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manual de taller ranger (ford) a partir del 2001

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Alex Morales
Alex Morales
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Table of Contents 1: General Information 00: Service Information 2: Chassis 04: Suspension 05: Driveline 06: Brake System 11: Steering System 3: Powertrain 03: Engine 07: Automatic Transmission 08: Manual Transmission, Clutch and Transfer Case 09: Exhaust System 10: Fuel System 4: Electrical 12: Climate Control System 13: Instrumentation and Warning Systems 14: Battery and Charging System 15: Audio Systems 17: Lighting 18: Electrical Distribution 19: Electronic Feature Group 5: Body and Paint 01: Body 02: Frame and Mounting
Diagnostic Trouble Code Chart Diagnostic Trouble Code (DTC) Chart DTC Description Source Action B1213 Anti-Theft Number of Programmed Keys is Below Minimum PCM REFER to Section 419-01. RCM REFER to Section 501-20B. B1231 Longitudinal Acceleration Threshold Exceeded B1309 Power Door Lock Circuit Short to Ground Central security module REFER to Section 501-14. B1313 Battery Saver Relay Coil Circuit Open, Short to Ground GEM REFER to Section 417-02. GEM REFER to Section 417-02. B1315 Battery Saver Relay Circuit Short to Battery B1317 Battery Voltage High 4WD control module REFER to Section 414-00. B1317 Battery Voltage High GEM REFER to Section 414-00. B1318 Battery Voltage Low 4WD control module REFER to Section 414-00. B1318 Battery Voltage Low RCM REFER to Section 414-00. B1318 Battery Voltage Low GEM REFER to Section 414-00. B1322 Driver Door Ajar Circuit Short to Ground GEM REFER to Section 417-02. B1323 Door Ajar Lamp Circuit Failure GEM REFER to Section 413-01. B1325 Door Ajar Lamp Circuit Short to Battery GEM REFER to Section 413-01. B1330 RF Door Ajar Circuit Short to Ground GEM REFER to Section 417-02. B1334 Decklid Ajar Rear Door Circuit Short to Ground GEM REFER to Section 417-02. B1340 Chime Input Request Circuit Short to Ground GEM REFER to Section 413-09. B1341 Power Door Unlock Circuit Short to Ground Central security module REFER to Section 501-14. B1342 ECU is Defective ABS module CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved, INSTALL a new ABS module. REFER to Section 206-09. CLEAR the DTCs. REPEAT the self-test. B1342 ECU is Defective Central security module CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved, INSTALL a new central security module. REFER to Vehicle Security Module in this section. CLEAR the DTCs. REPEAT the self-test. B1342 ECU is Defective 4WD CLEAR the DTCs. REPEAT the self-test. If DTC
control module B1342 is retrieved, INSTALL a new 4WD Control Module. REFER to Section 308-07A . CLEAR the DTCs. REPEAT the self-test. B1342 ECU is Defective GEM CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved, INSTALL a new GEM. REFER to Generic Electronic Module (GEM) in this section. CLEAR the DTCs. REPEAT the self-test. B1342 ECU is Defective RCM CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved, INSTALL a new RCM. REFER to Section 501-20B . CLEAR the DTCs. REPEAT the self-test. B1345 Heated Backlite Input Circuit Short to Ground GEM REFER to Section 501-11. B1347 Heated Backlite Relay Circuit Failure GEM REFER to Section 501-11. B1349 Heated Backlite Relay Short to Battery GEM REFER to Section 501-11. B1352 Ignition Key-In Circuit Failure GEM REFER to Section 413-09. B1355 Ignition Run Circuit Failure 4WD control module REFER to Section 211-05. B1355 Ignition Run Circuit Failure GEM REFER to Section 211-05. B1359 Ignition Run/Acc Circuit Failure GEM REFER to Section 211-05. B1365 Ignition Start Circuit Failure GEM REFER to Section 211-05. B1371 Illuminated Entry Relay Circuit Failure GEM REFER to Section 417-02. B1373 Illuminated Entry Relay Short to Battery GEM REFER to Section 417-02. B1398 LF Power Window One Touch Window Relay Circuit Failure GEM REFER to Section 501-11. B1400 LF Power Window One Touch Window Relay Circuit Short to Battery GEM REFER to Section 501-11. B1405 LF Power Window Down Circuit Short to Battery GEM REFER to Section 501-11. B1408 GEM REFER to Section 501-11. B1410 LF Power Window Motor Circuit Failure GEM REFER to Section 501-11. B1426 Safety Belt Lamp Circuit Short to Battery GEM REFER to Section 413-01. B1428 Safety Belt Lamp Circuit Failure GEM REFER to Section 413-01. B1431 Wiper Brake/Run Relay Circuit Failure GEM REFER to Section 501-16. B1432 Wiper Brake/Run Relay GEM REFER to Section 501-16. LF Power Window Up Circuit Short to Battery
Circuit Short to Battery B1434 Wiper Hi/Low Speed Relay Circuit Failure GEM REFER to Section 501-16. B1436 Wiper Hi/Low Speed Relay Circuit Short to Battery GEM REFER to Section 501-16. B1438 Wiper Mode Select Switch Circuit Failure GEM REFER to Section 501-16. B1441 Wiper Mode Select Switch Circuit Short to Ground GEM REFER to Section 501-16. B1446 Wiper Park Sense Circuit Failure GEM REFER to Section 501-16. B1450 Wiper Wash/Delay Switch Circuit Failure GEM REFER to Section 501-16. B1453 Wiper Wash/Delay Switch Circuit Short to Ground GEM REFER to Section 501-16. B1458 Wiper Washer Pump Motor Relay Circuit Failure GEM REFER to Section 501-16. B1460 Wiper Washer Pump Motor Relay Circuit Short to Battery GEM REFER to Section 501-16. B1462 Safety Belt Switch Circuit Failure GEM REFER to Section 413-09. B1466 Wiper Hi/Low Speed Not Switching GEM REFER to Section 501-16. B1473 Wiper Low Speed Circuit Motor Failure GEM REFER to Section 501-16. B1476 Wiper High Speed Circuit Motor Failure GEM REFER to Section 501-16. B1483 Brake Pedal Input Circuit Failure GEM REFER to Section 308-07A. B1485 Brake Pedal Input Circuit Short to Battery 4WD control module REFER to Section 308-07A. B1485 Brake Pedal Input Circuit Short to Battery ABS module REFER to Section 308-07A. B1485 Brake Pedal Input Circuit Short to Battery Central security module REFER to Section 308-07A. B1526 Keyless Entry Circuit Short to Ground Central security module REFER to Section 501-14. B1555 Ignition Run/Start Circuit Failure 4WD control module REFER to Section 211-05. B1562 Door Lock Cylinder Circuit Short to Ground Central security module REFER to Section 501-14. B1577 Park Lamp Input Circuit Short to Battery GEM REFER to Section 413-09.
