil.

13. CAUTION: This engine has aluminum components and requires a special corrosion-

inhibiting coolant formulation to avoid radiator damage. Refer to Section 03-03 for coolant
specifications.

Fill and bleed cooling system.

14. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

symptoms may occur while the powertrain control module (PCM) (12A650) relearns its
adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the
strategy.

Connect battery ground cable (14301).

15. Start engine (6007) and check for coolant, oil and exhaust leaks.

NOTE: Lightly oil all retaining bolt and stud threads before installation except those specified for

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Camshaft

Removal

1. NOTE: On 3.0L Aerostar it is necessary to remove the engine (6007) from the vehicle to
perform this procedure. Refer to Engine Assembly, Aerostar
section.

Disconnect ground cable at battery and set aside.

2. Rotate crankshaft (6303) so No. 1 piston is at 0 degrees at Top Dead Center (TDC) on the
compression stroke.

3. Remove radiator as outlined in Section 03-03 .

4. Recover A/C refrigerant and remove A/C condenser core as outlined in Section 12-00 .

5. Remove engine front cover (6019) and timing chain and sprockets as outlined in this section.

6. Remove intake manifold (9424) and valve covers (6582) as outlined in this section.

, Removal and Installation, in this

7. Loosen rocker arm bolts enough to allow the rocker arms (6564) to be lifted off the push rod (6565)
and rotated to one side.

8. Remove push rods. Identify each push rod's location. The push rods should be installed in their
original location and position during reassembly.

9. Loosen roller tappet guide plate retainer bolts (2). Remove tappet guide plate retainer from tappet
valley.

10. Remove valve tappet guide plates (6K512) from valve tappets (6500) by lifting straight up.

11. NOTE: If the valve tappets are stuck in the bores due to excessive varnish or gum deposits, it

may be necessary to use a claw-type tool to aid removal. Work the valve tappet up and down
in the bore to loosen it from the deposits.

Remove valve tappets by grasping each valve tappet and pulling in line with bore.

12. Remove the two camshaft thrust plate retaining bolts and camshaft thrust plate (6269).

13. CAUTION: Damage to camshaft bearings and/or camshaft can occur if camshaft is
allowed to drop on bearing surface or cylinder block.

Remove camshaft (6250) by pulling slowly toward front of engine keeping camshaft perfectly in line
with camshaft bores.

Installation

special sealant.

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1. CAUTION: Aluminum components gouge easily which can cause 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
valley preventing any particles from entering oil drain holes or cylinder head. Use a suitable solvent to
remove old rubber sealant. Clean gasket mating surfaces of engine front cover to cylinder block.

2. Inspect camshaft bearings for wear. Replace as outlined in this section.

3. Clean and inspect all components before installation.

4. Lubricate camshaft lobes, bearing surfaces, and distributor drive gear liberally with Engine Assembly
Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

5. Slide camshaft through bearings into cylinder blocks (6010) remembering to keep camshaft perfectly
in line with front bearing.

6. Lubricate camshaft thrust plate with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting
Ford specification ESR-M99C80-A and install with two retaining bolts. Tighten bolts to 8-12 Nm (6-8
lb-ft).

7. If installing a new camshaft, check end play as specified in Section 03-00 . If clearance is excessive,

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replace camshaft.

8. CAUTION: Do not replace camshaft sprocket bolt (6279) with a standard bolt or severe
engine damage will occur. This bolt is an oil carrying, precision component.

Lubricate timing chain and sprockets with Engine Assembly Lubricant D9AZ-19579-D or equivalent
meeting Ford specification ESR-M99C80-A and install as an assembly. Align marks as illustrated.
Inspect camshaft sprocket (6256) for blockage of drilled oil passages and clean as required. Install
camshaft sprocket bolt and washer and tighten to 50-70 Nm (37-52 lb-ft).

9. Lubricate valve tappets and bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent
meeting Ford specification ESR-M99C80-A.

10. Install valve tappets into original bores.

11. NOTE: Install valve tappet guide plates with the word "UP" or button visible.

Aligning tappet flats, install valve tappet guide plates.

12. Install tappet guide plate and retainer (6K564) over valve tappet guide plates. (NOTE: Retainer
orientation is not important.) Hand-start two retaining bolts. Tighten bolts to 10-14 Nm (7-10 lb-ft).

13. Apply a 5-6mm drop of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification
ESB-M4G92-A or ESE-M4G195-A to intersection of cylinder block and cylinder head assembly at four
corners.

14. Position intake manifold gaskets (9439) on tocylinder heads. Align the intake gasket locking tabs to
the provisions on the head gaskets (6051).

15. Install front and rear intake manifold seals. Secure with retaining features.

16. Lower intake manifold into position aligning manifold bolt holes to those in the cylinder head. Use
care to prevent disturbing the rubber sealer which can cause sealing voids. Install bolts 1, 2, 3 and 4
and hand-snug. Install remaining bolts. Tighten in numerical sequence to 15 Nm (11 lb-ft), then again
to 26-32 Nm (19-24 lb-ft).

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17. Completely coat camshaft position sensor gear teeth with Engine Assembly Lubricant D9AZ-19579-D
or equivalent meeting Ford specification ESR-M99C80-A.

18. CAUTION: If a new camshaft is installed, always add the rest of the pint of Engine

Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to
the engine oil by pouring it through the distributor hole onto the camshaft drive gear. Run
engine at idle for five minutes before driving vehicle.

Install camshaft position sensor. Refer to Section 03-14 .

19. Rotate engine socamshaft is in Position A, as shown, with camshaft sprocket timing mark and
crankshaft sprocket timing mark at top center.

20. NOTE: Lubricate each push rod, rocker arm, and rocker arm fulcrum with Engine Assembly

Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before
installing.

Install push rod, rocker arm, rocker arm fulcrum, and rocker arm bolt for valves:

 Cylinder No. 1 Intake

installing.

