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

Disassembly

Vehicles Equipped With A Manual Transmission

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1. Remove the bolts, the clutch pressure plate, and the clutch disc. All Vehicles
2. Remove the flywheel or flexplate.
3. Remove the engine-to-transmission spacer plate.
4. Mount the engine to a suitable engine stand and remove the lifting equipment and Lifting Eyes.
5. Disconnect the spark plug wires.
6. Disconnect the ignition coil electrical connector.
7. Remove the bolts and the ignition coil assembly.
8. Remove the bolts and the generator mounting bracket.
9. Remove the four bolts and the coolant pump pulley.
10. Remove the bolts and the crankshaft pulley.
11. Remove the crankshaft damper bolt.
12. Using a Crankshaft Vibration Damper Remover, remove the crankshaft damper.
13. Disconnect the engine control sensor wiring from: the Engine Coolant Temperature (ECT) sensor. the water temperature indicator sender unit. the fuel injectors. the Camshaft Position (CMP) sensor.
14. Remove the valve covers.
15. If necessary, remove the valve cover gaskets.
16. Clean the sealing surfaces.
17. Remove the rocker arms and the push rods.
18. Remove the lower intake manifold. Remove the eight bolts. Remove the lower intake manifold.
19. Remove and discard the intake manifold gaskets and end seals.
20. Clean the sealing surfaces.
21. Remove the screws and the Camshaft Position (CMP) sensor.
22. Remove the camshaft synchronizer bolt.
23. Remove the camshaft synchronizer.
24. Remove the oil pan. Remove the bolts.
25. Remove the oil pan baffle.
26. Remove the oil pan gasket.
27. Clean the surfaces.
28. Remove the Crankshaft Position (CKP) sensor.
29. Remove the engine front cover. Remove the ten bolts.
30. Remove the engine front cover gasket.
31. Clean the sealing surfaces.
32. Remove the oil level indicator tube.
33. Remove the oil filter.
34. Remove the bolts.
35. Remove the cylinder heads.
36. Remove the head gaskets.
37. Remove the valve tappet guide plate retainer.
38. Remove the valve tappet guide plates.
39. Remove the valve tappets.
40. Align the timing marks.
41. Remove the bolt.
42. Remove the timing sprockets and the timing chain as an assembly.
43. Remove the camshaft retainer.
44. Remove the camshaft.
45. If required, remove the camshaft bearings. Use the Camshaft Service Set.
46. Remove the oil pump.
47. Remove the piston and connecting rod assemblies one at a time. Remove the connecting rod nuts in pairs. Remove the connecting rod cap. Remove the piston and connecting rod assembly.
48. Remove the bolts.
49. Remove the main bearing caps.
50. Remove the lower crankshaft main bearings.
51. Remove the crankshaft rear oil seal.
52. Remove the crankshaft.
53. Remove the crankshaft upper main bearings.

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Assembly

All Vehicles

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1. Install the crankshaft upper main bearings.
2. Install the crankshaft.
3. Install the crankshaft rear oil seal.
4. Apply two dots of gasket maker between the rear bearing cap and the cylinder block.
5. Install the crankshaft lower main bearings.
6. Install the main bearing caps.
7. Wedge a large screwdriver at the location shown to hold the crankshaft forward until all the bolts are tightened.
8. Install the bolts. Tighten the bolts in pairs. For crankshaft and crankshaft bearing component tests, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) .
9. If removed, install the camshaft bearings. Use the Camshaft Service Set.
10. Install the camshaft.
11. Install the camshaft retainer.
12. Inspect the camshaft end play. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) .
13. Align the timing marks.
14. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
15. Install the bolt.
16. Install the piston and connecting rod assemblies. Use a piston ring compressor.
17. Install the connecting rod bearings.
18. Install the connecting rod caps and nuts. Tighten the nuts in pairs.
19. Install the oil pan baffle.
20. Install the oil pump.
21. Install the valve tappets.
22. Install the valve tappet guide plates.
23. Install the valve tappet guide plate retainer.
24. Install new head gaskets.
25. Install the cylinder heads.
26. 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.
27. Install the oil bypass filter.
28. Install the oil level indicator tube.
29. Align the timing marks.
30. Install a new engine front cover gasket and the engine front cover.
31. Apply pipe sealant with Teflon® on the bolts to be installed in the locations shown.
32. Install the bolts.
33. Install the Crankshaft Position (CKP) sensor.
34. Apply a 4.0-61.0 mm (0.16-0.23 inch) bead of silicone gasket and sealant to the junction of the rear main bearing cap and the cylinder block, and to the junction of the front cover assembly and cylinder block.
35. Position the oil pan gasket to the oil pan by aligning the fastener holes and securing the gasket with the gasket clips.
36. Tighten the oil pan bolts to 12 Nm (9 lb-ft) in the sequence shown.
37. Install the special tool (303-589) on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.
38. Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment gauge is 38 degrees from the centerline of the engine.
39. Install the camshaft synchronizer retaining bolt.
40. Install the Camshaft Position (CMP) sensor.
41. Apply four beads of silicone gasket and sealant.
42. Install the intake manifold gaskets and end seals. Position the end seals. Position the intake manifold gaskets.
43. Install the lower intake manifold. Tighten the bolts in the sequence shown.
44. Install the push rods and the rocker arms. Install the push rods. Install the rocker arms. Tighten the rocker arm bolts.
45. Apply a bead of silicone gasket and sealant to the four intake-to-cylinder head seams.
46. If removed, install the valve cover gaskets.
47. Install the valve cover. Tighten the bolts in the sequence shown.
48. Position the engine control sensor wiring and connect: the CMP sensor. the fuel injectors. the water temperature indicator sender unit. the engine control sensor wiring.
49. Using the Crankshaft Vibration Damper Installer, install the crankshaft damper.
50. Install the bolt.
51. Install the crankshaft vibration damper and the bolts.
52. Install the coolant pump pulley and the bolts.
53. Install the generator mounting bracket and the bolts.
54. Position the ignition coil assembly and install the bolts.
55. Connect the ignition coil.
56. Connect the spark plug wires. For additional information, refer to «IGNITION SYSTEMS»(ref-142378-S00414713402002073100000) .
57. Install the Lifting Eyes and the lifting equipment.
58. Remove the engine from work stand.
59. Install the engine-to-transmission spacer plate.
60. Install the flywheel or flexplate. Vehicles Equipped With A Manual Transmission
61. Adjust the clutch pressure plate. Using a suitable press, press downward on the fingers until the adjusting ring moves freely. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
62. Using the special tool, position the clutch disc on the flywheel.
63. Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern.

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