Ford Aerostar 1997 User Manual

IN-VEHICLE SERVICE
Valve Cover and Gasket, Ranger
Removal
1. Disconnect negative battery cable.
2. Drain cooling system.
3. Disconnect the wiring connectors and locator from the intake air temperature (IAT) and mass air flow
(MAF) sensors. Remove the breather hose from the RH valve cover and remove the air cleaner tube.
4. Remove the accelerator control splash shield. Disconnect the accelerator and speed control cables
from the throttle body. Remove the accelerator control bracket with cables attached and position
aside.
5. Disconnect the idle air control (IAC), differential pressure feedback EGR (DPFE) transducer, throttle
position sensor (TPS), EGR vacuum regulator (EVR) solenoid electrical connectors and vacuum
hoses.
6. Disconnect the brake booster vacuum hose, vacuum connectors from the upper intake manifold and
the positive crankcase ventilation (PCV) valve from the LH valve cover.
7. Disconnect the 42-pin connector and the powertrain control module (PCM) harness locator from the
bracket mounted to the under side of intake manifold.
8. Disconnect the ignition coil electrical connector, locator, and the noise suppressor electrical
connector. Disconnect the ignition wires from the spark plugs.
9. Disconnect the vent line from under the throttle body.
10. Disconnect the spark plug wires from the seven retaining clips. Remove the two ignition coil bolts
from the upper intake manifold and one bolt from RH exhaust manifold. Remove the coil pack with
ignition wires as an assembly.
11. Disconnect the vacuum hose from the EGR valve. Disconnect the EGR tube flange nut from the EGR
valve. Remove the EGR valve and gasket. Discard the gasket.
12. Remove the oil level indicator tube bracket nut and remove the oil level indicator tube and indicator.
13. Remove the stud retaining the EGR outlet tube bracket to the exhaust manifold. Remove the upper
intake manifold and gasket. Discard the gasket. Tape the lower intake manifold openings.
14. Disconnect the wiring connector from the oil pressure-sending unit and locators. Position harness
aside.
15. Disconnect the upper radiator hose from the thermostat housing. Disconnect the heater hose from the
intake manifold. Position the hoses aside.
16. Remove the LH valve cover (with gasket). Discard the gasket.
Section 03-01C: Engine, 4.0L V-6 1997 Aerostar, Ranger Workshop Manual
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Ford Aerostar 1997 Specifications

General

Brand	Ford
Model	Aerostar 1997
Category	Automobile
Language	English

Summary

Valve Cover and Gasket, Ranger

Removal

Steps to remove the valve cover and associated components.

Installation

Steps to install the valve cover and associated components.

Valve Cover and Gasket, Aerostar

Removal

Steps to remove the valve cover and associated components for Aerostar.

Installation

Steps to install the valve cover and associated components for Aerostar.

Rocker Arm Cover and Gasket, Installation

Installation of rocker arm cover and gasket.

Rocker Arm

Removal

Steps to remove rocker arm assemblies.

Installation

Steps to install rocker arm assemblies.

Valve Spring, Retainer and Valve Stem Seal

Removal

Steps to remove valve springs, retainers, and stem seals.

Installation

Steps to install valve springs, retainers, and stem seals.

Valve Tappet, Hydraulic

Removal

Steps to remove hydraulic valve tappets.

Installation

Steps to install hydraulic valve tappets.

Intake Manifold, Upper

Removal

Steps to remove the upper intake manifold.

Installation

Steps to install the upper intake manifold.

Intake Manifold, Lower

Removal

Steps to remove the lower intake manifold.

Installation

Steps to install the lower intake manifold.

Cylinder Head(s)

Removal

Steps to remove cylinder heads.

Installation

Steps to install cylinder heads.

Crankshaft Pulley/Damper/Front Oil Seal

Removal

Steps to remove crankshaft pulley, damper, and front oil seal.

Installation

Steps to install crankshaft pulley, damper, and front oil seal.

Front Cover Oil Seal

Removal

Steps to remove the front cover oil seal.

Installation

Steps to install the front cover oil seal.

Water Pump

Removal

Steps to remove the water pump.

Installation

Steps to install the water pump.

Engine Front Cover

Removal

Steps to remove the engine front cover.

Installation

Steps to install the engine front cover.

