Engine - 3.0L (2V): Other Ford Ranger I

Material

MATERIAL SPECIFICATIONS

Scheme 652

Scheme 653

Scheme 654

Scheme 655

Scheme 656

Scheme 657

1. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .
2. Remove both the valve covers. For additional information, refer to «VALVE COVER RH»(ref-204980-S27428554212005111600000) and «VALVE COVER LH»(ref-204980-S14283751372005111600000) .
3. Disconnect the upper radiator hose, heater hose and coolant bypass hose.
4. Disconnect the Engine Coolant Temperature (ECT) sensor and coolant temperature sender electrical connectors.
5. Disconnect the Crankshaft Position (CKP) sensor and detach the wiring from the stud bolt.
6. Disconnect the fuel injector electrical connectors and position the engine control wiring aside.
7. Release the fuel pressure and disconnect the fuel tube. For additional information, refer to «FUEL SYSTEMS»(ref-142378-S26708405812002073100000) .
8. Loosen all the rocker arm bolts.
9. Remove all the pushrods.
10. Remove the bolts from the lower intake manifold.
11. Remove the lower intake manifold.
12. Remove and discard the intake manifold gaskets and end seals.

Scheme 658

Scheme 659

Scheme 660

Scheme 661

Scheme 662

Scheme 663

Scheme 664

1. Install new intake manifold gaskets and seals. Apply a drop of silicone gasket and sealant at the four cylinder block-to-cylinder head seams. Position new intake manifold gaskets. Position new intake manifold front and rear seals.
2. Position the lower intake manifold.
3. Install the bolts and tighten in the sequence shown.
4. Install the pushrods.
5. Tighten the rocker arms.
6. Connect the fuel tube. For additional information, refer to «FUEL SYSTEMS»(ref-142378-S26708405812002073100000) .
7. Connect the fuel injector electrical connectors.
8. Connect the Crankshaft Position (CKP) sensor and attach the wiring from the stud bolt.
9. Connect the Engine Coolant Temperature (ECT) sensor and coolant temperature sender electrical connectors.
10. Connect the upper radiator hose, heater hose and coolant bypass hose.
11. Install both valve covers. For additional information, refer to «VALVE COVER RH»(ref-204980-S27428554212005111600000) and «VALVE COVER LH»(ref-204980-S14283751372005111600000) .
12. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .

MATERIAL SPECIFICATION

Scheme 665

Scheme 666

Scheme 667

Scheme 668

1. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-204980-S26602973152005111600000) .
2. Disconnect the LH spark plug wire holders.
3. Disconnect the engine control harness from the valve cover studs.
4. Remove the three bolts and the five stud bolts.
5. Remove the valve cover.
6. Remove the valve cover gasket, if required.

Scheme 669

Scheme 670

Scheme 671

Scheme 672

1. Clean all mating surfaces.
2. If removed, install the valve cover gasket.
3. Apply a bead of silicone gasket and sealant in two places where the cylinder head and lower intake manifold meet.
4. Install the valve cover. Position the valve cover. Tighten the three bolts and the five stud bolts in the sequence shown.
5. Connect the engine control harness to the valve cover.
6. Connect the LH spark plug wire holders.
7. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-204980-S26602973152005111600000) .

MATERIAL SPECIFICATIONS

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
2. Disconnect the ignition coil electrical connector.
3. Disconnect the spark plug wires by twisting while pulling upward.
4. Disconnect the heater hose support from the stud.
5. Disconnect the spark plug wire holders.
6. Disconnect the engine control sensor wiring from the Intake Air Temperature (IAT) sensor. For additional information, refer to «INTAKE AIR TEMPERATURE SENSOR»(ref-138346-S23086822792002040800000) .
7. Disconnect the engine control sensor wiring from the Mass Air Flow (MAF) sensor. Position the engine control sensor wiring aside.
8. Disconnect the vacuum hose.
9. Disconnect the wiring harness from the valve cover studs.
10. Disconnect the crankcase ventilation tube.
11. Remove the eight bolts and remove the valve cover.
12. Remove the valve cover gasket, if necessary.

