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HOMESERVICE MANUALSFORD1991RANGER 4WD V6-245 4.0LREPAIR AND DIAGNOSISENGINE, COOLING AND EXHAUSTENGINECYLINDER HEAD ASSEMBLYVALVE COVERSERVICE AND REPAIR
1991 Ford Ranger 4WD V6-245 4.0L
Valve Cover: Service and Repair
1991 Ford Ranger 4WD V6-245 4.0LSECTION Service and Repair
*** THIS ARTICLE REFLECTS CHANGES MADE BY TSB #91-5B-28, DATED March 22, 1991
REMOVAL
1. Disconnect negative battery cable.
2. Disconnect ignition wires from spark plugs.
3. Disconnect fuel supply and return fuel lines.
4. On LH valve cover, upper intake manifold removal may be required.
NOTE: For RH valve cover removal, refer to steps 5 through 12, then continue with the following steps for removal of both covers.
5. Remove the air inlet duct and the hose attached to the oil fill tube.
6. Remove the accessory drive belt from the alternator.
7. Remove the alternator from the engine.
8. Drain the cooling system.
9. Remove the upper radiator hose.
10. Remove the E-DIS ignition coil pack and bracket assembly.
11. Remove the low pressure A/C hose bracket from the upper intake manifold.
12. Remove vacuum hose from the air cleaner.
13. Remove the PCV valve hose and breather.
14. Remove rocker arm cover attaching screws and load distribution washers (patch pieces). Ensure washers are installed in their original position.
15. If necessary, with a light plastic hammer, tap rocker arm covers to break seal.
16. Remove rocker covers.
INSTALLATION
1. Clean all gasket material from cylinder heads, intake manifolds, and rocker cover gasket surfaces.
2. Peel the plastic film from the new gasket and stick the self adhesive side to the rocker cover. Apply RTV to the T-joints of cylinder head and intake manifold.
3. Apply an 8 mm ball of RTV to the bolt holes of the exhaust side of rocker cover (4 holes each side).
4. Install patch pieces together with new conical spring washer screws.
NOTE: Failure to install a new rocker cover gasket and rocker cover reinforcement pieces will result in oil leaks.
5. Tighten screws to 6-8 Nm (4.5-5.9 ft lb).
6. Install upper intake manifold, if removed.
7. On RH side, install the E-DIS ignition coil pack and bracket assembly.
8. On RH side, install vacuum hose to the air cleaner and A/C low pressue hose bracket.
9. On RH side, install the upper radiator hose. Fill and bleed the cooling system.
10. On RH side, install the alternator and accessory drive belt. Check belt tension.
11. On RH side, install air inlet duct and oil fill tube.
12. Install ignition wires.
13. Install PCV valve hose and breather.
14. Connect fuel supply and return lines to fuel rail.
15 Connect negative battery cable.
16. Start engine and check for fuel and oil leaks.
REMOVAL
1. Disconnect negative battery cable.
2. Disconnect ignition wires from spark plugs.
3. Disconnect fuel supply and return fuel lines.
4. On LH valve cover, upper intake manifold removal may be required.
NOTE: For RH valve cover removal, refer to steps 5 through 12, then continue with the following steps for removal of both covers.
5. Remove the air inlet duct and the hose attached to the oil fill tube.
6. Remove the accessory drive belt from the alternator.
7. Remove the alternator from the engine.
8. Drain the cooling system.
9. Remove the upper radiator hose.
10. Remove the E-DIS ignition coil pack and bracket assembly.
11. Remove the low pressure A/C hose bracket from the upper intake manifold.
12. Remove vacuum hose from the air cleaner.
13. Remove the PCV valve hose and breather.
14. Remove rocker arm cover attaching screws and load distribution washers (patch pieces). Ensure washers are installed in their original position.
15. If necessary, with a light plastic hammer, tap rocker arm covers to break seal.
16. Remove rocker covers.
INSTALLATION
Valve Covers:
1. Clean all gasket material from cylinder heads, intake manifolds, and rocker cover gasket surfaces.
2. Peel the plastic film from the new gasket and stick the self adhesive side to the rocker cover. Apply RTV to the T-joints of cylinder head and intake manifold.
3. Apply an 8 mm ball of RTV to the bolt holes of the exhaust side of rocker cover (4 holes each side).
4. Install patch pieces together with new conical spring washer screws.
NOTE: Failure to install a new rocker cover gasket and rocker cover reinforcement pieces will result in oil leaks.
5. Tighten screws to 6-8 Nm (4.5-5.9 ft lb).
6. Install upper intake manifold, if removed.
7. On RH side, install the E-DIS ignition coil pack and bracket assembly.
8. On RH side, install vacuum hose to the air cleaner and A/C low pressue hose bracket.
9. On RH side, install the upper radiator hose. Fill and bleed the cooling system.
10. On RH side, install the alternator and accessory drive belt. Check belt tension.
11. On RH side, install air inlet duct and oil fill tube.
12. Install ignition wires.
13. Install PCV valve hose and breather.
14. Connect fuel supply and return lines to fuel rail.
15 Connect negative battery cable.
16. Start engine and check for fuel and oil leaks.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.