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 Cylinder No. 2 Exhaust
 Cylinder No. 4 Intake
 Cylinder No. 5 Exhaust

Tighten rocker arm bolts to 11 Nm (8 lb-ft).

21. For valves in above step, check rocker arm-to-valve clearance. Clearance should be 2.15-4.69mm
(0.084-0.184 in.).

Camshaft Position A — Rocker Arm, Push Rod, and Fulcrum Installation

Item Part Number Description

1 — Centerline of Keyway Vertical Within Five Degrees
2 — Camshaft Sprocket Timing Mark at Top Center
3 — Crankshaft Sprocket Timing Mark at Top Center
4 6564 Rocker Arm, No. 1 Intake
5 6565 Push Rod
6 6A528 Rocker Arm Fulcrum
7 6A527 Rocker Arm Bolt
8 6564 Rocker Arm and Parts
9 6564 Rocker Arm and Parts
10 6564 Rocker Arm and Parts
A — Tighten to 11 Nm

(8 Lb-Ft)

22. Rotate engine so camshaft is in Position B, as shown, with camshaft sprocket timing mark at two
o'clock position and crankshaft sprocket timing mark at 4:30 position.

23. NOTE: Lubricate each push rod, rocker arm, and rocker arm fulcrum with Engine Assembly

Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A before

Install push rod, rocker arm, rocker arm seat (6A528), and rocker arm bolt for valves:

Item

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 Cylinder No. 1 Exhaust
 Cylinder No. 2 Intake
 Cylinder No. 3 Exhaust
 Cylinder No. 3 Intake
 Cylinder No. 4 Exhaust
 Cylinder No. 5 Intake
 Cylinder No. 6 Exhaust
 Cylinder No. 6 Intake

Tighten rocker arm bolts to 11 Nm (8lb-ft).

24. For valves in above step, check rocker arm-to-valve clearance. Clearance should be 2.15-4.69mm
(0.084-0.184 in.).

Camshaft Position B — Rocker Arm, Push Rod, and Fulcrum Installation

Part

Number Description

1 — Centerline
2 — Camshaft Sprocket Timing Mark at Two o'Clock

Position
3 — Crankshaft Sprocket Timing Mark at 4:30 Position
4 6564 Rocker Arm (No. 1 Exhaust Rocker Arm and Parts)
5 6564 Rocker Arm (No. 2 Intake Rocker Arm and Parts)
6 6564 Rocker Arm (No. 3 Exhaust Rocker Arm and Parts)
7 6564 Rocker Arm (No. 3 Intake Rocker Arm and Parts)
8 6564 Rocker Arm (No. 6 Exhaust Rocker Arm and Parts)
9 6564 Rocker Arm (No. 6 Intake Rocker Arm and Parts)
10 6564 Rocker Arm (No. 5 Intake Rocker Arm and Parts)
11 6564 Rocker Arm (No. 4 Exhaust Rocker Arm and Parts)

25. CAUTION: Rocker arm fulcrum must be fully seated into cylinder head and push rod

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must be fully seated into lifter sockets before final tightening.

Final-tighten allrocker arm bolts (6A527) to 26-38 Nm (19-28 lb-ft) with camshaft in any position.

26. Installengine front cover including oil pan (6675), crankshaft vibration damper and front accessory
components as outlined in this section for Aerostar or Ranger.

27. On Ranger vehicles, position the air conditioning hose and manifold assembly in engine compartment
with hoses as originally routed with no kinks or binds.

28. Remove all caps and plugs. Push suction hose into coupling on accumulator and liquid line into
coupling on condenser.

29. Position hose assembly manifold to A/C compressor and install retaining bolt. Tighten to 25-30 Nm
(18-22 lb-ft).

30. Evacuate and recharge air conditioning system as outlined in Section 12

31. Install valve covers as outlined in this section.

32. Install fuel injector electrical harness to each injector. Secure with standoffs to inboard rocker arm
cover studs.

33. Install throttle body (9E926) as outlined in Section 03-04B .

34. Install ignition coil and bracket assembly (Ranger only). Tighten retaining nuts to 16-20 Nm (12-15 lb­ft).

-00 .

35. Position the EGR tube in the EGR valve and start the first few threads of the flare nut. Install the bolt
at the exhaust manifold end and tighten to 20-30 Nm (15-22 lb-ft). Tighten the flare nut to 35-65 Nm
(26-48 lb-ft).

36. Connect two pressure differential hoses from the EGR pressure sensor to the EGR tube.

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EGR Tube — Ranger

Item Part Number Description

1 — Throttle Body
2 — Transducer Hose
3 — EGR Valve
4 — Bolt & Washer
5 — EGR Tube Upper Fitting
6 — Exhaust Manifold (L.H.)
7 — EGR Valve to Exhaust Manifold Tube
8 — EGR Tube Lower Fitting
A — Tighten to 20-30 Nm (15-22 lb/ft)
B — Tighten to 35-65 Nm 26-48 lb/ft)
C — Tighten to 35-65 Nm (26-48 Lb-Ft)

37. Connect fuel lines tofuel injection supply manifold (9F792) as outlined in Section 03

-04B .

38. Install fuel line safety clips.

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39. Connect vacuum lines to premarked locations.

40. Connect electrical connections of:

 Intake air temperature sensor (IAT sensor) (12A697)
 Idle air control valve (IAC valve) (9F715)
 Engine coolant temperature sensor (ECT sensor) (12A648)
 Camshaft position sensor
 Ignition coil
 Radio ignition interference capacitor (18801)
 Water temperature indicator sender unit (10884)
 EGR pressure sensor, if equipped
 EGR vacuum regulator control, if equipped

Refer to Section 18-01 for further information.

41. Fill and bleed cooling system with specified coolant and proper mixture.

42. Fill crankcase with specified amount and viscosity of oil.

43. Install air cleaner outlet tube to throttle body and MAF sensor (12B579) . Tighten retaining clamps to

1.9 Nm (16 lb-in).

44. Install closure hose to valve cover and air cleaner outlet tube provisions.

45. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

symptoms may occur while thepowertrain control module (PCM) (12A650) relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

Connect ground cable at battery.