Scheme 681

Scheme 682

Scheme 683

Scheme 684

Scheme 685

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

1. Clean all the mating surfaces.
2. Install the valve cover gasket, if removed.
3. Apply a bead of silicone gasket and sealant in two places where the cylinder head and lower intake manifold meet.
4. Install the valve cover. Position the valve cover. Tighten the eight bolts in the sequence shown.
5. Connect the crankcase ventilation tube.
6. Connect the wiring harness to the valve cover studs.
7. Connect the vacuum hose.
8. Position the engine control sensor wiring and connect it to the mass air flow sensor.
9. Connect the intake air temperature sensor electrical connector.
10. Connect the spark plug wires to the RH spark plug wire holders.
11. Connect the heater hose support.
12. Install the spark plug wires.
13. Connect the ignition coil electrical connector.
14. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .

Scheme 691

MATERIAL SPECIFICATIONS

Scheme 692

Scheme 693

Scheme 694

Scheme 695

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
2. Remove the air cleaner outlet tube.
3. Remove the fan blade and the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-204985) .
4. Remove the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
5. Remove the crankshaft pulley.
6. Remove the bolt and the washer.
7. Using a Crankshaft Vibration Damper Remover, remove the crankshaft damper.
8. Remove the crankshaft key, if necessary.

Scheme 696

Scheme 697

Scheme 698

1. If removed, install the crankshaft key.
2. Using a Crankshaft Vibration Damper Installer, install the crankshaft damper. Coat the sealing surfaces of the crankshaft damper with clean engine oil. Coat the crankshaft damper keyway with silicone gasket and sealant. Install the crankshaft damper.
3. Install the bolt and the washer.
4. Install the crankshaft pulley.
5. Install the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
6. Install the fan blade and the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-204985) .
7. Install the air cleaner outlet tube.
8. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .

Scheme 699

MATERIAL SPECIFICATIONS

Scheme 700

1. Remove the crankshaft vibration damper. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204980-S00811182432005111600000) .
2. Remove the crankshaft front seal.

Scheme 701

1. Install the crankshaft front seal. Lubricate the seal lip with clean engine oil. Using the Crankshaft Vibration Damper Installer, install the crankshaft front seal.
2. Install the crankshaft damper. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204980-S00811182432005111600000) .

MATERIAL SPECIFICATION

Scheme 702

Scheme 703

Scheme 704

Scheme 705

Scheme 706

Scheme 707

Scheme 708

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-204985) .
3. Remove the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
4. Remove the fan and shroud assembly. For additional information, refer to «ENGINE COOLING»(ref-204985) .
5. Remove the bolts and the coolant pump pulley.
6. Remove the nuts and detach the fuel tube bracket and the wiring harness bracket.
7. Remove the studbolts from the A/C compressor mounting bracket.
8. Remove the bolts and position the power steering bracket and compressor aside.
9. Disconnect the lower radiator hose at the water pump outlet.
10. Remove the crankshaft front oil seal. For additional information, refer to «CRANKSHAFT FRONT OIL SEAL»(ref-204980-S34942033782005111600000) .
11. Remove the oil pan. For additional information, refer to «OIL PAN - 4X2»(ref-204980-S38350659102005111600000) or «OIL PAN - 4x4»(ref-204980-S25566763702005111600000) .
12. Remove the Crankshaft Position (CKP) sensor.
13. Remove the engine front cover and the coolant pump as an assembly. Remove the bolts.
14. Remove and discard the front cover gasket.

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

1. Clean all sealing surfaces and position a new front cover gasket.
2. Position the engine front cover.
3. Apply pipe sealant with Teflon® to the bolts to be installed in the locations shown.
4. Install the engine front cover bolts.
5. Install the crankshaft position sensor.
6. Install the oil pan. For additional information, refer to «OIL PAN - 4X2»(ref-204980-S38350659102005111600000) or «OIL PAN - 4x4»(ref-204980-S25566763702005111600000) .
7. Install the crankshaft front oil seal. For additional information, refer to «CRANKSHAFT FRONT OIL SEAL»(ref-204980-S34942033782005111600000) .
8. Connect the lower radiator hose to the water pump outlet.
9. Position back the A/C compressor and power steering bracket.
10. Install the studbolts to the A/C compressor mounting bracket.
11. Position the wiring harness bracket, the fuel tube bracket, and install the nuts.
12. Install the coolant pump pulley and the bolts.
13. Install the fan and shroud assembly. For additional information, refer to «ENGINE COOLING»(ref-204985) .
14. Install the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
15. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
16. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .

Scheme 718

Scheme 719

Scheme 720

Scheme 721

Scheme 722

1. Remove the valve covers. For additional information, refer to «VALVE COVER RH»(ref-204980-S27428554212005111600000) and «VALVE COVER LH»(ref-204980-S14283751372005111600000) .
2. Remove the rocker arms.
3. Using a valve spring compressor, remove the valve spring retainer keys.
4. Remove the valve spring retainer.
5. Remove the valve spring. Refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) for component tests for the valve spring.
6. Remove the valve stem seal.
7. To install, reverse the removal procedure.

MATERIAL SPECIFICATION

MATERIAL SPECIFICATIONS

Scheme 723

1. Remove the radiator assembly. For additional information, refer to «ENGINE COOLING»(ref-204985) .
2. Remove the hydraulic lash adjusters. For additional information, refer to «HYDRAULIC LASH ADJUSTERS»(ref-204980-S37199951072005111600000) .
3. Remove the timing chain. For additional information, refer to «TIMING CHAIN»(ref-204980-S14355967512005111600000) .
4. Remove the camshaft synchronizer assembly. For additional information, refer to «CAMSHAFT POSITION SYNCHRONIZER (3.0L)»(ref-142378-S21469988752002073100000) .
5. Remove the bolts and the camshaft thrust plate.
6. Remove the camshaft.

MATERIAL SPECIFICATIONS

Scheme 724

Scheme 725

Scheme 726

Scheme 727

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
3. Remove the exhaust flange nuts.
4. Remove the nut and the oil level indicator and tube assembly.
5. Remove the upper intake manifold support brace.
6. Remove the bolts, nuts and the exhaust manifold and gasket.

Scheme 728

Scheme 729

Scheme 730

Scheme 731

1. Install the exhaust manifold gasket, exhaust manifold and the bolts and nuts. Tighten the nuts and the bolts in the sequence shown, in two stages: Stage 1: Tighten to 10 Nm (8 lb-ft). Stage 2: Tighten to 23 Nm (17 lb-ft).
2. Install the upper intake manifold support brace.
3. Install the oil level indicator and tube assembly. Coat the oil level indicator tube with silicone gasket and sealant.
4. Install the oil level indicator tube bracket nut.
5. Install the exhaust flange nuts.
6. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .

Scheme 732

Scheme 733

1. With the vehicle in NEUTRAL, position it on a hoist. .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
3. Remove the exhaust flange nuts.
4. Remove the exhaust manifold bolts and stud bolts.
5. Remove the exhaust manifold gasket and the exhaust manifold.

Scheme 734

Scheme 735

1. Position the exhaust manifold gasket and the exhaust manifold.
2. Install the bolts and the nuts. Tighten in the sequence shown in two stages. Stage 1: Tighten to 10 Nm (8 lb-ft). Stage 2: Tighten to 23 Nm (17 lb-ft).
3. Install the exhaust flange nuts.
4. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .

MATERIAL SPECIFICATION

Scheme 736

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
3. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-204980-S42193920742005111600000) .
4. Remove the A/C compressor. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139348) .
5. Remove the generator (GEN). For additional information, refer to «GENERATORS & REGULATORS»(ref-139405) .
6. Remove the power steering pump. For additional information, refer to «POWER STEERING»(ref-204971) .
7. Remove the generator mounting bracket.
8. Remove the rocker arms and the push rods.
9. Remove the nuts and detach the fuel tube bracket and the wiring harness bracket.
10. Remove the two studbolts from the rear of the A/C compressor mounting bracket.
11. Remove the bolts and remove the front of the A/C compressor mounting bracket.
12. Remove the exhaust manifolds. For additional information, refer to «EXHAUST MANIFOLD RH»(ref-204980-S31731720072005111600000) and «EXHAUST MANIFOLD LH»(ref-204980-S35426062812005111600000) .
13. Remove and discard the eight cylinder head bolts.
14. Remove the cylinder heads.
15. Remove and discard the cylinder head gaskets.

