Engine - 3.0L (2V): Removal & Installation Ford Ranger I

Removal

Note. For a valve train noise concern, inspect the valve-to-rocker arm clearance, rocker arms and push rods for wear. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .
3. Remove the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-204980-S42193920742005111600000) .
4. Remove the rocker arms and the push rods.
5. Remove the tappet guide plate retainer.
6. Remove the valve tappet guide plates.
7. Remove the valve tappets.

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1. Install the valve tappets.
2. Install the valve tappet guide plates.
3. Install the tappet guide plate retainer.
4. Install the push rods and the rocker arms.
5. Install the lower intake manifold. For additional information, refer to «LOWER INTAKE MANIFOLD»(ref-204980-S42193920742005111600000) .
6. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
7. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .

Installation

1. Install the camshaft.
2. Install the camshaft thrust plate and the bolts.
3. Measure the camshaft end play. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) .
4. Install the camshaft synchronizer assembly. For additional information, refer to «CAMSHAFT POSITION SYNCHRONIZER (3.0L)»(ref-142378-S21469988752002073100000) .
5. Install the timing chain. For additional information, refer to «TIMING CHAIN»(ref-204980-S14355967512005111600000) .
6. Install the hydraulic lash adjusters. For additional information, refer to «HYDRAULIC LASH ADJUSTERS»(ref-204980-S37199951072005111600000) .
7. Install the radiator assembly. For additional information, refer to «ENGINE COOLING»(ref-204985) .
8. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
9. Drain the engine oil.
10. Fill the engine with clean engine oil.
11. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
2. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-204980-S06159402242005111600000) .
3. Rotate the crankshaft and align the timing marks.
4. Remove the bolt.
5. Remove the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.

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1. Align the timing marks.
2. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
3. Install the bolt.
4. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-204980-S06159402242005111600000) .
5. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .

All Vehicles

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1. Remove the flywheel or flexplate. For additional information, refer to «FLYWHEEL»(ref-204980-S24449972292005111600000) or «FLEXPLATE»(ref-204980-S21905023292005111600000) .
2. Drain the engine oil. Vehicles Equipped With Coil Springs
3. Remove the air cleaner outlet tube.
4. Remove the nuts from the engine mounts.
5. Install the Lifting Eyes, the Three-Bar Engine Support and raise the engine 43 mm (1.72 in).
6. Install blocks between the engine mounts and the support brackets. All Vehicles
7. Remove the bolts and the oil pan. Discard the gasket.

All Vehicles

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1. Thoroughly wash the oil pan and clean old sealer from all gasket surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A.
2. Apply a 4-61 mm (0.16-0.23) bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the junction of the main bearing cap and the cylinder block and to the junction of the front cover assembly and the cylinder block.
3. Position the oil pan gasket to the oil pan by aligning the fastener holes and securing the gasket with the gasket clips.
4. Tighten the oil pan bolts to 12 Nm (9 lb-ft) in the sequence shown. Vehicles Equipped With Coil Springs
5. Remove the blocks from between the engine mounts and the support brackets.
6. Lower the engine and remove the Three-Bar Engine Support and the Lifting Eyes.
7. Install the nuts.
8. 8. Install the air cleaner outlet tube. All Vehicles
9. Install the flywheel or flexplate. For additional information, refer to «FLYWHEEL»(ref-204980-S24449972292005111600000) or «FLEXPLATE»(ref-204980-S21905023292005111600000) .
10. Fill the engine with Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent meeting Ford specification WSS-M2C153-H.
11. Start the engine and check for leaks.

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1. Remove the flywheel or flexplate. For additional information, refer to «FLYWHEEL»(ref-204980-S24449972292005111600000) or «FLEXPLATE»(ref-204980-S21905023292005111600000) .
2. Remove the front driveshaft from the front axle pinion flange. Discard the bolts and straps.
3. Drain the engine oil.
4. Secure the front axle housing to a suitable jack.
5. Remove the three axle housing mounting bolts and lower the axle housing approximately two inches.
6. Remove the oil pan bolts and the oil pan.
7. Remove and discard the oil pan gasket.

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1. Thoroughly wash the oil pan and clean the old sealer from all gasket surfaces. Thoroughly clean all exposed areas with metal surface cleaner. Thoroughly clean the transmission bell housing area. Clean and inspect the oil inlet tube.
2. 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.
3. Position the oil pan gasket to the oil pan by aligning the fastener holes and securing the gasket with the gasket clips.
4. Tighten the oil pan bolts to 12 Nm (9 lb-ft) in the sequence shown.
5. Raise the front axle into place and install the three front axle mounting bolts.
6. Remove the jack.
7. Install the front driveshaft to the front axle pinion flange.
8. Install the flywheel or flexplate. For additional information, refer to «FLYWHEEL»(ref-204980-S24449972292005111600000) or «FLEXPLATE»(ref-204980-S21905023292005111600000) .
9. Fill the engine with clean engine oil.