46. Start engine and check for coolant, oil, fuel and vacuum leaks.

47. Verify and correct default base initial engine timing to 10 degrees BTDC. Refer to the Powertrain
Control/Emissions Diagnosis Manual. Tighten retaining bolt to 24 Nm (18 lb-ft).

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Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Exhaust Manifolds

Removal

WARNING: ALLOW ENGINE (6007) TO COOL SUFFICIENTLY BEFORE REMOVING MANIFOLDS.

SERIOUS INJURY WILL RESULT FROM CONTACT WITH HOT EXHAUST MANIFOLDS.

1. Disconnect ground cable at battery and set aside.

2. NOTE: Spray retaining nuts with rust penetrant prior to loosening to prevent removal of stud
with nut.

Raise vehicle. Loosen and remove muffler inlet pipe retaining nuts from exhaust manifolds (9430).

3. Lower vehicle.

ight-Hand Side

R

1. Remove spark plugs (12405).

2. Remove exhaust manifold retaining bolts and studs.

3. Remove exhaust manifold from vehicle.

eft-Hand Side

L

1. Disconnect two Delta PFE sensor hoses from EGR valve to exhaust manifold tube (9D477).

2. Loosen EGR tube flare nut at EGR valve (EGR valve) (9D475).

3. On Ranger, remove EGR tube bolt at exhaust manifold. On Aerostar, loosen and remove flare nut at
exhaust manifold connector (9F485).

4. Remove engine oil level indicator dipstick tube retaining nut. Rotate or remove tube out of way.

5. Remove exhaust manifold and exhaust manifold gasket (9448) from vehicle.

Exhaust Manifold Installation

tube prior to installation if tube was removed.

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Item Part Number Description

1 9430 Exhaust Manifold, Right
2 N804468-S Stud
3 N804465-S2 Screw and Washer
4 — Bolt
5 N805702-S2 Hex Flange Stud, M8 x

1.25 x 90
6 9430 Exhaust Manifold, Left
7 — Screw and Washer
A — Tighten to 20-30 Nm

(15-22 Lb-Ft)

Installation

1. Clean mating surfaces of exhaust manifolds and cylinder heads (6049) of carbon deposits.

2. Position right or left exhaust manifold and exhaust manifold gasket in place to cylinder head and
hand-tighten retaining bolts and studs. Tighten to 20-30 Nm (15-22 lb-ft).

3. Rotate or install oil level indicator tube (6754) to appropriate exhaust stud and install retaining nut if
exhaust manifold was removed. Tighten to 16-20 Nm (12-15 lb-ft). Apply ESE-M4G217-A sealer to

4. Install spark plugs. Tighten to 11 Nm (8 lb-ft).

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5. Install EGR tube flare nut into exhaust manifold connector (9F485) (Aerostar) finger tight.

6. Install EGR tube flare nut into EGR valve finger-tight.

7. Install bolt in EGR valve to exhaust manifold tube at exhaust manifold and tighten to 20-30 Nm (15-22
lb-ft).

8. Tighten flare nuts to 35-65 Nm (26-48 lb-ft).

9. Connect two Delta PFE sensor hoses onto ports in EGR tube.

10. Connect exhaust inlet pipe to left exhaust manifold and right exhaust manifold. Tighten retaining nuts
to 41 Nm (30 lb-ft). Tighten both nuts in equal amounts to correctly seat inlet pipe flange.

11. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

symptoms may occur while the powertrain control module (PCM) (12A650) relearns its
adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the
strategy.

Connect ground cable at battery.

12. Start engine and check for oil and exhaust leaks.

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

Tool Number

Engine Lifting Sling

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IN-VEHICLE SERVICE

Oil Pan, Ranger

SPECIAL SERVICE TOOL(S)
REQUIRED

Description

014-00036

Removal

1. Disconnect battery ground cable. For additional information, refer to Section 14-01 .

2. Remove air cleaner outlet tube assembly by unclipping air cleaner clamp, loosening hose clamp at
outlet tube, disconnecting intake air temperature (IAT) sensor and mass air flow (MAF) sensor
connectors, and crankcase ventilation hose.

3. Remove oil level indicator fan shroud retaining bolts. Position shroud over fan blade.

4. Remove radiator support bolts. Raise and secure radiator to front core support.

5. Remove engine mount nuts from studs.

6. Unclip 42-pin connector from bracket and position it aside.

7. Install suitable lifting brackets to left and right exhaust manifolds. Attach Rotunda Engine Lifting Sling
014-00036 (or equivalent) to lifting brackets. With a suitable lifting device raise engine approximately

50.8 mm (2 in). Install wood blocks between engine mounts and support brackets. Remove lifting
device.

8. Raise vehicle on hoist. For additional information, refer to Section 00

9. Drain the oil.

10. Remove transmission insulator retaining nuts and install a jack stand to extension housing. Raise
transmission about 25.4-101.6mm (1-4 in) to gain access for removal of oil pan.

11. Remove transmission inspection cover.

12. Remove starter motor splash shield.

13. Remove starter motor retaining bolts and secure starter aside.

14. If equipped, disconnect and remove low oil level sensor.

-02 .

15. NOTE: Oil pan fits tightly between transmission spacer plate and oil pump pickup tube. Use
care when removing pan to avoid damaging either part.

Remove oil pan bolts and lower pan.

16. Remove oil pump retaining bolts. Lower and twist pump to allow the oil pan to lower completely.

Remove the pump and pan assembly from vehicle.

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17. Remove and discard oil pan gasket.

18. Clean the oil pan mating surface.

Installation

1. NOTE: When using silicone rubber sealer, assembly should occur within 15 minutes after

sealer application. After this time, the sealer may start to set up, and its sealing effectiveness
could be reduced.

