FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS
| WARNING | Fuel system is under pressure. Pressure must be released before servicing fuel system components. |
- Remove fuel tank cap to release fuel tank pressure. Using Pressure Gauge (T80L-9974-B), release fuel pressure from pressure relief valve on fuel rail.
- Before disconnecting fuel lines, disconnect negative battery cable. To disconnect fuel lines, remove retaining clip from outside of fuel line coupling.
- Use Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line. Install spring lock coupling remover on fuel line coupling so it enters cage opening. (Scheme 24)
- Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove spring lock coupling remover.
- When installing fuel lines, install NEW "O" rings on fuel lines. Use only specified fuel resistant "O" rings (Brown in color). Before installing, lightly coat them with clean engine oil. Clean fittings and replace garter spring (if necessary).
- Install female fitting to male fitting and push until garter spring snaps over flared end of female fitting. Ensure lines are locked together and garter spring is over female fitting flared end.
- Install retaining clip. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line.
Scheme 24
VALVE COVER
Note. Valve covers have integral (built-in) gaskets which are made to last the life of the vehicle. If necessary, replacement gaskets are available.
TIMING CHAIN & SPROCKETS
Note. Check timing chain deflection (stretch) before removal to determine component wear.
CAMSHAFT
Note. Removal of engine is necessary on Windstar. No in-vehicle service procedure is available from manufacturer.
CMP SYNCHRONIZER
| CAUTION | A special tool and procedure are required to properly install camshaft position sensor synchronizer. Failure to do so during installation will cause fuel injection to be out of time and may cause engine damage. |
For camshaft position sensor synchronizer removal, installation and alignment procedure, see
- 1998 Ranger «REMOVE/INSTALL/OVERHAUL - 3.0L»(ref-131337) article in ENGINE PERFORMANCE
- 1999 Ranger «REMOVAL, OVERHAUL & INSTALLATION»(ref-2285) article in ENGINE PERFORMANCE
- 2000 Ranger «REMOVAL, OVERHAUL & INSTALLATION»(ref-2871) article in ENGINE PERFORMANCE
- 1998 Windstar «REMOVE/INSTALL/OVERHAUL - 3.0L»(ref-131341) article in ENGINE PERFORMANCE
- 1999 Windstar «REMOVAL, OVERHAUL & INSTALLATION»(ref-2285) article in ENGINE PERFORMANCE
CYLINDER HEAD
Note. When valve and/or valve seat are machined, valve clearance is reduced and may cause improper valve operation. Valve lifter must be collapsed and clearance checked. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.
Check cylinder head warpage at deck surface. Resurface cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
| CAUTION | DO NOT machine more than .010" (.25 mm) from cylinder head original thickness. |
Valve Springs
- Inspect valve spring free length and pressure. Replace valve spring if not within specification. See «VALVES & VALVE SPRINGS»(ref-1331-S36954744572000031300000) table under ENGINE SPECIFICATIONS.
- Measure valve spring installed height from top of spring seat to underside of spring retainer. If installed height is not within specification, replace valve spring. See «VALVES & VALVE SPRINGS»(ref-1331-S36954744572000031300000) table.
Valve Stem Oil Seals
Intake and exhaust valve stem seals are not interchangeable. Intake valve seal contains a Silver band, and exhaust valve contains a Red band around seal.
Valve Guides
- Valve guides must be reamed for oversize valves if valve stem-to-guide oil clearance exceeds specification. See «CYLINDER HEAD»(ref-1331-S21239303412000031300000) table under ENGINE SPECIFICATIONS. Valves are available in .015" (.38 mm) and .030" (.76 mm) oversize.
- Valve guides may also be bored out and fitted with a service guide if oversize valves are not available or guide is damaged. Ream valve guides until proper valve stem-to-guide oil clearance exists.
Note. DO NOT ream valve guides from standard to maximum oversize in one step. Ream valve guides to oversize in gradual steps, so valve guides are reamed in relation to valve seat. Valve seats must be ground when valve guide is reamed or replaced.
Valve Seat
Valve seat angle, seat width and seat runout must be within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. Replacement information is not available from manufacturer.
Valves
Ensure head diameter, valve face runout, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
| CAUTION | DO NOT remove more than .010" (.25 mm) from end of valve stem when resurfacing tip of valve. |
Valve Seat Correction Angles
If valve seat width is too wide after grinding valve seat, use a 60-degree angle stone to remove stock from bottom of the seat (to raise seat) or a 30-degree stone to remove stock from top of the seat (to lower seat).
Fitting Pistons
- Check piston-to-bore clearance. See «PISTONS, PINS & RINGS»(ref-1331-S13471093092000031300000) table under ENGINE SPECIFICATIONS. Standard size pistons are color-coded Red, Blue or Yellow on piston dome. Oversize pistons are also available.