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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 fasteners and the oil pan baffle.
3. To install reverse the removal procedure.

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
2. Remove the oil pan. For additional information, refer to «OIL PAN - 4X2»(ref-204980-S38350659102005111600000) or «OIL PAN - 4x4»(ref-204980-S25566763702005111600000) .
3. Remove the bolt and the oil pump.
4. Clean and inspect the oil pump assembly. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204976) .

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1. Clean all the sealing surfaces.
2. Install the oil pump and the bolt.
3. Install the oil pan. For additional information, refer to «OIL PAN - 4X2»(ref-204980-S38350659102005111600000) or «OIL PAN - 4x4»(ref-204980-S25566763702005111600000) .
4. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .

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1. Remove the clutch. For additional information, refer to «CLUTCHES»(ref-153163) .
2. Remove the flywheel bolts.
3. Remove the flywheel.

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1. Install the flywheel. Install the six bolts. Tighten the bolts in a criss-cross pattern.
2. Install the clutch. For additional information, refer to «CLUTCHES»(ref-153163) .

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1. Remove the transmission. For additional information, refer to «REMOVAL & INSTALLATION - A/T»(ref-156143) .
2. Remove the bolts and the flexplate. Inspect the flexplate for cracks or other damage. Install a new flexplate if necessary.

Note. Special bolts are used for the installation. Do not use standard bolts.

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1. Position the flexplate on the crankshaft and install the bolts. Tighten the bolts in a criss-cross pattern.
2. Install the transmission. For additional information, refer to «REMOVAL & INSTALLATION - A/T»(ref-156143) .

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All Vehicles

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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 hood.
4. Remove the fan. For additional information, refer to «ENGINE COOLING»(ref-204985) .
5. Attach the Engine Lifting Eyes.
6. Remove the engine support insulator nuts.
7. Raise the engine and support with a Three-Bar Engine Support. 4X2 Vehicles
8. Remove the engine support insulator nut. 4X4 Vehicles
9. Remove and discard the bolts and straps. Secure the driveshaft out of the way.
10. Secure the front axle housing to a suitable jack.
11. Remove the three axle housing mounting bolts and lower the axle housing approximately 50 mm (2 inches).
12. Remove the engine support insulator nut. All Vehicles
13. Remove the engine support insulator.

All Vehicles

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1. Position the engine support insulator. 4X4 Vehicles
2. Install the engine support insulator nut.
3. Raise the front axle into place and install the three front axle mounting bolts.
4. Remove the jack.
5. Align the index marks and install new front driveshaft straps and bolts. 4X2 Vehicles
6. Install the engine support insulator nut. All Vehicles
7. Lower the engine and remove the Three-Bar Engine Support.
8. Install the engine support insulator nuts.
9. Remove the Engine Lifting Eyes.
10. Install the fan blade. For additional information, refer to «ENGINE COOLING»(ref-204985) .
11. Install the hood.
12. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .

All Vehicles

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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 hood.
4. Remove the fan blade. For additional information, refer to «ENGINE COOLING»(ref-204985) .
5. Attach the Engine Lifting Eyes.
6. Remove the engine support insulator nuts.
7. Raise the engine and support with a Three-Bar Engine Support Kit. 4X2 Vehicles
8. Remove the right front spring. For additional information, REFER to «FRONT - 2WD»(ref-166188) .
9. Remove the engine support insulator nut. 4X4 Vehicles
10. Remove the RH front halfshaft. For additional information, refer to «AXLE SHAFTS (4WD)»(ref-164282) .
11. Remove the engine support insulator nut. All Vehicles
12. Remove the engine support insulator.

All Vehicles

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1. Position the engine support insulator. 4X4 Vehicles
2. Install the engine support insulator nut.
3. Install the RH front halfshaft. For additional information, refer to «AXLE SHAFTS (4WD)»(ref-164282) . 4X2 Vehicles
4. Install the engine support insulator nut.
5. Install the right front spring. For additional information, REFER to «FRONT - 2WD»(ref-166188) . All Vehicles
6. Lower the engine and remove the Three-Bar Engine Support Kit.
7. Install the engine support insulator nuts.
8. Remove the Engine Lifting Eyes.
9. Install the fan blade. For additional information, refer to «ENGINE COOLING»(ref-204985) .
10. Install the hood.
11. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .

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1. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .
2. Remove the hood (16612).
3. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-204980-S26602973152005111600000) .
4. Remove the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
5. Using the Strap Wrench, remove the fan clutch and the fan blade as an assembly.
6. Remove the fan shroud. Remove the bolts. Remove the fan shroud.
7. Remove the radiator. For additional information, refer to «ENGINE COOLING»(ref-204985) .
8. Disconnect the heater hoses.
9. Recover the A/C system. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139348) .
10. Disconnect the A/C manifold and tube.
11. Disconnect the A/C manifold and tube at the accumulator.
12. Remove the nut and position the line aside.
13. Remove the nut.
14. Disconnect the A/C compressor wiring.
15. Remove the bolt and nut.
16. Set the A/C compressor and the A/C compressor mounting bracket aside as an assembly. Remove the bolts. Set the assembly aside.
17. Remove the nut and position the ground cable aside.
18. Disconnect the fuel hoses. For additional information, refer to «FUEL SYSTEMS»(ref-142378-S26708405812002073100000) .
19. Disconnect the vacuum hose.
20. Disconnect the powertrain control module connector.
21. Remove the nut from the powertrain control module harness.
22. Remove the stud bolt and the powertrain control module ground strap.
23. Disconnect the generator wiring and position aside.
24. Disconnect both Heated Oxygen Sensors (HO2S).
25. Disconnect the transmission harness connectors.
26. Disconnect the vacuum hose to the vacuum reservoir.
27. Disconnect the Mass Air Flow (MAF) sensor.
28. Raise the vehicle on a hoist.
29. Remove the LH heated oxygen sensor.
30. Remove the nuts and disconnect the dual converter Y pipe from both exhaust manifolds.
31. Remove the starter motor. For additional information, refer to «STARTER MOTOR»(ref-139412-S24809496782002043000000) . Vehicles Equipped With Automatic Transmission
32. Remove the torque converter nuts. Remove the access plate. Remove the four nuts.
33. Remove the bolt. All vehicles
34. Remove the eight transmission-to-engine bolts.
35. Lower the vehicle.
36. Install the Lifting Eyes.
37. Remove the four nuts.
38. Support the transmission with a floor jack.
39. Remove the engine from the vehicle.

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All Vehicles

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1. Position the engine in the vehicle.
2. Install the four nuts.
3. Remove the Lifting Eyes.
4. Raise and support the vehicle.
5. Install the eight transmission-to-engine bolts. Vehicles Equipped With Automatic Transmission
6. Install the transmission cooler line bracket and bolt.
7. Install the four torque converter nuts. Install the nuts. Install the access plate. All Vehicles
8. Install the starter motor. For additional information, refer to «STARTERS»(ref-139412) .
9. Connect the dual converter Y-pipe and install the nuts.
10. Install the LH Heated Oxygen Sensor (HO2S). For additional information, refer to «HEATED OXYGEN SENSOR»(ref-142378-S38809592142002073100000) .
11. Lower the vehicle.
12. Connect the engine sensor control wiring to the Mass Air Flow (MAF) sensor.
13. Connect the vacuum hose to the vacuum reservoir.
14. Connect the transmission wiring harness connectors.
15. Connect both heated oxygen sensor electrical connectors.
16. Position and connect the generator wiring harness. For additional information, refer to «GENERATORS & REGULATORS»(ref-139405) .
17. Install the powertrain control module ground strap.
18. Install the powertrain control module wiring bracket.
19. Connect the engine control wiring harness to the Powertrain Control Module (PCM).
20. Connect the fuel hoses. For additional information, refer to «FUEL SYSTEMS»(ref-142378-S26708405812002073100000) .
21. Install the ground cable.
22. Install the PCM wiring harness.
23. Install the A/C compressor and A/C compressor mounting bracket as an assembly. Position the assembly. Install the front bolts. Install the two rear bolts.
24. Connect the A/C compressor wiring.
25. Install the fuel line bracket.
26. Position the A/C suction/discharge line and install the nut.
27. Connect the A/C line at the accumulator.
28. Install the suction/discharge manifold on the A/C compressor. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139348) .
29. Connect the engine sensor control wiring to the A/C cut-out switch.
30. Connect the heater hoses.
31. Install the radiator. For additional information, refer to «ENGINE COOLING»(ref-204985) .
32. Install the fan shroud. Position the fan shroud. Install the bolts.
33. Using the Strap Wrench install the fan clutch and the fan blade.
34. Install the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
35. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-204980-S26602973152005111600000) .
36. Install the hood.
37. Fill the engine with clean engine oil.
38. Connect the battery ground cable.
39. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .
40. Charge the A/C system. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139348) .
41. Inspect the engine and cooling system for leaks.
42. After the engine has warmed to operating temperature, retighten the oil pan bolts starting from the rear of the oil pan and work forward. Tighten the oil pan bolts to 12 Nm (106 lb-in).