Apply a 4.0-6.0 mm (1/5 inch) bead of Silicone Rubber D6AZ-19562-AA or -BA (or equivalent meeting
Ford specifications ESB-M4G92-A and ESE-M4G195-A) to junction of rear main bearing cap and
cylinder block and to junction of front cover assembly and cylinder block. Position oil pan gasket to
cylinder block and secure it with Gasket and Trim Adhesive D7AZ-19B508-B (or equivalent meeting
Ford specifications ESR-M11P17-A and ESE-M2G52-A).

2. Install oil pump assembly and bolt. Tighten bolt to 40-55 Nm (30-40 lb-ft).

3. NOTE: If oil pan is replaced with a new pan you must tighten new pan to spec then loosen and
retighten.

Position oil pan to cylinder block and install oil pan to engine bolts. Tighten bolts to 10-14 Nm (7-10
lb-ft).

4. Remove jack stand and install transmission insulator retaining nuts. Tighten nuts to 85-118 Nm (63­87 lb-ft).

5. NOTE: When replacing low oil level sensor, use a new metal gasket with a rubber O-ring.

Install low oil level sensor. Tighten sensor to 20-34 Nm (15-25 lb-ft).

6. Install transmission inspection cover and retaining bolts. Tighten bolts to 10-14 Nm (7-10 lb-ft).

7. Install starter motor and bolts. Tighten bolts to 22-28 Nm (17-20 lb-ft).

8. Securely install starter motor splash shield.

9. Lower vehicle.

10. Install lifting device and support engine. Remove wood blocks and lower engine back into original
position. Remove lifting device and Rotunda Engine Lifting Sling 014-00036 (or equivalent). Remove
lifting brackets from right and left exhaust manifolds.

11. Remove support straps, lower radiator into position, and install radiator bolts to core support. Position
fan shroud and install the retaining bolts. Tighten bolts to 6-8 Nm (52-71 lb-in).

12. Install engine mount nuts and tighten to 98-132 Nm (72-97 lb-ft).

13. Connect 42-pin connector to the bracket and install oil level indicator.

14. Install engine air cleaner outlet tube assembly. Connect IAT sensor, MAF sensor, and crankcase
ventilation hose. Securely tighten the hose clamp.

15. NOTE: When battery has been disconnected and reconnected, some abnormal drive

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symptoms can occur while powertrain control module (PCM) (12A650) relearns its adaptive
strategy. Vehicle may need to be driven 16 km (10 miles) or more to relearn strategy.

Connect battery ground cable.

16. Fill crankcase with correct viscosity and amount of engine oil.

17. Start engine and check for oil leaks.

Oil Pan Installation — Ranger

Item Part Number Description

1 6010 Cylinder Block
2 6710 Oil Pan Gasket
3 6675 Oil Pan
4 N803159-S Screw and Washer
5 6734 Oil Pan Drain Plug Gasket
6 6730 Oil Pan Drain Plug
7 ESE-M4G195-B Sealer
8 6059 Front Cover
9 — Rear Main Bearing Cap

(Part of 6010)

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A — Tighten to 10-14 Nm

(7-10 Lb-Ft)
B D6AZ-19562-BA Silicone Sealer — 4 Places
C — Stop Bead 3mm from Timing Chain Cavity

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Oil Pan, Aerostar

Removal

1. Disconnect ground cable at battery and set aside.

2. Remove oil level dipstick (6750).

3. Raise vehicle.

4. Remove retainer clip at sensor, if equipped with a low oil level sensor (6C624). Remove electrical
connector from sensor.

5. Drain crankcase.

6. Remove starter motor.

7. Remove transmission as outlined in Section 07

8. Remove oil pan retaining bolts. Remove oil pan (6675).

9. Remove old oil pan gasket (6710) and discard.

Installation

NOTE: Lightly oil all bolt threads before installation.

1. Clean the gasket surfaces on the cylinder blocks (6010) and oil pan.

2. NOTE: When using silicone rubber sealer, assembly should occur within 15 minutes after

sealer application. After this time, the sealer may start to set up, and its sealing effectiveness
may be reduced.

Apply a 4.0-6.0mm (1/5-inch) bead of Silicone Sealer D6AZ-19562-AA or -BA or equivalent meeting
Ford specification ESB-M4G9Z-A to the junction of the rear main bearing cap and cylinder block and
junction of the front cover assembly and cylinder block. See following illustration.

3. Position oil pan gasket to cylinder blocks and secure with Gasket and Trim Adhesive D7AZ-19B508-B
or equivalent meeting Ford specification ESE-M2G52-A.

4. Position oil pan to cylinder block.

-01A .

5. Install oil pan attaching bolts and tighten to 10-14 Nm (7-10 lb-ft).

6. Install transmission as outlined in Section 07

7. Install starter motor and transmission inspection cover.

8. Install low oil level sensor connector to sensor and install retainer clip.

-01A .

9. Lower vehicle.

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10. Replace oil level dipstick.

11. Fill crankcase with correct viscosity and amount of engine oil.

12. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

symptoms may occur while the powertrain control module (PCM) (12A650) relearns its
adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the
strategy.

Connect ground cable at battery.

13. Start engine (6007) and check for engine oil leaks.

Oil Pan Installation — Aerostar

Part Number Description

1 6010 Cylinder Blocks
2 F1AZ-19562-A RTV Sealer (4 Places)

3 6710 Oil Pan Gasket
4 6675 Oil Pan
5 N803159-S Screw and Washer

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6 6734 Oil Pan Drain Plug Gasket
7 6730 Oil Pan Drain Plug
8 6C624 Low Oil Level Sensor
9 6C626 Low Oil Level Sensor Washer
10 6019 Engine Front Cover
11 — Rear Main Bearing Cap

(Part of 6010)

A — Tighten to 27-41 Nm

(20-30 Lb-Ft)

B — Stop Bead 3mm (0.117 In.) from Timing Chain

Cavity

C — 4-6mm (0.156-0.234 In.)