Timing Chain, Sprockets, Tensioners and Guides

Removal

Steps to remove timing chain, sprockets, tensioners, and guides.

Installation

Steps to install timing chain, sprockets, tensioners, and guides.

Camshaft

Removal

Steps to remove the camshaft.

Installation

Steps to install the camshaft.

Exhaust Manifold, RH

Removal

Steps to remove the right-hand exhaust manifold.

Installation

Steps to install the right-hand exhaust manifold.

Exhaust Manifold, LH

Removal

Steps to remove the left-hand exhaust manifold.

Installation

Steps to install the left-hand exhaust manifold.

Oil Pan, Aerostar and Aerostar E-4WD

Removal

Steps to remove the oil pan and related components.

Installation

Steps to install the oil pan and related components.

Oil Pump

Removal

Steps to remove the oil pump.

Installation

Steps to install the oil pump.

Crankshaft Main Bearings

Removal

Steps to remove crankshaft main bearings.

Installation

Steps to install crankshaft main bearings.

Pistons and Connecting Rods

Removal

Steps to remove pistons and connecting rods.

Installation

Steps to install pistons and connecting rods.

Connecting Rod Bearings

Removal

Steps to remove connecting rod bearings.

Installation

Steps to install connecting rod bearings.

Flywheel

Removal

Steps to remove the flywheel or flexplate.

Installation

Steps to install the flywheel or flexplate.

Crankshaft Rear Oil Seal

Removal

Steps to remove the crankshaft rear oil seal.

Installation

Steps to install the crankshaft rear oil seal.

Camshaft Rear Bearing Cover

Removal

Steps to remove the camshaft rear bearing cover.

Oil Filter

Removal

Steps to remove the oil filter and bypass filter.

Installation

Steps to install the oil filter and bypass filter.

Oil Filter Adapter

Removal

Steps to remove the oil filter adapter.

Installation

Steps to install the oil filter adapter.

Low Oil Level Sensor

Removal

Steps to remove the low oil level sensor.

Installation

Steps to install the low oil level sensor.

Oil Pressure Sender/Switch

Removal and Installation (4.0L Engine)

Steps to remove and install the oil pressure sender/switch.

Camshaft Bearings

Removal

Steps to remove camshaft bearings.

Installation

Steps to install camshaft bearings.

Oil Pan, Ranger

Removal

Steps to remove the oil pan and related components.

Installation

Steps to install the oil pan and related components.

Engine Assembly, Ranger

Removal

Steps to remove the engine assembly from the vehicle.

Installation

Steps to install the engine assembly into the vehicle.

Engine Assembly, Aerostar

Removal

Steps to remove the engine assembly from the vehicle.

Installation

Steps to install the engine assembly into the vehicle.

Crankshaft

Removal

Steps to remove the crankshaft.

Installation

Steps to install the crankshaft.

Cylinder Head

Disassembly

Steps to disassemble the cylinder head.

Assembly

Steps to assemble the cylinder head.

Pistons, Piston Pins and Rings

Disassembly

Steps to disassemble pistons, pins, and rings.

Assembly

Steps to assemble pistons, pins, and rings.

Cylinder Block Assembly

Disassembly

Steps to disassemble the cylinder block assembly.

Assembly

Steps to assemble the cylinder block.

Cylinder Block, Bare

Disassembly

Steps to disassemble a bare cylinder block.

Assembly

Steps to assemble a bare cylinder block.

Rocker Arm Shaft Assembly

Disassembly

Steps to disassemble the rocker arm shaft assembly.

Assembly

Steps to assemble the rocker arm shaft assembly.

Valve Clearance

Valve Clearance

Information on valve clearance and tappet adjustment.

SPECIFICATIONS

Engine Specifications

General engine specifications and data.

Cylinder Head And Valve Train

Specifications for cylinder head and valve train components.

Camshaft

Specifications for camshaft lobe lift, end play, etc.

Cylinder Block

Specifications for cylinder block flatness and runout.

Cylinder Bore And Piston

Specifications for cylinder bore and piston dimensions.

Crankshaft And Flywheel

Specifications for crankshaft and flywheel journals.

Connecting Rod Bearings

Specifications for connecting rod bearing clearance and thickness.

Connecting Rod

Specifications for connecting rod dimensions and alignment.

Lubricating System

Specifications for oil pump and oil capacity.

Torque Specifications

List of torque values for various engine components.