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Ford 1997 Aerostar, Workshop Manual

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Ford 1997 Aerostar Workshop Manual Download Page 24

 

 
 

Item 

Part Number 

Description 

1 

9002 

Fuel Tank 

2 

9054 

Fuel Tank Support Strap, Front 

3 

9092 

Fuel Tank Support Strap, Rear 

4 

N801107-S426 

Nut, U-Lock 

5 

5030 

Crossmember, No. 4 

6 

9A147 

Skid Plate Assembly  
(4x4 Only) 

7 

9A032 

Fuel Tank Heat Shield 

8 

N605920-S426 

Bolt 

9 

5025 

Crossmember 

10 

N807164-S426 

Nut and Retainer 

Page 5 of 6

1997 Aerostar/Ranger

2011-04-29

file://C:\TSO\tsocache\VDTOM_5368\SVK~us~en~file=SVKA1016.HTM~gen~ref.HTM

[email protected]

Summary of Contents for 1997 Aerostar

Page 1: ...nsors to compute the required fuel flow rate necessary to maintain a prescribed air fuel ratio throughout the entire engine operational range The powertrain control module then outputs a command to the fuel injector nozzle tips 9E527 to meter the appropriate quantity of fuel The powertrain control module also determines and compensates for the age of the vehicle and its uniqueness The powertrain c...

Page 2: ...nd or external vent lines within the fuel tank filler pipe and fuel tank A venting system is used to provide an air space within the fuel tank when the fuel tank is filled to capacity This air space provides for thermal expansion of the fuel as well as being an aid to the in tank vapor vent system Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L ...

Page 3: ...pressure buildup Air must enter the fuel tank as fuel is used because the fuel leaving the fuel tank would create a partial vacuum which could become strong enough that the fuel pump 9350 could not overcome it causing fuel starvation Also air pressure on the outside of the fuel tank could collapse the fuel tank If pressure from fuel expansion and vaporization were to rise too high the pressure cou...

Page 4: ...ilter element inlet filter sock is mounted on the in tank electric fuel pump inlet inside the fuel tank 9002 and is used to protect the fuel pump 9350 from fuel tank contaminants The in tank filter is not serviced separately To service the in tank filter replace the fuel pump and sender assembly Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L 3 ...

Page 5: ...rative emission valve in the top of the fuel tank The vapors leave the evaporative emission valve through a single vapor line and continue to the evaporative emissions canister in the engine compartment for storage until such time as they are purged to the engine 6007 In the event of extreme conditions excessive fuel tank pressure the purge port of the evaporative emission valve opens up allowing ...

Page 6: ...Page 2 of 2 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1005 HTM gen ref HTM tomsn048 gmail com ...

Page 7: ... the orificed fuel tank evaporative emission valve in the top of the fuel tank The vapors leave the evaporative emission valve through a single vapor line and continue to the fuel vapor canister in the engine compartment for storage until such time as they are purged to the engine 6007 Fuel Vapor Valve Ranger Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equippe...

Page 8: ...Page 2 of 2 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1006 HTM gen ref HTM tomsn048 gmail com ...

Page 9: ...ity check to determine if there is an evaporative leak Variations in pressure will be converted into an analog voltage input signal to the powertrain control module PCM 12A650 Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L 3 0L and 4 0L Gasoline Engines Workshop Manual Page 1 of 1 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 S...

Page 10: ...ead of the plastic or stainless steel push connect fittings The spring lock couplings work by insertion of the fitting s male end which is surrounded by two O rings into a female flared end engine fitting The coupling engagement is secured by a garter spring which prevents the female flared end from becoming disengaged from the male end Spring Lock Coupling Disconnect Tool D87L 9280 B or equivalen...

Page 11: ...mum fuel pump pressure to 850 kPa 125 psi This only takes effect if there is a system blockage causing system pressure to rise too high The system pressure is controlled by a pressure regulator on the engine 6007 The fuel pump is protected at its inlet by a nylon pickup element This nylon element filters dirt and contaminants which could plug or damage the internal pump components while at the sam...