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Oil Pump

Removal

1. Remove oil pan (6675) as outlined.

2. Remove retaining bolt and remove oil pump and intermediate shaft.

nstallation

I

1. NOTE: If replacing oil pump make sure to remove oil pump intermediate shaft (6A618) from oil
pump.

If replacing oil pump (6600), insert oil pump intermediate shaft assembly into hex drive hole in oil
pump until oil pump intermediate shaft retaining ring (6629) "clicks" into place.

2. Install oil pump with oil pump intermediate shaft through intermediate shaft hole in rear main bearing
cap. Position oil pump over locating pins.

3. Install retaining bolt and tighten to 40-55 Nm (30-40 lb-ft).

4. Install oil pan as outlined.

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Crankshaft

Removal

1. Remove engine (6007) from vehicle as outlined in this section, remove flywheel and engine rear
plate, and install on a work stand.

2. Drain crankcase oil.

3. Remove spark plugs (12405).

4. Remove oil pan (6675) as outlined in In-Vehicle procedures in this section.

5. Remove engine front cover (6019) as outlined in In-Vehicle procedures in this section.

6. Check timing chain deflection as outlined in Section 03

7. Remove camshaft sprocket bolt (6279) and camshaft sprocket washer (6278).

8. Remove timing chain/belt (6268), camshaft sprocket (6256) and crankshaft sprocket (6306) as an
assembly. Using one hand on the camshaft sprocket and the other on the crankshaft sprocket, pull
assembly forward and off of camshaft (6250) and crankshaft (6303).

9. Rotate engine 180 degrees on engine stand. Remove oil pump retaining bolt and lift oil pump (6600)
off of bearing cap.

10. NOTE: All main bearing caps are marked with arrows. One arrow identifies No. 1 main bearing

cap, two arrows identify No. 2 cap, etc. All connecting rods (6200) and caps are identified by
matching correlation letters. Connecting rods are not identified to a cylinder number.

Remove connecting rod caps. Rotate crankshaft to position cap to be removed to bottom of stroke.
Loosen and remove two retaining nuts per cap. Place retaining nuts so that they may be reinstalled
on the same rod bolt.

11. Tap cap with a plastic mallet to separate from connecting rod bolt (6214). Remove cap from
crankshaft. If lower bearing remained on crankshaft, carefully grasp both sides of bearing and pull
straight up away from journal (oil acts as an adhesive between two precision fitted components).
Place bearing back into cap and tag for cylinder position number.

12. Install protective rubber caps such as fuel hose onto connecting rod bolts. Using a wooden hammer
handle or similar device, tap piston (6108) into cylinder bore while guiding connecting rod bolt away
from crankshaft. Push assembly in far enough to prevent crankshaft rotation from hitting connecting
rod bolt. Make sure upper connecting rod bearing is still seated in rod.

-00 .

13. Perform above three steps for remaining connecting rod bolts.

14. Loosen and remove crankshaft main bearing cap bolts. Place retaining bolts so that they may be
reinstalled in the original position.

15. Lift crankshaft straight up from cylinder blocks (6010). Make sure crankshaft bearing surfaces are not

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scratched or damaged by contact with cylinder block.

16. NOTE: If crankshaft main bearings (6333) are to be reused, they should be identified to make
sure that they are installed in their original positions.

Remove crankshaft main bearings from cylinder blocks and bearing caps.

17. Remove connecting rod bearing (6211) from the connecting rods and caps.

18. CAUTION: Make sure bearing inserts and bearing bores are clean. Foreign material under
the inserts will distort the bearing and cause a failure.

Inspect all machined surfaces on the crankshaft for nicks, scratches, scores, etc., which could cause
premature bearing wear. Lightly stone all such surfaces.

Crankshaft and Bearing Installation

Part

Number Description

1 E1FZ-

19562-A

Sealer

2 6337 Crankshaft Thrust Main Bearing, Upper

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3 6333 Crankshaft Main Bearing, Rear Upper
4 6303 Crankshaft
5 6337 Crankshaft Thrust Main Bearing, Lower
6 6333 Crankshaft Main Bearing, Rear Lower
7 — Rear Intermediate Cap

(Part of 6010)
8 — Rear Cap (Part of 6010)
9 6345 Crankshaft Main Bearing Cap Stud
10 — Front Intermediate Cap

(Part of 6010)
11 — Front Cap. Assemble Caps with Arrows on Caps

Pointing Forward. Caps Are Identified 1 Through 4

Front to Rear.

(Part of 6010)
12 6333 Crankshaft Main Bearing, Lower
13 6B316 Crankshaft Key
14 6333 Crankshaft Main Bearing, Upper
A — Tighten to 75-85 Nm

(55-63 Lb-Ft)
B — 5-6mm (.20-.24 In.)
C — 2mm (0.08 In.)

Installation

1. If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct
undersize crankshaft main bearings.

2. Place upper main bearing inserts in position in the bores with the tang fitted in the slot provided.

3. Install lower main bearing inserts in bearing caps.

4. Lower crankshaft into place carefully.

5. Check the clearance of each main bearing. Select fit the bearings for proper clearance. Refer to

Section 03-00 .

6. NOTE: Make sure that the main bearing caps are installed in their original positions and
orientation.

After bearings have been fitted, apply a light coat of heavy engine oil, SAE 50, to the journal's
bearings and rear seal surface. Install all bearing caps. Apply a 6mm (1/4-inch) dot of Gasket
Eliminator E1FZ-19562-A or equivalent meeting Ford specification WSK-M2G348-A4 between rear
cap and cylinder block (two places). Refer to the procedure in this section.