- If bore diameter is in lower one-third of specification, use a Red coded piston. If bore diameter is in middle one-third of specification, use a Blue coded piston. If bore diameter is in upper one-third of specification, use Yellow coded piston. Use proper size piston to obtain specified clearance. See «PISTON SELECTION»(ref-1331-S06207097082000031300000) table.
| Cylinder Bore Diameter - In. (mm) | Piston Color Code |
|---|---|
| 3.5024-3.5031 (88.962-88.978) | Red |
| 3.5035-3.5041 (88.988-89.004) | Blue |
| 3.5045-3.5051 (89.014-89.030) | Yellow |
PISTON SELECTION
Piston Rings
- Select rings for bore diameter. Place ring in cylinder bore in which it will be installed. Use piston to square ring in bore, and place ring below normal ring wear area. Measure ring end gap. If ring end gap is too small, remove material from end of ring. If ring end gap exceeds specification, try another ring set. See «PISTONS, PINS & RINGS»(ref-1331-S13471093092000031300000) table under ENGINE SPECIFICATIONS.
- Check side clearance of rings after installing on piston. Ensure clearance is within specification around entire circumference. Replace piston and/or rings if clearance is not as specified. Ensure rings are properly spaced on piston before installing pistons into cylinder. (Scheme 25)
Scheme 25
Rod Bearings
- Using Plastigage method, check rod bearing clearance. If proper oil clearance cannot be obtained with standard bearings, try a combination of undersize bearings. DO NOT use any bearing combinations other than those listed. See «UNDERSIZE MAIN & ROD BEARING COMBINATIONS»(ref-1331-S00678745462000031300000) table. To check connecting rod specifications, see «CONNECTING RODS»(ref-1331-S35552744102000031300000) table.
- If use of bearing combinations does not bring clearance within specification, machine or replace crankshaft as necessary. Always replace bearings in pairs. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-1331-S28079002512000031300000) table under ENGINE SPECIFICATIONS.
| Excess Bearing Clearance - In. (mm) | Use Upper Bearing - In. (mm) | Use Lower Bearing - In. (mm) |
|---|---|---|
| .0-.0005 (.0-.013) | .001 (.025) | (2) |
| .0005-0010 (.013-.025) | .001 (.025) | .001 (.025) |
| .0010-.0015 (.025-.039) | .002 (.050) | .001 (.025) |
| .0015-.0020 (.039-.050) | .002 (.050) | .002 (.050) |
| (1) DO NOT use any other bearing combination other than what is listed. If use of bearing combinations does not bring clearance within specification, machine or replace crankshaft as necessary. (2) Use standard bearing. | ||
| (1) | DO NOT use any other bearing combination other than what is listed. If use of bearing combinations does not bring clearance within specification, machine or replace crankshaft as necessary. |
| (2) | Use standard bearing. |
UNDERSIZE MAIN & ROD BEARING COMBINATIONS (1)
Crankshaft & Main Bearings
- When checking main bearing clearance in vehicle, position a jack under adjoining bearing counterweight being checked. Remove only one main bearing cap at a time.
- Using Plastigage method, check main bearing clearance. If proper oil clearance cannot be obtained with standard bearings, try a combination of undersize bearings. DO NOT use any bearing combinations other than those listed. See «UNDERSIZE MAIN & ROD BEARING COMBINATIONS»(ref-1331-S00678745462000031300000) table.
- If use of bearing combinations does not bring clearance within specification, machine or replace crankshaft as necessary. Always replace bearings in pairs. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-1331-S28079002512000031300000) table under ENGINE SPECIFICATIONS.
- Tighten main bearing cap bolts finger tight. Pry crankshaft forward and tighten bearing caps to specification. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000) .
- Check crankshaft end play. Replace thrust bearing if end play is not within specification. Thrust bearing is No. 3 (from front) main bearing in block. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-1331-S28079002512000031300000) table.
Cylinder Block
- Using a feeler gauge and straightedge, check cylinder block head gasket surface for warpage. Check cylinder bore for wear, taper, out-of-round and piston fit. See «CYLINDER BLOCK»(ref-1331-S36954744572000031300000) table under ENGINE SPECIFICATIONS.
- Install all main bearing caps and tighten to specification before honing cylinder bore. See «TORQUE SPECIFICATIONS»(ref-1331-S15552572152000031300000) . Ensure bearing caps are installed in their original location, with arrow on cap pointing toward front of engine.
- Use only a spring-loaded type cylinder hone. After honing, thoroughly clean bore with detergent and water solution. Rinse solution from bore thoroughly with clean water. Wipe bore clean with lint-free cloth. Lubricate cylinder bores with engine oil.
Oil Pressure
Normal oil pressure at 2500 RPM should be 40-60 psi (2.8-4.2 kg/cm 2 ) with engine at normal operating temperature.
Pressure Relief Valve
Pressure relief valve is located in oil pump and is not adjustable.
OIL PUMP
Note. Oil pump is serviced as an assembly only. Replace assembly if measurements are not within specifications. See OIL PUMP SPECIFICATIONS table.