Page 12: ...nge Part of 9H307 4 Fuel Gauge Sender to Electrical Connector Spade Connection Part of 9H307 5 9350 Fuel Pump 6 Sender Float Part of 9H307 7 Inlet Filter Sock Part of 9H307 Page 2 of 3 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1009 HTM gen ref HTM tomsn048 gmail com ...

Page 13: ...el Gauge Sender Assembly Part of 9H307 9 Fuel Return Tube Part of 9H307 Page 3 of 3 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1009 HTM gen ref HTM tomsn048 gmail com ...

Page 14: ...e diaphragm Balancing one side of the diaphragm with manifold pressure maintains a constant fuel pressure drop across the injectors Fuel in excess of that used by the engine is bypassed through the regulator and returns to the fuel tank 9002 Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L 3 0L and 4 0L Gasoline Engines Workshop Manual Item Part ...

Page 15: ...Page 2 of 2 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1010 HTM gen ref HTM tomsn048 gmail com ...

Page 16: ...ine On Ranger vehicles the inertia fuel shutoff switch is located on the toe board to the right of the transmission hump On Aerostar vehicles it is located on the kick panel to the right of the front passenger seat Inertia Fuel Shutoff Switch Location Ranger Inertia Fuel Shutoff Switch Location Aerostar Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with...

Page 17: ...Shutoff Switch 2 Reset Button Part of 9341 3 20124 Door RH Side 4 02018 Cowl Panel RH Side 5 01610 Dash Panel RH Side Page 2 of 2 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1012 HTM gen ref HTM tomsn048 gmail com ...

Page 18: ...se at the fuel pump to fuel tube connection and drain the fuel tank 9002 Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L 3 0L and 4 0L Gasoline Engines Workshop Manual Page 1 of 1 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1014 HTM gen ref HTM tomsn048 gmail com ...

Page 19: ...fuel due to temperature increases or overfilling topping off can cause fuel overflow at the fuel tank filler cap 9030 when the vehicle is standing or the fuel tank filler cap is removed To minimize this condition it is recommended that the amount of fuel put in the fuel tank be limited to the third automatic pump shutoff Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ra...

Page 20: ...sender unit 9 Remove fuel vapor hose from evaporative emission valve 9B593 10 Lower fuel tank from vehicle 11 For installation follow removal procedures in reverse order The fittings used on 7 9mm 5 16 inch nominal diameter nylon tubing use a hairpin clip Clips should be replaced whenever a connector is removed Refer to Push Connect Fittings in this section Tighten bolts securing fuel tank support...

Page 21: ...er Cap 5 42127 S2 Screw and Washer 6 383526 S Clamp 7 9047 Fuel Tank to Filler Pipe Hose 8 9002 Fuel Tank 9 N800394 S36 Bolt 10 N800312 S36 Screw and Washer 11 385701 S Nut 1 4 Insert Page 2 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1016 HTM gen ref HTM tomsn048 gmail com ...

Page 22: ...e front fuel tank support strap 12 9092 Fuel Tank Support Strap 13 N620480 S36 Nut 14 9A032 Fuel Tank Heat Shield 15 N802253 S36 Bolt 16 9240 Insulator Fuel Tank 17 N801107 S36 U Nut 18 9A307 Fuel Tank Sending Unit Locking Retainer Ring 19 9323 Tube Assembly Fuel Tank to Filter 20 9B324 Tube Assembly Fuel Rear 21 9H307 Fuel Pump and Sender Assembly 22 9417 Fuel Pump Mounting Gasket A Tighten to 3 ...

Page 23: ... tank from vehicle 14 For installation follow removal procedures in reverse order The fittings used on 7 9mm 5 16 inch nominal diameter nylon tubing use a hairpin clip Clips should be replaced whenever a connector is removed Refer to Push Connect Fittings in this section Tighten U lock nuts securing front and rear fuel tank support straps to 34 46 Nm 25 34 lb ft Tighten clamp securing fuel tank fi...