7. Lubricate the journal with engine oil and install the thrust bearing cap with the bolts finger-tight. Pry

the crankshaft forward against the thrust surface of the upper half of the bearing. Hold the crankshaft

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cap to the rear. This will align the thrust surfaces of both halves of the bearing. Retain the forward
pressure on the crankshaft. Tighten the crankshaft main bearing cap stud (6345) to 75-85 Nm (55-63
lb-ft).

Thrust Bearings, Alignment

8. Check crankshaft end play. Refer to Section 03

9. If end play exceeds specification, replace upper and lower crankshaft thrust main bearing (6337). If
the end play is less than specification, inspect the bearing and crankshaft thrust faces for damage,
dirt or improper alignment. Install thrust bearing and align the faces. Recheck end play.

10. Install new connecting rod bearings in the connecting rods and caps. Check the clearance of each
bearing. Refer to Section 03

11. If bearing clearances are to specification, apply a light coat of heavy engine oil, SAE 50, to the
journals and bearings.

12. Turn the crankshaft throw to the bottom of the stroke. Push the piston, pin and ring (6102) all the way
down until the rod bearings seat on the crankshaft journal.

13. Make sure connecting rod is seated on crankshaft journal and install connecting rod cap. Tighten
attaching nuts to 31-39 Nm (23-28 lb-ft).

14. After piston, pin and ring and connecting rod assemblies have been installed, check connecting rod
crankshaft journal.

15. Turn engine on the work stand so that the front end is up. Install timing chain/belt, crankshaft,
crankshaft sprockets, engine front cover, new oil seal and crankshaft vibration damper as outlined in
the In-Vehicle part of this section.

-00 .

-00 .

16. Turn engine on the work stand so that the rear end is up. Install crankshaft rear oil seal (6701).

17. Clean oil pan, oil pump and oil pump screen assembly.

18. Prime oil pump by filling the inlet opening with oil and rotating the pump shaft until oil emerges from
the outlet opening. Install oil pump and oil pan as outlined.

19. Position flywheel (6375) on the crankshaft. Tighten to specification.

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20. Install crankshaft pulley. Install and adjust drive belt to specification. Refer to Section 03-05 .

21. Remove engine from the work stand and install in vehicle.

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Crankshaft Main Bearings

The main bearing inserts are a precision selective fit. To check the bearing clearances or to select fit a new
bearing, refer to Section 03-00 .

Removal

1. Disconnect ground cable at battery and set aside.

2. Remove engine accessory drive belt (8620).

3. Remove oil pan (6675) as outlined in this section.

4. Remove oil pump (6600).

5. Replace one bearing at a time, leaving the other bearings securely fastened. Remove main bearing
cap to which new bearings are to be installed.

6. NOTE: Rotate remover against end of crankshaft main bearing (6333) opposite locating tang.

Insert Main Bearing Insert Tool TOOL-6331-E or equivalent in the oil hole in the crankshaft (6303).

7. Rotate crankshaft in the direction of the engine rotation to force the bearing out of the cylinder blocks
(6010).

8. Clean crankshaft journals. Inspect journals and thrust faces (thrust bearings) for nicks, burrs, or
bearing pickup that would cause premature bearing wear.

9. Refer to Crankshaft Rear Oil Seal
replaced.

Installation

NOTE: Lightly oil all bolt and stud threads before installation.

1. Lubricate and position the upper crankshaft main bearing on the crankshaft journal with the plain end
started into the side of the cylinder block with the locking tang slot. Line up the bearing tang with the
slot in the block.

2. Install Main Bearing Insert Tool TOOL-6331-E or equivalent in the crankshaft journal oil hole.

3. With the bearing and tool in position, rotate the crankshaft so that the tool catches the edge of the
bearing, pushes into position, and seats in the cylinder block. Remove tool.

in this section if the crankshaft rear oil seal (6701) is to be

4. Install bearing insert in the main cap.

5. If bearing insert clearance is to be checked, refer to Section 03

6. If No. 1 or No. 2 crankshaft main bearing was removed, lubricate the bearing surface with Engine
Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install

-00 .

main cap. Tighten attaching bolts to 80 Nm (60 lb-ft).

Item

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Crankshaft and Bearings

Part

Number Description

1 E1FZ-

19562-A
2 6337 Crankshaft Thrust Main Bearing
3 6333 Crankshaft Main Bearing, Rear Upper
4 6303 Crankshaft
5 6337 Crankshaft Thrust Main Bearing, Lower
6 6333 Crankshaft Main Bearing, Rear Lower
7 6327 Rear Intermediate Cap

8 — Rear Cap (Part of 6010)
9 6345 Crankshaft Main Bearing Cap Stud
10 — Front Intermediate Cap

Sealer

(Part of 6010)

(Part of 6010)

11 — Front Cap. Assemble Caps with Arrows on Caps

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Pointing Forward. Caps Are Identified 1 Through 4
Front to Rear.

(Part of 6010)
12 6333 Crankshaft Main Bearing, Lower
13 6B316 Crankshaft Key
14 6333 Crankshaft Main Bearing
A — Tighten to 80 Nm

(60 Lb-Ft)
B — 5-6mm (.20-.24 In.)
C — 2mm (0.08 In.)

7. Perform the following if the rear main bearing cap was removed:

a. Remove all traces of sealant from the main bearing cap to cylinder block parting line.
b. Apply a 6mm (1/4-inch) dot of Gasket Eliminator E1FZ-19562-A or equivalent meeting Ford

specification WSKM2G348-A4 between rear cap and cylinder blocks (two places). (See
illustration.)

c. Lubricate bearing surfaces with Engine Assembly Lubricant D9AZ-19579-B or equivalent

meeting Ford specification ESR-M99C80-A. Install main bearing cap. Tighten attaching bolts to
75-85 Nm (55-63 lb-ft).

8. If the thrust bearing inserts were removed, perform the following:

a. Lubricate bearing surface with Engine Assembly Lubricant D9AZ-19579-B or equivalent

meeting Ford specification ESR-M99C80-A, and install the main bearing cap with bolts finger­tight.

b. Pry crankshaft forward against the thrust surface on the upper bearing insert while holding the

bearing cap to the rear. This aligns thrust rear surfaces on both halves of the bearing.

c. While holding the crankshaft forward, tighten cap attaching bolts to 75-88 Nm (55-63 lb-ft).