B1600 PATS Ignition Key Transponder Signal is Not Received PCM REFER to Section 419-01. B1601 PATS Received Incorrect Key-Code From Ignition Key Transponder PCM REFER to Section 419-01. B1602 PATS Received Invalid Format of Key-Code From Ignition Key Transponder PCM REFER to Section 419-01. B1610 Illuminated Entry Input Circuit Short to Ground GEM REFER to Section 417-02. B1629 PRNDL Reverse Input Short to Battery Central security module REFER to Section 501-14. B1676 Battery Pack Voltage Out of Range ABS module REFER to Section 206-09. B1681 PATS Transceiver Module Signal is Not Received PCM REFER to Section 419-01. B1840 Wiper Front Power Circuit Failure GEM REFER to Section 501-16. B1869 Lamp Air Bag Warning Indicator Circuit Open RCM REFER to Section 501-20B. B1870 Lamp Air Bag Warning Indicator Circuit Short to Battery RCM REFER to Section 501-20B. B1871 Passenger Air Bag Deactivate Module Fault RCM REFER to Section 501-20B. B1877 Driver Safety Belt Pretensioner Circuit Open RCM REFER to Section 501-20B. B1878 Driver Safety Belt Pretensioner Circuit Short to Battery RCM REFER to Section 501-20B. B1879 Driver Safety Belt Pretensioner Circuit Short to Ground RCM REFER to Section 501-20B. B1881 Passenger Safety Belt Pretensioner Circuit Open RCM REFER to Section 501-20B. B1882 Passenger Safety Belt Pretensioner Circuit Short to Battery RCM REFER to Section 501-20B. B1883 Passenger Safety Belt Pretensioner Circuit Short to Ground RCM REFER to Section 501-20B. B1884 PAD Warning Lamp Inoperative RCM REFER to Section 501-20B. B1885 Driver Safety Belt Pretensioner Circuit Resistance Low on Squib RCM REFER to Section 501-20B. B1886 Passenger Safety Belt Pretensioner Circuit Resistance Low on Squib RCM REFER to Section 501-20B. B1887 Driver Air Bag Circuit RCM REFER to Section 501-20B.
Short to Ground B1888 Passenger Air Bag Circuit Short to Ground RCM REFER to Section 501-20B. B1889 Passenger Air Bag Deactivate Module Sensor Obstructed RCM REFER to Section 501-20B. B1890 PAD Warning Lamp Circuit Short to Battery RCM REFER to Section 501-14. B1891 Air Bag tone Warning Indicator Circuit Short to Battery RCM REFER to Section 501-20B. B1892 Air Bag Tone Warning Indicator Circuit Failure RCM REFER to Section 501-20B. B1901 Air Bag Crash Sensor No. 1 Feed/Return Circuit Short to Ground RCM REFER to Section 501-20B. B1916 Driver Air Bag Circuit Short to Battery RCM REFER to Section 501-20B. B1921 Air Bag Diagnostic Monitor Ground Circuit Open RCM REFER to Section 501-20B. B1925 Passenger Air Bag Circuit Short to Battery RCM REFER to Section 501-20B. B1932 RCM REFER to Section 501-20B. B1933 Passenger Air Bag Circuit Open RCM REFER to Section 501-20B. B1934 Driver Air Bag Inflator Circuit Resistance Low on Squib RCM REFER to Section 501-20B. B1935 Passenger Air Bag Inflator Circuit Resistance Low on Squib RCM REFER to Section 501-20B. B1941 Air Bag Crash Sensor No. 1 Feed/Return Circuit Open RCM REFER to Section 501-20B. B2103 PCM REFER to Section 419-01. B2106 Throttle Position Input Out of Range High 4WD control module REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual.. B2276 Less Than Two Transmitters Programmed Central security module REFER to Section 501-14. B2425 Remote Keyless Entry Out of Synchronization Central security module REFER to Section 501-14. B2431 Transponder Programming Failure PCM REFER to Section 419-01. Central security module REFER to Section 418-01. B2477 Driver Air Bag Circuit Open Antenna Not Connected Module Configuration Failure
B2477 Module Configuration Failure GEM REFER to Section 418-01. B2477 Module Configuration Failure RCM REFER to Section 418-01. B9610 Illuminated Entry Input Short Circuit to Ground GEM No Action C1095 ABS Hydraulic Pump Motor Circuit Failure ABS module REFER to Section 206-09. C1145 RF Wheel Speed Sensor Input Circuit Failure ABS module REFER to Section 206-09. C1155 LF Wheel Speed Sensor Input Circuit Failure ABS module REFER to Section 206-09. C1230 Wheel Speed Sensor Rear Center Input Circuit Failure ABS module REFER to Section 206-09. C1233 LF Wheel Speed Input Signal Missing ABS module REFER to Section 206-09. C1234 RF Wheel Speed Input Signal Missing ABS module REFER to Section 206-09. C1237 Rear Wheel Speed Input Signal Missing ABS module REFER to Section 206-09. C1728 Transfer Case Unable to Transition Between 2H and 4H 4WD control module REFER to Section 308-07A. C1729 Transfer Case Unable to Transition Between 4H and 4L 4WD control module REFER to Section 308-07A. C1939 Brake Pressure Switch Input Circuit Failure ABS module REFER to Section 206-09. P0500 Vehicle Speed Sensor (VSS) Malfunction 4WD control module REFER to Section 206-09. P0500 Vehicle Speed Sensor (VSS) Malfunction GEM REFER to Section 308-07A. P1804 Transmission 4-Wheel Drive High Indicator Circuit Failure 4WD control module REFER to Section 308-07A. P1806 Transmission 4-Wheel Drive High Indicator Circuit Short to Battery 4WD control module REFER to Section 308-07A. P1808 Transmission 4-Wheel Drive Low Indicator Circuit Failure 4WD control module REFER to Section 308-07A. P1810 Transmission 4-Wheel Drive Low Indicator Circuit Short to Battery 4WD control module REFER to Section 308-07A. P1812 Transmission 4-Wheel Drive Mode Select Circuit Failure 4WD control module REFER to Section 308-07A. P1815 Transmission 4-Wheel Drive Mode Select Circuit Short to Ground 4WD control module REFER to Section 308-07A.