Page 24: ... N801107 S426 Nut U Lock 5 5030 Crossmember No 4 6 9A147 Skid Plate Assembly 4x4 Only 7 9A032 Fuel Tank Heat Shield 8 N605920 S426 Bolt 9 5025 Crossmember 10 N807164 S426 Nut and Retainer Page 5 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1016 HTM gen ref HTM tomsn048 gmail com ...

Page 25: ...11 9A032 Fuel Tank Heat Shield A Tighten to 34 46 Nm 25 34 Lb Ft Page 6 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1016 HTM gen ref HTM tomsn048 gmail com ...

Page 26: ...l 2 Remove three bolts which secure the fuel tank filler pipe to the body side 3 Loosen clamp that secures the outer fuel tank filler pipe to the lower fuel tank to filler pipe hose 4 Disconnect the fuel tank filler pipe from the lower fuel tank to filler pipe hose 5 Remove the upper fuel tank filler pipe by pulling the assembly up through the body side 6 If required the fuel tank filler cap 9030 ...

Page 27: ...Page 2 of 2 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1017 HTM gen ref HTM tomsn048 gmail com ...

Page 28: ... tank filler pipe to body housing Tighten screws to 3 5 Nm 30 lb in 2 Tighten screw clamps attaching fuel tank to filler pipe hose to 3 4 Nm 27 35 lb in Fuel Filler System Ranger Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L 3 0L and 4 0L Gasoline Engines Workshop Manual Page 1 of 2 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_536...

Page 29: ... Fuel Pump and Sender Assembly 6 9002 Fuel Tank 7 9030 Fuel Tank Filler Cap 8 9034 Fuel Tank Filler Pipe 9 Clamp Part of 9034 10 N807605 S412 Screw Assembly A Tighten to 53 72 Nm 39 53 Lb Ft B Tighten to 3 4 Nm 27 35 Lb In C Tighten to 4 Nm 30 Lb In Page 2 of 2 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1018 HTM gen ref HTM tomsn048 gmail com ...

Page 30: ...e front or if the fuel tank 9002 is pressurized fuel leakage or siphoning from the tank fuel from the lines could occur To prevent this condition maintain the vehicle front end at or above the level of the rear of vehicle Also relieve tank pressure by loosening the fuel tank filler cap 9030 Fuel tank filler cap should be retightened after pressure is relieved If vehicle is warm change the fuel fil...

Page 31: ...stall push connect fittings at both ends of filter as described in Removal and Installation Push Connect Fittings in this section 3 Lower vehicle 4 Start engine and check for leaks Item Part Number Description 1 9323 Fuel Tank to Filter Tube 2 9H334 Front Tube 3 9B072 Filter and Bracket 4 N802693 S36 Rivet Page 2 of 3 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SV...

Page 32: ...Page 3 of 3 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1019 HTM gen ref HTM tomsn048 gmail com ...

Page 33: ...mp and sender assembly 5 Remove fuel pump mounting gasket 9417 and discard Installation 1 Clean the fuel pump mounting flange and the fuel tank mounting surface and groove in fuel tank sending unit locking retainer ring 2 Put a light coating of Premium Long Life Grease XG 1 C or K or equivalent meeting Ford specification ESA M1C75 B on a new fuel pump mounting gasket to hold it in place during ass...

Page 34: ...stop 5 Install fuel tank as described in Removal and Installation Fuel Tanks in this section Fuel Pump and Sending Unit Aerostar Item Part Number Description 1 Fuel Supply Tube Part of 9H307 2 Fuel Return Tube Part of 9H307 3 Fuel Gauge Sender Assembly Part of 9H307 Page 2 of 7 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1020 HTM gen ref HTM tomsn048 gmail com...