9. Install oil pump.

10. Install oil pan and new oil pump as outlined.

11. Install engine accessory drive belt.

12. Connect ground cable to battery.

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CAUTION: Use extreme care to prevent scratching or nicking crankshaft journal.

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Pistons and Connecting Rods

Removal

NOTE: If more than one piston (6108) is being removed, identify the piston and connecting rod cap
to the cylinder number. Caps are matched to connecting rods (6200) and are identified with matching
correlation letters as illustrated. Each component should be installed in its original position during
assembly.

1. NOTE: On 3.0L Aerostar it is necessary to remove the engine (6007) from the vehicle to

perform this procedure. Refer to Engine Assembly, Aerostar
section.

Disconnect ground cable at battery and set aside.

2. Remove spark plugs and bring number 1 cylinder to top dead center of compression stroke.

3. Drain cooling system.

, Removal and Installation in this

4. Perform all intake manifold removal steps as outlined in this section.

5. Remove cylinder heads (6049) as outlined in this section. If only one cylinder head is to be removed,
remove spark plugs (12405) from remaining cylinder head.

6. Remove oil pan (6675) as outlined in this section.

7. Loosen and remove retaining bolt and remove oil pump (6600) and oil pump intermediate shaft
(6A618).

8. Inspect the top of the cylinder bore(s) before removing the piston, pin and ring (6102) assembly. If a
ridge has formed at the top of the cylinder, it must be removed before piston extraction. Remove ridge
as follows:

a. Turn crankshaft (6303) until the piston and connecting rod to be removed is at the bottom of

the cylinder bore.
b. Place a clean shop cloth over the piston head to collect cuttings.
c. Remove ridge using a suitable ridge reamer following the manufacturer's instructions. Never

cut into the piston ring travel more than 0.794mm (1/32 inch) when removing the ridge.

9. Loosen connecting rod cap retaining nuts.

10. Rotate crankshaft to place piston and connecting rod assembly at bottom of its travel in bore.

11. Remove connecting rod nuts (6212) from cap. Place connecting rod nut so that they may be
reinstalled on the same rod bolt.

12.

Tap cap with a plastic mallet to separate from connecting rod. Carefully remove cap from crankshaft.

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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

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.

Disassembly in this section if piston, pin and ring is to be disassembled.

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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6. Install piston ring compressor D81L-6002-C or equivalent to piston.

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Item Part Number Description

1 6212 Connecting Rod Nut
2 6210 Rod Cap

3 6211 Connecting Rod Bearing

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4 6010 Cylinder Blocks
5 D81L-6002-C Piston Ring Compression Tool
6 6200 Connecting Rod
7 6108 Piston
A — Tighten to 31-39 Nm

(23-29 Lb-Ft)

7. Install clean, dry upper connecting rod bearing.

8. Lubricate bearing surfaces and crankshaft journal with Engine Assembly Lubricant D9AZ-19579-D or
equivalent meeting Ford specification ESR-M99C80-A engine oil, if clearances are within
specification.

9. Carefully align piston to cylinder bore making sure piston dome notch and button on connecting rod
face the front of engine. Install piston by tapping with wooden hammer handle or similar device while
aligning connecting rod to crankshaft journal. Remove protective rubber caps and install cap with a
clean, dry bearing.

10. Check connecting rod bearing and side clearances. Refer to Section 03-00 .

11. Make sure connecting rod is seated correctly on crankshaft journal. Install cap and lubricated bearing
assembly. Tighten retaining nuts to 31-39 Nm (23-29 lb-ft).

12. Install oil pump and oil pump intermediate shaft. Tighten retaining bolt to 40-55 Nm (30-41 lb-ft).

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Item Part Number Description

1 — Bolt (Part of 6600)
2 6600 Oil Pump
3 6629 Oil Pump Intermediate Shaft Retaining Ring
4 6A618 Oil Pump Intermediate Shaft
5 6010 Cylinder Blocks
A — Tighten to 40-55 Nm

(30-41 Lb-Ft)

13. Install oil pan as outlined in this section.

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14. CAUTION: If a new distributor or camshaft position sensor is installed, run engine at idle
for five minutes before driving vehicle.

Dip entire distributor or camshaft position sensor drive gear in Engine Assembly Lubricant D9AZ­19579-D or equivalent meeting Ford specification ESR-M99C80-A.

15. Pour the rest of the pint of Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford
specification ESR-M99C80-A through distributor hole onto cam drive gear.

16. For Ranger, install camshaft position sensor. Refer to Section 03
fuel injection timing.

17. Install cylinder heads as outlined in this section.

18. Install and perform intake manifold installation procedures as outlined in this section.

19. Fill crankcase with specified amount and viscosity of engine oil.

20. Fill and bleed cooling system.

21. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

symptoms may occur while the powertrain control module (PCM) (12A650) relearns its
adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the
strategy.

Connect ground cable at battery.

22. Start engine and check for oil, exhaust, coolant and vacuum leaks.

23. Check and set initial ignition timing.

-14 , Engine Controls, Electronic, for

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Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Connecting Rod Bearings

The connecting rod bearings are a selective fit to provide for necessary operational clearances and oil
pressure. Refer to Section 03-00 to measure bearing clearances and selection of the proper bearing insert.

NOTE: This operation is performed easiest with engine out of the vehicle. However, it can be
performed with the engine in the vehicle.

emoval

R

1. Disconnect ground cable at battery and set aside.

2. Remove all six spark plugs (12405) to allow for uninhibited crankshaft rotation.

3. Raise vehicle.

4. Remove oil pan (6675) as outlined in this section.

5. Remove oil pump (6600) if required as outlined in this section.

6. Turn connecting rod (6200) until crankshaft (6303) from which the bearings are to be removed is at
the lowest point of travel.