P1816 Transmission Neutral Safety Switch Circuit Failure 4WD control module REFER to Section 308-07A. P1819 Transmission Neutral Safety Switch Circuit Short to Ground 4WD control module REFER to Section 308-07A. P1849 Transmission Transfer Case Contact Plate A Circuit Short to Ground 4WD control module REFER to Section 308-07A. P1853 Transmission Transfer Case Contact Plate B Circuit Short to Ground 4WD control module REFER to Section 308-07A. P1857 Transmission Transfer Case Contact Plate C Circuit Short to Ground 4WD control module REFER to Section 308-07A. P1861 Transmission Transfer Case Contact Plate D Circuit Short to Ground 4WD control module REFER to Section 308-07A. P1867 Transmission Transfer Case Contact Plate General Circuit Failure 4WD control module REFER to Section 308-07A. P1891 Transmission Transfer Case Contact Plate Ground Return Circuit Open 4WD control module REFER to Section 308-07A.
2001 Ranger Contents/Index GROUP 06: Brake System SECTION 206-00: Brake System — General Information SECTION 206-02: Drum Brake SECTION 206-03: Front Disc Brake SECTION 206-05: Parking Brake and Actuation SECTION 206-06: Hydraulic Brake Actuation SECTION 206-07: Power Brake Actuation SECTION 206-09: Anti-Lock Control
2001 Ranger Contents/Index GROUP 06: Brake System SECTION 206-09: Anti-Lock Control SPECIFICATIONS DESCRIPTION AND OPERATION Anti-Lock Control — (4WABS) DIAGNOSIS AND TESTING Anti-Lock Control Principles of Operation Inspection and Verification Symptom Chart Pinpoint Tests REMOVAL AND INSTALLATION Hydraulic Control Unit Anti-Lock Brake System (ABS) Module Sensor — Front 4x2 Sensor — Front 4x4 Sensor — Rear Sensor Indicator — Front 4x2 Sensor Indicator — Front 4x4 Sensor Indicator — Rear
SECTION 206-09: Anti-Lock Control SPECIFICATIONS 2001 Ranger Workshop Manual Procedure revision date: 03/08/2004 Torque Specifications Description Nm lb-ft lb-in Battery ground cable bolt 8.5 — 75.5 Anti-lock brake system (ABS) module bolts 2.0 — 18 Hydraulic control unit (HCU) to bracket bolts 9 — 80 Front wheel speed sensor bolt (4x2) 12 8.5 — Front wheel speed sensor bolt (4x4) 8 — 71 Front wheel speed sensor wire retaining bolt (4x4) 8 — 71 Inlet brake line to HCU nuts (M10-1) 23 17 — Outlet brake line to HCU nuts (M12-1) 18 13 — Rear axle speed sensor bolt 27 20 —
SECTION 206-09: Anti-Lock Control DESCRIPTION AND OPERATION 2001 Ranger Workshop Manual Procedure revision date: 03/08/2004 Anti-Lock Control — (4WABS) The anti-lock control system consists of the following components: • hydraulic control unit (HCU) • anti-lock brake system (ABS) module • rear axle speed sensor • rear axle speed sensor indicator • front wheel speed sensor • front wheel speed sensor indicator • yellow ABS warning indicator • brake pressure switch
SECTION 206-09: Anti-Lock Control DIAGNOSIS AND TESTING 2001 Ranger Workshop Manual Procedure revision date: 03/08/2004 Anti-Lock Control Refer to Wiring Diagrams Section 206-09 for schematic and connector information. Special Tool(s) Digital Analog DMM (Series III) 105-R0057 or equivalent Automotive DMM w/Pickup 105-R0053 or equivalent Breakout Box, EEC-IV Control System 418-005 (014-00322) (T83L-50-EEC-IV) or equivalent Worldwide Diagnostic System (WDS) 418-F224 or equivalent diagnostic tool with appropriate adapter cable Connector, ABS Electrical System 418-063 (T97P-50-ALA) Principles of Operation The anti-lock brake system (ABS) operates as follows: • When the brakes are applied, fluid is forced from the brake master cylinder outlet ports to the hydraulic control unit (HCU) inlet ports. This pressure is transmitted through four normally open solenoid valves contained inside the HCU and then through the outlet ports of the HCU to each wheel. • If the ABS module senses a wheel is about to lock, based on wheel speed sensor data, it closes the normally open solenoid valve for that circuit. This prevents any more fluid from entering that circuit. • The ABS module then looks at the wheel speed sensor signal from the affected wheel(s) again. • If that wheel(s) is still decelerating, it opens the closed solenoid valve for that circuit.