Scheme 744

Scheme 745

Scheme 746

Scheme 747

Scheme 748

Scheme 749

Scheme 750

Scheme 751

1. Clean all the sealing surfaces.
2. Check the cylinder head for flatness. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) .
3. Install new cylinder head gaskets.
4. Install the cylinder heads.
5. Install the bolts. Tighten the bolts in five stages in the sequence shown. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Loosen the bolts one full turn. Stage 3: Tighten to 30 Nm (22 lb-ft). Stage 4: Tighten the bolts 90 degrees. Stage 5: Tighten the bolts an additional 90 degrees.
6. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-204980-S42193920742005111600000) .
7. Install the exhaust manifolds. For additional information, refer to «EXHAUST MANIFOLD RH»(ref-204980-S31731720072005111600000) and «EXHAUST MANIFOLD LH»(ref-204980-S35426062812005111600000) .
8. Install the A/C compressor mounting bracket.
9. Install the studbolts to the A/C compressor mounting bracket.
10. Position the wiring harness bracket and the fuel tube bracket and install the nuts.
11. Install the push rods and the rocker arms.
12. Install the generator mounting bracket. Install the bolts.
13. Install the power steering pump. For additional information, refer to «POWER STEERING»(ref-204971) .
14. Install the generator. For additional information, refer to «GENERATORS & REGULATORS»(ref-139405) .
15. Install the A/C compressor. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139348) .
16. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
17. Drain the engine oil.
18. Fill the engine with clean engine oil.
19. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .
20. Fill the power steering system. For additional information, refer to «POWER STEERING»(ref-204971) .
21. Charge the A/C system. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139348) .

Scheme 752

Scheme 753

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
2. Disconnect the engine control sensor wiring from the oil pressure sensor.
3. Remove the oil pressure sensor.
4. To install, reverse the removal procedure.

MATERIAL SPECIFICATION

Scheme 754

1. Remove the oil level indicator tube assembly.

Scheme 755

Scheme 756

1. Coat the sealing surfaces of the oil level indicator tube with silicone gasket and sealant.
2. Install the oil level indicator tube assembly.

Scheme 757

MATERIAL SPECIFICATION

Scheme 758

1. Remove the flywheel or flexplate. For additional information, refer to «FLYWHEEL»(ref-204980-S24449972292005111600000) or «FLEXPLATE»(ref-204980-S21905023292005111600000) .
2. 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.

Scheme 759

1. Lubricate the outer lips and the inner seal on the crankshaft rear oil seal with clean engine oil.
2. Using the special tool, install the crankshaft rear oil seal. Alternate bolt tightening to correctly seat the crankshaft rear oil seal.
3. Install the flywheel or flexplate. For additional information, refer to «FLYWHEEL»(ref-204980-S24449972292005111600000) or «FLEXPLATE»(ref-204980-S21905023292005111600000) .

MATERIAL SPECIFICATION

Scheme 760

Scheme 761

1. Remove the oil pan. For additional information, refer to «OIL PAN - 4X2»(ref-204980-S38350659102005111600000) or «OIL PAN - 4x4»(ref-204980-S25566763702005111600000) .
2. Remove the oil pan baffle.
3. Remove the connecting rod bearing cap.
4. Lift the piston slightly and remove the connecting rod bearings.

Scheme 762

1. The connecting rod bearings are precision fit. Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-204976) for checking clearances or bearing selection.
2. Install the connecting rod bearings.
3. Install the connecting rod bearing cap.
4. Repeat the procedure until all the connecting rod bearings are installed.
5. Install the oil pan baffle.
6. Install the oil pan. For additional information, refer to «OIL PAN - 4X2»(ref-204980-S38350659102005111600000) or «OIL PAN - 4x4»(ref-204980-S25566763702005111600000) .

Scheme 763

MATERIAL SPECIFICATION

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

1. Remove the exhaust manifold. Remove the bolts. Remove the exhaust manifold.
2. Remove the exhaust manifold gasket.
3. Using a valve spring compressor, remove the valve spring retainer key.
4. Remove the valve spring retainer. For component tests for the valve spring retainer, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) .
5. Remove the valve stem seal.
6. Remove the valve. For component tests for the valve, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) . For component tests for the cylinder head, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) .

Scheme 770

1. To assemble, reverse the disassembly. Lubricate the valve stem and the valve stem seal with clean engine oil. Tighten the exhaust manifold in the sequence shown in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 23 Nm (17 lb-ft).

MATERIAL SPECIFICATION

Scheme 771

1. Remove the piston rings.
2. Use a suitable piston pin tool to press the piston pin out of the piston connecting rod assembly.
3. Remove the connecting rod from the piston.
4. Clean and inspect the connecting rod and the piston. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) .

Scheme 772

1. Lubricate the piston pin and piston pin bore. Use clean engine oil.
2. Use a suitable piston pin tool to press the piston pin into the piston and the connecting rod.
3. Install the piston rings.
4. Check piston ring end gap and ring-to-groove side clearance. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) .

Scheme 773

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION