1996 Aerostar/Ranger/Explorer

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1 Page 1 of 10 Section 03-01B: Engine, 3.0L V-6 IN-VEHICLE SERVICE 1996 Aerostar and Ranger Vehicles Workshop Manual Engine Front Cover SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fan Clutch Holding Tool T84T-6312-C Fan Clutch Nut Wrench T84T-6312-D Vibration Damper and Seal Replacer T82L-6316-A Vibration Damper Remover Adapter T82L-6316-B Crankshaft Damper Remover T58P-6316-D Removal 1. Disconnect ground cable at battery. 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 block (6010) and 2 nuts in front at timing cover studs. Engine Accessory Installation, 3.0L, Ranger

2 Page 2 of 10 Item Part Number Description 1 N S2 Bolt Generator Generator Mounting Bracket 4 N S2 Bolt A/C Compressor Crankshaft Pulley 7 3A674 Power Steering Pump 8 N S100 Bolt 9 N S2 Stud 10 N S2 Bolt A/C Compressor Mounting Bracket

3 Page 3 of N S8M Bolt 13 3A733 Power Steering Pump Pulley 14 6B209 Drive Belt Tensioner 15 N60608-S2 Bolt 16 N S2 Bolt 17 3F671 Belt Adjuster 18 N S2 Bolt Water Pump Pulley A Tighten to Nm (30-41 Lb-Ft) B Tighten to Nm (15-21 Lb-Ft) C Tighten to Nm (39-53 Lb-Ft) Engine Accessory Installation, Aerostar Item Part Number Description Cylinder Head (RH) 2 N S309 Bolt 3 N S309 Stud 4 10A313 Generator Bracket

4 Page 4 of Generator 6 N S309 Nut 7 N S309 Bolt 8 N S309 Bolt 9 3F671 Power Steering Belt Idler Support Belt Idler Bracket 11 A/C Compressor Bracket (Part of 19703) 12 N S309 Bolt A/C Compressor 14 N S309 Bolt A Tighten to Nm (30-41 Lb-Ft) B Tighten to Nm (16-21 Lb-Ft) Engine Accessory Installation, Aerostar Item Part Number 1 3A674 Power Steering Pump Description 2 3C511 Power Steering Pump Support 3 N Bolt

5 Page 5 of 10 S A733 Power Steering Pump Pulley 5 6B209 Drive Belt Tensioner 6 N S309 Bolt 7 3F671 Power Steering Belt Idler Support A Tighten to 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 Nm (22-37 Lb-Ft) 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). 11. Lower vehicle. Fastener Location, Water Pump Front Cover

6 Page 6 of 10 Fasteners Fastener and Hole No. Part No. Size Nm Lb-Ft 1 a N M8 x 1.25 x a N M8 x 1.25 x a N S8 M8 x 1.25 x N S8 M8 x 1.25 x N M8 x 1.25 x N M8 x 1.25 x N S8 M8 x 1.25 x N S8 M8 x 1.25 x N S8 M8 x 1.25 x N S2 M8 x 1.25 x

7 Page 7 of N S8 M6 x 1.0 x N S8 M6 x 1.0 x N S8 M6 x 1.0 x N S8 M6 x 1.0 x N S8 M6 x 1.0 x a Apply Pipe Sealant with Teflon D8AZ 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 Installation CAUTION: Aluminum components gouge easily, which may result in gasket leaks. Always use care when servicing aluminum gasket surfaces. 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 block and engine front cover.

8 Page 8 of Align new engine front cover gasket on cylinder block dowel pins. Note bolts that require pipe sealant on accompanying chart. Fasteners Fastener and Hole No. Part No. Size Nm Lb-Ft 1 a N M8 x 1.25 x a N M8 x 1.25 x a N S8 M8 x 1.25 x N S8 M8 x 1.25 x N S8 M8 x 1.25 x N M8 x 1.25 x N S8 M8 x 1.25 x

9 Page 9 of 10 a Apply Pipe Sealant with Teflon D8AZ 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 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 , 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 Nm ( lb-ft). 8. Install crankshaft pulley and torque 4 screws to 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 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 Nm (17-21 lb-ft). 11. Lower vehicle. 8 N S8 M8 x 1.25 x N S8 M8 x 1.25 x N S2 M8 x 1.25 x N S8 M6 x 1.0 x N S8 M6 x 1.0 x N S8 M6 x 1.0 x N S8 M6 x 1.0 x N S8 M6 x 1.0 x Install water pump as outlined in this section (if removed).

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1996 Aerostar/Ranger/Explorer

1996 Aerostar/Ranger/Explorer Page 1 of 11 Section 03-01B: Engine, 3.0L V-6 IN-VEHICLE SERVICE 1996 Aerostar and Ranger Vehicles Workshop Manual Water Pump SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Fan Clutch Holding