• Once the affected wheel comes back up to speed, the ABS module returns the valves to their normal condition, allowing fluid to flow to the affected brake. • The ABS module monitors the electromechanical components of the system. • A malfunction in the ABS will cause the ABS module to shut off or inhibit the system. However, normal power-assisted braking remains. • Malfunctions are indicated by a yellow ABS warning indicator in the instrument cluster (10849). • The ABS is self-monitoring. When the ignition switch is turned to the RUN position, the ABS module will carry out a preliminary self-check on the anti-lock electrical system indicated by a three-second illumination of the yellow ABS warning indicator in the instrument cluster. • During vehicle operation, including normal and anti-lock braking, the ABS module monitors all electrical anti-lock functions and some hydraulic operations. • Each time the vehicle is driven to approximately 32 km/h (20 mph), the ABS module turns on the pump motor for approximately one-half second. At this time, a mechanical noise may be heard. This is a normal function of the self-check by the ABS module. • Pedal pulsation coupled with noise while braking on loose gravel, bumps, wet or snowy roads is normal and indicates correct functioning of the vehicle's ABS system. Hydraulic Control Unit (HCU) The HCU consists of the following components: • brake pressure control valve block • pump motor New brake pressure control valve block and pump motor are installed as an assembly. Anti-Lock Brake System (ABS) Module NOTE: The ABS module is 4x2 and 4x4 specific. Do not interchange modules. The ABS module is mounted to the HCU. It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and the necessary circuitry for their operation. The ABS module monitors system operation during normal driving as well as during anti-lock braking. ABS module operation is as follows: • Under normal driving conditions, the microprocessor produces short test pulses to the solenoid valves that check the electrical system without any mechanical reaction. • Impending wheel lock conditions trigger signals from the ABS module that open and close the appropriate solenoid valves. This results in moderate pulsations in the brake pedal (2455). • The ABS module used in 4x4 application includes a G-sensor. It detects vehicle movements during a brake lockup event that is transferred to other wheels through the powertrain. During normal braking, the brake pedal feel will be identical to a standard brake system. Most faults that occur in the ABS will be stored as a diagnostic trouble code (DTC) in the keep-alive memory of the ABS module. The DTCs can be retrieved by following the on-board diagnostic procedures.
Wheel Speed Sensor NOTE: Any time a wheel speed sensor is removed, thoroughly clean the mounting surfaces. On front wheel speed sensors, apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. The ABS uses three variable-reluctance sensors to determine vehicle speed. The wheel speed sensors operate on magnetic induction principle. As the teeth on the wheel speed sensor indicator rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and sent to the ABS module through a twisted cable and shielded wiring harness. Inspection and Verification 1. Verify the customer concern by applying the brakes under different conditions. 2. Visually inspect for obvious signs of mechanical and electrical damage. Visual Inspection Chart Mechanical Electrical • Parking brake cable • • Tire pressure 14 (10A) • Tire size or mismatched tires 11 (7.5A) Central junction box (CJB) fuse(s): 9 (7.5A) • Battery junction box (BJB) Maxi-Fuse 3 (50A) • BJB Mini-Fuse 7 (30A) • Connectors or connections • Harness routing • Wire chafing • Circuitry open/shorted • Indicator bulb 3. If the fault is not visually evident, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: • check that the program card is correctly installed. • check the connections to the vehicle. • check the ignition switch position. 4. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
• SCP or ISO = all electronic control units no response/not equipped, refer to Section 418-00. • No response/not equipped for the ABS module, GO to Pinpoint Test A. • System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the ABS module. 6. If the DTCs retrieved are related to the concern, go to the Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart. Warning Lamp Indicators The ABS uses the yellow ABS warning indicator to alert the driver of malfunctions in the ABS. The yellow ABS warning indicator will come on for numerous reasons. It warns the driver that the ABS has been deactivated due to a symptom that exists in the ABS. Normal power assist braking remains, but wheels can lock during a panic stop while the yellow ABS warning indicator is illuminated. The diagnostic procedures must be followed step-by-step in order to correct the condition. Electronic Brake Distribution (EBD) The electronic brake distribution (EBD) controls rear brake pressure and acts as an electronic proportioning valve. It is controlled by the ABS module. When EBD is disabled, the brake warning indicator will illuminate. Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Index DTC Description Source Action B1342 Anti-Lock Brake Control Module Failure ABS Module INSTALL a new ABS module. REFER to AntiLock Brake System (ABS) Module in this section. REPEAT the self-test. B1485 Brake Pedal Position (BPP) Switch Circuit Failure ABS Module IGNORE the DTC. This DTC applies only to traction control vehicles. B1676 Battery Voltage Out Of Range ABS Module GO to Pinpoint Test B. C1939 Brake Pressure Switch Circuit Failure ABS Module GO to Pinpoint Test G. C1095 Hydraulic Pump Motor Circuit Failure ABS Module GO to Pinpoint Test E. C1145 RF Wheel Speed Sensor Circuit Failure (Static) ABS Module GO to Pinpoint Test C. C1155 LF Wheel Speed Sensor Circuit Failure (Static) ABS Module GO to Pinpoint Test C. C1230 Rear Axle Speed Sensor Circuit Failure (Static) ABS Module GO to Pinpoint Test C. C1233 LF Wheel Speed Sensor Output Failure (Dynamic) ABS Module GO to Pinpoint Test D. C1234 RF Wheel Speed Sensor Output Failure (Dynamic) ABS Module GO to Pinpoint Test D.
C1237 Rear Axle Speed Sensor Output Failure (Dynamic) ABS Module GO to Pinpoint Test D. Symptom Chart Symptom Chart Condition • Possible Sources ABS module. • Wheel speed sensor indicator. • Sensor output is weak. Air gap. • Circuitry. • Wheel speed sensor. Maladjusted rear brakes or "grabby" brake shoe or pad linings • Rear brake adjustment. • Linings. Base brake mechanical concern for wheels lockup • Rear brake shoe linings. • Wheel cylinder. Rear brakes. • No communication with the anti-lock brake system (ABS) module Loss of sensor signal during vehicle deceleration or sensor signal drops out at low speed Unwarranted ABS activity Base brake hydraulic concern (soft pedal) • GO to Pinpoint Test A. • GO to Pinpoint Test D. • GO to Pinpoint Test D. • REFER to Section 206-00. • REFER to Section 206-00. Parking brake. • REFER to Section 206-05. • • Circuitry. • • Central junction box (CJB) fuse 14 (10A). • • • • • Battery junction box (BJB) fuse 3 (50A). • • • Action Rear axle seal. • REFER to Section 205-00. • Brake line or hose, fitting, master cylinder, wheel cylinder or caliper. • REFER to Section 206-00. • Air in brake
system. Base brake mechanical concern for vehicle pulls Brake line or hose. • Brake line or hose, fitting, master cylinder, wheel cylinder or caliper. Air in brake system. • Vacuum boost. • Wheel cylinder or caliper. Brake line or hose. Brake shoe or pad linings. • Rear brake. • Caliper. • • Wheel cylinder or caliper. • Base brake mechanical concern during medium/hard brake application • • • Base brake hydraulic concern during medium/hard brake application Vacuum boost. • • Base brake mechanical concern (hard pedal) • • • Brake pad or shoe wear. • REFER to Section 206-00. • REFER to Section 206-00. • REFER to Section 206-00. • REFER to Section 206-00. • Base brake hydraulic concern for vehicle pulls • Brake line or hose. • REFER to Section 206-00. • One wheel locks up; no DTCs recorded • Base brake. • REFER to Section 206-00. • Dump valve. • • ISO valve. INSTALL a new hydraulic control unit (HCU). REFER to Hydraulic Control Unit in this section. • Bulb. • • GO to Pinpoint Test F. Circuitry. • Instrument cluster. • The yellow ABS warning indicator does not self-check
• • Yellow ABS light always on, no DTC Brake line or hose, fitting, master cylinder, wheel cylinder, wheel cylinder or caliper. Air in brake system. • Soft or excessive brake pedal • • • Anti-lock brake system (ABS) module. Hydraulic control unit (HCU). • Circuitry. • Module. • Section 206-00. • GO to Pinpoint Test H. Pinpoint Tests PINPOINT TEST A: NO COMMUNICATION WITH THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE CONDITIONS DETAILS/RESULTS/ACTIONS A1 CHECK CIRCUIT 601 (LB/PK), 534 (YE/LG) AND 483 (RD) ABS Module C135 Connect the breakout box. Measure the voltage between the breakout box pins and ground as follows: Breakout Box Pin 20 Circuit 601 (LB/PK)
25 9 • 483 (RD) 534 (YE/LG) Are the voltages greater than 10 volts? Yes GO to A2. No REPAIR the circuit(s) in question. TEST the system for normal operation. A2 CHECK CIRCUIT 57 (BK) FOR AN OPEN Measure the resistance between the breakout box pin 8, circuit 57 (BK) and ground; and between the breakout box pin 24, circuit 57 (BK) and ground. • Are the resistances less than 5 ohms? Yes REFER to Section 418-00. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. PINPOINT TEST B: DTC B1676 — BATTERY VOLTAGE OUT OF RANGE
NOTE: DTC B1676 is generated when the ABS module detects system voltage is less than 9 volts or greater than 19 volts for more than 8 seconds. CONDITIONS DETAILS/RESULTS/ACTIONS B1 CHECK RECENT VEHICLE HISTORY Check recent vehicle history. • Has the vehicle been jumpstarted within the past two weeks? Yes The system is OK. CLEAR the DTCs. REPEAT the self-test. No GO to B2. B2 CHECK THE BATTERY VOLTAGE Measure the voltage between the positive and negative battery posts. • Is the voltage between 9 and 19 volts? Yes GO to B3. No REFER to Section 414-00. B3 CHECK CIRCUIT 601 (LB/PK) FOR CORRECT VOLTAGE ABS Module C135 Connect the breakout box. Measure the voltage between the breakout box pin 20, circuit 601 (LB/PK) and ground.