7. Loosen retaining nuts and remove from cap. Place retaining nuts so that they may be reinstalled on
the same rod bolt.

8. CAUTION: Use extreme care to not scratch crankshaft journal.

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 and remove (oil acts as an
adhesive between two precision fitted components).

9. NOTE: Protective caps may be made from rubber fuel line.

Install protective rubber caps onto connecting rod bolts to protect crankshaft journal from bolt threads.

10. Push piston (6108) up into cylinder bore to provide clearance for removal. Remove upper connecting
rod bearing (6211).

11. Inspect connecting rod bearings, crankshaft journal and connecting rod bearing surfaces for damage
or wear.

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Item Part Number Description

1 6102 Piston, Pin and Ring
2 6200 Connecting Rod

3 6214 Connecting Rod Bolt

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4 6102 Piston, Pin, Ring and Connecting Rod Assembly
5 6211 Connecting Rod Bearing
6 6010 Cylinder Blocks
7 — Connecting Rod Cap

(Part of 6010)
8 6212 Connecting Rod Nut
A — Tighten to 31-39 Nm

(23-29 Lb-Ft)

Installation

NOTE: Lightly oil all bolt and stud threads before installation.

1. CAUTION: Contaminants allowed to remain on the cap or connecting rod bearing can
distort the bearing or damage the crankshaft journals.

Thoroughly clean connecting rod bearings (including new bearings), connecting rod cap and
connecting rod with solvent.

2. Clean crankshaft journal and lubricate with Engine Assembly Lubricant D9AZ-19579-B or equivalent
meeting Ford specification ESR-M99C80-A. Make sure the entire journal is well lubricated.

3. Install upper connecting rod bearing in the connecting rod. Align locating tab with relief in connecting
rod and seat fully into the rod. Lubricate bearing surface with Engine Assembly Lubricant D9AZ­19579-B or equivalent meeting Ford specification ESR-M99C80-A.

4. Pull connecting rod down until it seats onto the crankshaft journal.

5. Install connecting rod bearing into rod cap. Align locating tab to relief cap. Lubricate bearing surface
with Engine Assembly Lubricant D9AZ-19579-B or equivalent meeting Ford specification ESR­M99C80-A.

6. Remove protective rubber caps from rod bolts.

7. NOTE: Connecting rods and caps are matched to each other. Never mix connecting rod caps

between other connecting rods. Match code letters stamped on the side of cap and connecting
rod so that they are both on the same side.

Install connecting rod cap and the retaining nuts. Tighten retaining nuts to 31-39 Nm (23-29 lb-ft).

8. Install oil pump if removed. Align oil pump intermediate shaft (6A618) with camshaft position sensor,
align pump with dowels and install retaining bolt. Tighten to 40-55 Nm (30-41 lb-ft).

9. Inspect and clean oil pump intake screen.

10. Install oil pan and new oil pan gasket (6710) as outlined.

11. Lower vehicle.

12. Install spark plugs. Tighten to 9-20 Nm (7-15 lb-ft).

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13. Add correct amount and viscosity engine oil.

14. NOTE: When the battery has been disconnected and reconnected, some abnormal drive

symptoms may occur while the powertrain control module (PCM) (12A650) relearns its
adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the
strategy.

Connect ground cable at battery.

15. Disconnect electrical connector at EDIS coil pack. Crank engine for 15 seconds to re-establish oil to
oil pump and bearing surfaces then reconnect coil pack.

16. Start engine and check for oil leaks.

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

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IN-VEHICLE SERVICE

Flywheel

Removal

. Remove transmission as outlined in the appropriate section in Group 07.

1

2. NOTE: The engine rear plate can be removed.

Remove flywheel-to-crankshaft bolts (6379), flywheel reinforcing plate (6A366) (if equipped) and
flywheel (6375).

Installation

All major rotating components including flex plate/flywheel are individually balanced to zero. Engine
assembly balancing is not required. Balance weights should NOT be installed on new flywheels.

1. Install engine rear plate, if removed.

2. Position flywheel on the crankshaft, flywheel reinforcing plate (if equipped), and install attaching bolts.
Tighten attaching bolts to 73-87 Nm (54-64 lb-ft) using the standard cross-tightening sequence.

3. Install transmission. See applicable section in Group 07.

Flywheel Installation

Item Part Number Description

1 6379 Flywheel-To-Crankshaft Bolt

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2 6375 Flywheel
3 — Dowel (3 Req'd)

(Part of 6375)
4 — Alignment Tool
A — Tighten to 73-87 Nm

(54-64 Lb-Ft)
B — Dowel Must Be Bottomed in Flywheel

Section 03-01B: Engine, 3.0L V-6 1997 Aerostar, Ranger Workshop Manual

Tool Number

Crankshaft Rear Seal Replacer

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IN-VEHICLE SERVICE

Crankshaft Rear Oil Seal

SPECIAL SERVICE TOOL(S) REQUIRED

Description

Jet Plug Remover T77L-9533-B

T88L-6701-A

Removal

1. Remove the flywheel. For additional information, refer to Flywheel in this section.

2. CAUTION: Use care to avoid scratching or damaging the oil seal surface or leakage may
occur.

Using a sharp awl, punch one hole into the crankshaft rear oil seal metal surface between the seal lip
and the cylinder block.

3. Screw the threaded end of the special tool into the oil seal. Use the special tool to remove the
crankshaft rear oil seal.

 A0034454

Installation

1. Lubricate the outer lips and the inner seal on the crankshaft rear oil seal with Super Premium SAE
5W-30 Motor Oil XO-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

2. Using the special tool, install the crankshaft rear oil seal. Alternate bolt tightening to correctly seat the
crankshaft rear oil seal.

 A0034391

3. Install the flywheel. For additional inforamtion, refer to Flywheel in this section.