Page 35: ... Pump Part of 9H307 7 Fuel Gauge Sender to Electrical Connector Spade Connection Part of 9H307 8 Flange Part of 9H307 9 Electrical Connector Part of 9H307 Item Part Number Description Page 3 of 7 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1020 HTM gen ref HTM tomsn048 gmail com ...

Page 36: ...Sender to Electrical Connector Spade Connection Part of 9H307 5 Fuel Pump Part of 9H307 6 Sender Float Part of 9H307 7 Inlet Filter Sock Part of 9H307 8 Fuel Gauge Sender Assembly Part of 9H307 9 Fuel Return Tube Part of 9H307 Page 4 of 7 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1020 HTM gen ref HTM tomsn048 gmail com ...

Page 37: ...bly Part of 9H307 5 Sender Float Part of 9H307 6 Fuel Pump Part of 9H307 7 Inlet Filter Sock Part of 9H307 8 Fuel Gauge Sender to Electrical Connector Spade Connection Part of 9H307 9 Fuel Supply Tube Part of 9H307 Page 5 of 7 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1020 HTM gen ref HTM tomsn048 gmail com ...

Page 38: ...uel tanks 3 If no fuel leak is apparent reset the inertia fuel shutoff switch by pushing the reset button on the top of the inertia fuel shutoff switch 4 Turn ignition switch to START for a few seconds then to OFF 5 Again check for leaking fuel Inertia Fuel Shutoff Switch Location Ranger Inertia Fuel Shutoff Switch Location Aerostar Page 6 of 7 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache V...

Page 39: ...Shutoff Switch 2 Reset Button Part of 9341 3 20124 Door RH Side 4 02018 Cowl Panel RH Side 5 01610 Dash Panel RH Side Page 7 of 7 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1020 HTM gen ref HTM tomsn048 gmail com ...

Page 40: ...ative emission valve refer to Removal and Installation Fuel Tanks in this section Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L 3 0L and 4 0L Gasoline Engines Workshop Manual Page 1 of 1 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1021 HTM gen ref HTM tomsn048 gmail com ...

Page 41: ...rch or high heat producing equipment is to be used for service in the following areas 1 Exhaust or suspension components in proximity to fuel tubes 2 Underbody rails and crossmembers left side 3 Dash panel under vehicle or inside the passenger compartment lower right side 4 Front or rear wheel house fender apron right side PTFE Teflon and Stainless Steel In a high heat environment Teflon hose and ...

Page 42: ...ION IS REQUIRED TO DISCONNECT WHEN DISCONNECTION OCCURS BOTH HANDS COULD SHARPLY AND UNCONTROLLABLY MOVE IN THE DIRECTION OF EACH HAND S PULLING BE CAREFUL THAT NO SHARP OR POSSIBLE DAMAGING OBJECTS ARE IN LINE WITH THE DIRECTION OF PULL TO PREVENT PHYSICAL INJURY AND OR DAMAGE TO THE OBJECTS THAT WILL BE IMPACTED BY THE HANDS WHEN DISCONNECTION OCCURS Once the hose component joint has been broken...

Page 43: ...uble 5 N802769 S Clip Double 6 9002 Fuel Tank 7 9323 Tube Assembly Fuel Tank to Filter 8 N802769 S Brake Line Clip Do Not Install Vapor Line in Brake Line Clip 9 N802768 S Clip Single 10 N803994 S Clip Triple Page 3 of 10 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1022 HTM gen ref HTM tomsn048 gmail com ...

Page 44: ... 3 0L Only 15 9B072 Fuel Filter and Base 16 9A317 Fuel Tube Clip 17 9B324 Rear Fuel Tube 18 N802693 S36 Rivet 4 8 x 11 5 19 5005 Frame 20 N807364 S2 Bolt M6 1 0 A Tighten to 11 13 Nm 98 115 Lb In B Valve Must Be Installed As Shown and Fully Seated Page 4 of 10 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1022 HTM gen ref HTM tomsn048 gmail com ...

Page 45: ... Clip 1 2 2 9S286 Front Fuel Supply Return and Vapor Tube 3 5005 Frame 4 9B262 Filter 5 N620481 S2 Nut M8 1 25 Page 5 of 10 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1022 HTM gen ref HTM tomsn048 gmail com ...

Page 46: ...ifold See Section 03 04C Fuel Charging and Controls 2 3L B For Continuation Fuel Supply Manifold See Section 03 04C Fuel Charging and Controls 4 0L C For Continuation See Illustration Fuel Line System Rear Lines Ranger in this Section D For Continuation See Illustration Fuel Line System Rear Lines Ranger in this Section E Tighten to 15 20 Nm 11 15 Lb Ft Page 6 of 10 1997 Aerostar Ranger 2011 04 29...

Page 47: ...2 N805528 S190 Clip 1 2 3 N620481 S2 Nut M8 1 25 4 N805526 S190 Clip 3 8 5 N611192 S2 Screw M8 1 25 x 12 Hex Washer Tap Page 7 of 10 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1022 HTM gen ref HTM tomsn048 gmail com ...

Page 48: ...N803640 S Clip 11 9D653 Evaporative Emissions Canister 12 N805528 S190 Clip 1 2 13 N805526 S190 Clip 3 8 A For Continuation See Illustration Fuel Line System Rear Lines Ranger in This Section B Tighten to 15 20 Nm 11 15 Lb Ft Page 8 of 10 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1022 HTM gen ref HTM tomsn048 gmail com ...

Page 49: ...eturn Tube 3 9002 Fuel Tank 4 N803640 S Clip A For Continuation See Fuel Line System Front Lines Ranger 2 3L and 4 0L Engines or Fuel Line System Page 9 of 10 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1022 HTM gen ref HTM tomsn048 gmail com ...

Page 50: ...Front Lines Ranger 3 0L Engines in This Section Page 10 of 10 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1022 HTM gen ref HTM tomsn048 gmail com ...

Page 51: ...e fuel tank heat shield is removed and the tank is partially lowered just before removing the fuel tank 9002 completely Plastic Hairpin Clip Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L 3 0L and 4 0L Gasoline Engines Workshop Manual Item Part Number Description 1 N802239 S Hairpin Clip 2 Shipping Tab Part of N802239 S 3 O Rings Part of 3H307 ...

Page 52: ... the fitting from the steel or nylon tube 5 When fitting is removed from the tube end inspect the fitting and tube for any internal parts that may have been dislodged from the fitting Any loose internal parts should be immediately installed using the mating tube to insert the parts Installation 1 Install the new clip by inserting clip into any two adjacent openings with the triangular portion poin...

Page 53: ...r Quick Disconnect Tool 5 16 Inch Part of T90T 9550 S T90T 9550 B Quick Disconnect Tool 3 8 Inch Part of T90T 9550 S T90T 9550 C Page 3 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1023 HTM gen ref HTM tomsn048 gmail com ...

Page 54: ...end 4 Pull the female fitting and the male tube end apart 5 Remove the tool from the disconnected fitting 6 Inspect the fitting for any internal parts that may have been damaged Fuel tube should be replaced if internal parts are damaged Installation 1 Align the fitting and tube axially 2 Push the tube into the fitting When properly engaged a click will be heard Page 4 of 6 1997 Aerostar Ranger 201...

Page 55: ...the fitting to make sure it is fully engaged 4 Lock assembly with safety clip Page 5 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1023 HTM gen ref HTM tomsn048 gmail com ...

Page 56: ...Page 6 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1023 HTM gen ref HTM tomsn048 gmail com ...

Page 57: ...ter spring which prevents the female flared end from becoming disengaged from the male end Spring Lock Coupling Disconnect Tool D87L 9280 B or equivalent is used to disconnect the 12 7mm 1 2 inch spring lock coupling supply fitting Tool D87L 9280 A or equivalent is used to disconnect the 9 52mm 3 8 inch spring lock coupling return fitting Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pum...

Page 58: ...elease the garter spring 2 Push the tool into the cage opening to release the female fitting from the garter spring Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L 3 0L and 4 0L Gasoline Engines Workshop Manual Page 1 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1025 HTM gen ref HTM tomsn048 gmail com ...

Page 59: ...k coupling Connecting 1 Check for missing or damaged garter spring If spring is damaged or missing remove damaged spring with small hooked wire and install a new spring Page 2 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1025 HTM gen ref HTM tomsn048 gmail com ...

Page 60: ...ant oil and assemble fitting by pushing with a slight twisting motion 3 Visually check to be sure garter spring is over flared end of female fitting and pull on fitting to ensure full engagement Page 3 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1025 HTM gen ref HTM tomsn048 gmail com ...

Page 61: ...is not locked in place refer to Connecting Spring Lock Connector procedure in this section 3 NOTE The black 12 7mm 1 2 inch clip fits the fuel supply line The silver 9 5mm 3 8 inch clip fits fuel return line Install large end of clip to garter spring side of fuel line making sure that clip is properly positioned Page 4 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en f...

Page 62: ...the following illustration 4 Attach the tether to the fuel line and snap shut Page 5 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1025 HTM gen ref HTM tomsn048 gmail com ...

Page 63: ...Page 6 of 6 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1025 HTM gen ref HTM tomsn048 gmail com ...

Page 64: ...o Allen retaining screws from regulator housing and discard 4 Remove fuel pressure regulator O rings Discard O rings 5 If scraping is necessary be careful not to damage fuel pressure regulator or fuel supply line O ring surfaces Installation Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L 3 0L and 4 0L Gasoline Engines Workshop Manual SPECIAL SE...

Page 65: ...lator and fuel injection manifold are clean 3 Install new O rings on fuel pressure regulator 4 Using new Allen head retaining screws install fuel pressure regulator on injector manifold Tighten two retaining screws to 3 5 Nm 27 44 lb ft 5 Install vacuum line at fuel pressure regulator Page 2 of 2 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1026 HTM gen ref HTM...

Page 66: ... prolonged period as it may damage distort fuel tank Plastic Fuel Tank Repair CAUTION Leaks or damage to the polyethylene fuel tanks are not repairable This applies to Aerostar and Ranger fuel tanks including all polyethylene portions of the fuel tank body and fittings Fuel tank replacement is the only acceptable service There are no reliable repair procedures that meet the same standards as a new...

Page 67: ...sure measuring port on the engine fuel rail Direct drain hose to a suitable container and depress the pressure relief button Alternate Method Disconnect the inertia switch Crank the engine for 15 to 20 seconds to relieve pressure Section 10 01 Fuel Tank Filters Lines and Electric Fuel Pump 1997 Aerostar Ranger Equipped with 2 3L 3 0L and 4 0L Gasoline Engines Workshop Manual SPECIAL SERVICE TOOL S...

Page 68: ...p Bolts 47 61 35 45 Fuel Tank Heat Shield Screws 3 6 27 53 Fuel Tank Filler Pipe Clamp 3 4 27 35 Fuel Tank Support Strap U Nuts 34 46 25 34 Ground Strap to Frame Attaching Screw 12 15 9 11 Fuel Tank Sending Unit Locking Retainer Ring 55 74 40 55 Fuel Pressure Regulator to Injector Manifold Retaining Screws 3 5 27 44 Fuel Tank Filler Pipe 2 3 18 25 Fuel Tank Support Strap Bolt 47 61 35 45 Fuel Filt...

Page 69: ...Page 2 of 2 1997 Aerostar Ranger 2011 04 29 file C TSO tsocache VDTOM_5368 SVK us en file SVKA1029 HTM gen ref HTM tomsn048 gmail com ...

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