• Is the voltage greater than 10 volts? Yes GO to B4. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. B4 CHECK CIRCUIT 483 (RD) FOR AN OPEN Measure the voltage between the breakout box pin 25, circuit 483 (RD) and ground. • Is the voltage greater than 10 volts? Yes GO to B5. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. B5 CHECK CIRCUIT 534 (YE/LG) FOR AN OPEN Measure the voltage between the breakout box pin 9, circuit 534 (YE/LG) and ground.
• Is the voltage greater than 10 volts? Yes GO to B6. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. B6 CHECK CIRCUIT 57 (BK) FOR AN OPEN Measure the resistance between the breakout box pin 8, circuit 57 (BK) and ground; and between the breakout box pin 24, circuit 57 (BK) and ground. • Are the resistances less than 5 ohms? Yes INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. REPEAT the self-test. No REPAIR the circuit. CLEAR the DTCs. PINPOINT TEST C: DTCS C1145, C1155, AND C1230 — ANTI-LOCK BRAKE SENSOR CIRCUIT FAILURE CONDITIONS DETAILS/RESULTS/ACTIONS
C1 CHECK THE WHEEL SPEED SENSOR RESISTANCE AT BREAKOUT BOX ABS Module C135 Connect EEC-IV 60-Pin Breakout Box. Measure the resistance between EEC-IV 60-Pin Breakout Box pins for the suspect wheel speed sensor as follows: Wheel Speed Sensor EEC-IV 60-Pin Breakout Box Positive Negative Probe Probe LF 18 RF 3 4 Rear • 17 22 21 Is the resistance between 800 and 1400 ohms (front 4x2), 800 and 2500 ohms (rear), or 380 and 480 ohms (front 4x4)? Yes GO to C5. No GO to C2. C2 CHECK WHEEL SPEED SENSOR RESISTANCE Suspect Wheel Speed Sensor Measure the resistance between suspect wheel speed sensor terminals.
• Is the resistance between 800 and 1400 ohms (front 4x2), 800 and 3500 ohms (rear), or 380 and 480 ohms (front 4x4)? Yes GO to C3. No INSTALL a new wheel speed sensor. If the front wheel speed sensor (4x4), REFER to Sensor — Front 4x4 in this section. CLEAR the DTCs. REPEAT the self-test. If the front wheel speed sensor (4x2), REFER to Sensor — Front 4x2 in this section. CLEAR the DTCs. REPEAT the self-test. If the rear axle speed sensor, REFER to Sensor — Rear in this section. CLEAR the DTCs. REPEAT the self-test. C3 CHECK CIRCUIT 521 (TN/OG), 514 (YE/RD), OR 523 (RD/PK) Measure the resistance between the suspect wheel speed sensor and EEC-IV 60-Pin Breakout Box; and between the suspect wheel speed sensor and ground as follows:
AntiSensor EEC-IV Lock Connector 60-Pin Brake and Breakout Box Sensor Circuit LF 17 RF C158 Pin 2, Circuit 514 (YE/RD) 3 Rear • C151 Pin 2, Circuit 521 (TN/OG) C421 Pin 2, Circuit 523 (RD/PK) 21 Is the resistance between the suspect wheel speed sensor and EEC-IV 60-Pin Breakout Box less than 5 ohms; and between the suspect wheel speed sensor and ground greater than 10,000 ohms? Yes GO to C4. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. C4 CHECK CIRCUIT 522 (TN/BK), 516 (YE/BK) OR 519 (LG/BK) Measure the resistance between the suspect wheel speed sensor and EEC-IV 60-Pin Breakout Box; and between the suspect wheel speed sensor and ground as follows: AntiSensor EEC-IV Lock Connector 60-Pin Brake and Breakout Sensor Circuit Box LF C151 Pin 1, Circuit 522 (TN/BK) 18
RF 19 Rear • C158 Pin 1, Circuit 516 (YE/BK) C421 Pin 1, Circuit 519 (LG/BK) 22 Is the resistance between the suspect wheel speed sensor and EEC-IV 60-Pin Breakout Box less than 5 ohms; and between the suspect wheel speed sensor and ground greater than 10,000 ohms? Yes GO to C8. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. C5 CHECK THE SUSPECT WHEEL SPEED SENSOR CIRCUIT FOR SHORT TO POWER Suspect Wheel Speed Sensor Measure the voltage between the suspect EEC-IV 60-Pin Breakout Box pins and ground as follows: Wheel Speed Sensor EEC-IV 60-Pin Breakout Box
LF RF 3 Rear • 17 22 Is voltage present? Yes REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. No GO to C6. C6 CHECK CIRCUIT 521 (TN/OG), 514 (YE/RD) or 523 (RD/PK) FOR SHORT TO GROUND Measure the resistance between EEC-IV 60-Pin Breakout Box and ground for the suspect wheel speed sensor as follows: Wheel Speed Sensor LF 17 RF 3 Rear • EEC-IV 60-Pin Breakout Box 21 Is the resistance greater than 10,000 ohms? Yes GO to C7. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. C7 CHECK CIRCUIT 522 (TN/BK), 516 (YE/BK) OR 519 (LG/BK) FOR SHORT TO GROUND Measure the resistance between EEC-IV 60-Pin Breakout Box and ground as follows: Wheel Speed Sensor EEC-IV 60-Pin Breakout Box
LF RF 4 Rear • 18 22 Is the resistance greater than 10,000 ohms? Yes GO to C8. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. C8 CHECK FOR SHORT TO SPINDLE If front wheel speed sensor is suspected, measure the resistance between the spindle near the sensor and both terminals of the wheel speed sensor. If the rear axle speed sensor is suspected, measure the resistance between the rear axle housing near the sensor and both terminals of the wheel speed sensor. • Yes Is the resistance greater than 10,000 ohms?
GO to C9. No INSTALL a new wheel speed sensor. If the front wheel speed sensor (4x4), REFER to Sensor — Front 4x4 in this section. CLEAR the DTCs. REPEAT the self-test. If the front wheel speed sensor (4x2), REFER to Sensor — Front 4x2 in this section. CLEAR the DTCs. REPEAT the self-test. If the rear axle speed sensor, REFER to Sensor — Rear in this section. CLEAR the DTCs. REPEAT the self-test. C9 CHECK WHEEL END ROUTING FOR DAMAGE Inspect the wheel speed sensor cable at the affected wheel end for chafing or other wiring damage. • Is damage found? Yes INSTALL a new wheel speed sensor. If the front wheel speed sensor (4x4), REFER to Sensor — Front 4x4 in this section. CLEAR the DTCs. REPEAT the self-test. If the front wheel speed sensor (4x2), REFER to Sensor — Front 4x2 in this section. CLEAR the DTCs. REPEAT the self-test. If the rear axle speed sensor, REFER to Sensor — Rear in this section. CLEAR the DTCs. REPEAT the self-test. No INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. REPEAT the self-test. PINPOINT TEST D: DTCS C1233, C1234, AND C1237 WHEEL SPEED SENSOR OUTPUT FAILURE NOTE: Any time a wheel speed sensor is removed, thoroughly clean the mounting surfaces. On front wheel speed sensors, apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590A or equivalent meeting Ford specification ESA-M1C198-A. CONDITIONS DETAILS/RESULTS/ACTIONS D1 CHECK THE DTCs FROM THE SELF-TEST Using the recorded results from the ABS self-test:
• Are DTCs C1145, C1155 or C1230 present? Yes GO to Pinpoint Test C. No GO to D2. D2 MONITOR THE WHEEL SPEED PIDS ABS Module PIDs Use the diagnostic tool to monitor the ABS module wheel speed sensor PIDs while driving the vehicle at a constant speed. • Are all the wheel speed sensor PID values similar? Yes CLEAR the DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If DTC C1233, C1234 or C1237 is present, GO to D10. No GO to D3. D3 INSPECT THE WHEEL SPEED SENSOR MOUNTING Raise and support the vehicle. Refer to Section 100-04. Inspect the wheel speed sensor for looseness. • Is the wheel speed sensor
loose? Yes TORQUE the wheel speed sensor to specification. CLEAR the DTCs. GO to D4. No GO to D5. D4 RECHECK THE WHEEL SPEED PIDS ABS Module PIDs Use the diagnostic tool to monitor the ABS module wheel speed sensor PIDs while driving the vehicle at a constant speed. • Are all the wheel speed sensor PID values similar? Yes The vehicle is OK. Concern may have been caused by a loose wheel speed sensor. No GO to D5. D5 CHECK THE WHEEL SPEED SENSOR FOR DAMAGE Raise and support the vehicle. Refer to Section 100-04. CAUTION: Examine the wheel speed sensor wire carefully with a good light source. Failure to verify damage in the wheel speed sensor wire can lead to unnecessary installation of a new component.
Inspect the wheel speed sensor for general damage. • Is the wheel speed sensor OK? Yes GO to D6. No INSTALL a new wheel speed sensor. REFER to Sensor — Front 4x2, Sensor — Front 4x4 or Sensor — Rear in this section. CLEAR the DTCs. TEST the system for normal operation. D6 CHECK FOR WHEEL SPEED SENSOR RING DAMAGE Remove the wheel speed sensor. Refer to Sensor — Front 4x2, Sensor — Front 4x4 or Sensor — Rear in this section. Inspect the wheel speed sensor ring for damaged or missing teeth. Rotate the wheel to verify that no teeth are missing. • Is the wheel speed sensor ring OK? Yes GO to D7. No INSTALL a new hub and bearing (front wheel), rear halfshaft (rear wheel) or ring gear. REFER to Section 204-00 or Section 205-00 respectively. CLEAR the DTCs. REPEAT the self-test. D7 CHECK FOR BEARING DAMAGE Inspect the wheel bearings for damage. • Are the wheel bearings OK? Yes GO to D8. No INSTALL a new wheel bearing as necessary. REFER to Section 20400. CLEAR the DTCs. REPEAT the self-test. D8 CHECK WHEEL SPEED SENSOR OUTPUT AT EEC-IV 60-PIN BREAKOUT BOX
Raise the vehicle so that all wheels are free to spin. ABS Module C135 Connect EEC-IV 60-Pin Breakout Box. While spinning the suspect wheel at a constant speed, measure the AC voltage of the suspect wheel speed sensor between EEC-IV 60-Pin Breakout Box pins as follows: EEC-IV 60-Pin Breakout Box Wheel Speed Positive Negative Sensor Probe Probe LF 18 RF 3 4 Rear • 17 22 21 Is there any voltage present? Yes INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. REPEAT the self-test. No GO to D9. D9 CHECK THE WHEEL SPEED SENSOR OUTPUT Suspect Wheel Speed Sensor While spinning the suspect wheel at a constant speed, measure the AC voltage between the suspect wheel speed sensor terminals.
• Is there any voltage present? Yes REPAIR the suspect wheel speed sensor circuit(s) in question. CLEAR the DTCs. REPEAT the self-test. No INSTALL a new wheel speed sensor. If front wheel speed sensor (4x4), REFER to Sensor — Front 4x4 in this section. CLEAR the DTCs. REPEAT the self-test. If front wheel speed sensor (4x2), REFER to Sensor — Front 4x2 in this section. CLEAR the DTC's. REPEAT the self-test. If rear wheel speed sensor; REFER to Sensor — Rear in this section. D10 CHECK FOR CORRECT ABS MODULE OPERATION Disconnect all ABS connectors. Check for: • corrosion • pushed-out pins
Connect all ABS connectors and make sure they seat correctly. Operate the system and verify the concern is still present. • Is the concern still present? Yes INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. TEST the system for normal operation. No The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. PINPOINT TEST E: DTC C1095 — HYDRAULIC PUMP MOTOR CIRCUIT FAILURE CONDITIONS DETAILS/RESULTS/ACTIONS E1 CHECK THE ABS PUMP MOTOR • Is the pump motor on constantly? Yes INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. CLEAR the DTCs. REPEAT the self-test. No GO to E2. E2 CHECK THE PUMP MOTOR OPERATION Diagnostic Tool
Trigger the ABS module active command PMP MOTOR ON. • Does the pump motor operate? Yes CLEAR the DTC. CHECK the yellow ABS warning indicator while driving the vehicle above 40 km/h (25 mph). If the yellow ABS warning indicator illuminates, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. CLEAR the DTCs. REPEAT the selftest. If the yellow ABS warning indicator does not illuminate, CLEAR the DTCs. REPEAT the self-test. No GO to E3. E3 CHECK THE PUMP MOTOR Pump Motor Connector Connect a fused 30A jumper wire between the positive battery terminal and red ABS pump motor terminal. Connect a jumper wire between the negative battery terminal and brown ABS pump motor terminal. • Is the ABS pump motor
running? Yes GO to E4. No INSTALL a new HCU. REFER to Hydraulic Control Unit in this section. REPEAT the self-test. E4 CHECK CIRCUIT 534 (YE/LG) AND CIRCUIT 601 (LB/PK) FOR AN OPEN ABS Module C135 Connect the breakout box. Measure the voltage between the breakout box pin 9, circuit 534 (YE/LG) and ground; and between the breakout box pin 20, circuit 601 (LB/PK) and ground. • Are the voltages greater than 10 volts? Yes GO to E5. No REPAIR the circuit(s) in question. CLEAR the DTCs. REPEAT the selftest. E5 CHECK CIRCUIT 57 (BK) FOR AN OPEN
Measure the resistance between the breakout box pin 8, circuit 57 (BK) and ground; and between the breakout box pin 24, circuit 57 (BK), and ground. • Are the resistances less than 5 ohms? Yes INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. REPEAT the self-test. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. PINPOINT TEST F: THE YELLOW ABS WARNING INDICATOR DOES NOT SELF-CHECK CONDITIONS DETAILS/RESULTS/ACTIONS F1 CHECK THE ABS MODULE ABS Module C135 Connect the breakout box. Connect a fused (10A) jumper
between the breakout box pin 16, circuit 603 (DG) and ground. • Does the yellow ABS warning indicator illuminate? Yes VERIFY that all repair procedures have been carried out and DTCs have been repaired. INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. REPEAT the self-test. No GO to F2. F2 CHECK CIRCUIT 603 (DG) FOR AN OPEN Instrument Cluster C288 Measure the resistance between the breakout box pin 16, circuit 603 (DG) and instrument cluster C288 pin 6, circuit 603 (DG). • Is the resistance less than 5 ohms? Yes INSTALL a new instrument cluster printed circuit. REFER to Section 413-01. TEST the system for normal
operation. No REPAIR the circuit. TEST the system for normal operation. PINPOINT TEST G: DTC C1939: BRAKE PRESSURE SWITCH (BPS) CIRCUIT FAILURE CONDITIONS DETAILS/RESULTS/ACTIONS G1 VERIFY DTC Clear DTC. Road Test. Repeat the self-test. • Does code repeat? Yes GO to G2. No REVERIFY. G2 MONITOR BRAKE PRESSURE SWITCH (BPS) PID • With foot off brake pedal, is battery voltage present?
Yes GO to G3. No GO to G4. G3 MONITOR BPS • While applying the brake pedal, is battery voltage present? Yes INSTALL a new ABS module. No GO to G7. G4 CHECK VOLTAGE TO BPS Brake Pressure Switch C1025 Measure the voltage between BPS C1025, circuit 276 (BN) and ground.
• Is the voltage greater than 10 volts? Yes GO to G5. No REPAIR the circuit and RETEST. REPAIR/INSTALL new as necessary. G5 CHECK CIRCUIT 307 (BK/YE) FOR SHORT TO GROUND ABS Module C135 Brake Pressure Switch C1025 Connect the breakout box. Measure the resistance between breakout box pin 13 and ground.
• Is the resistance greater than 10,000 ohms? Yes GO to G6. No REPAIR circuit 307 (BK/YE) and REPEAT the self-test. G6 CHECK CIRCUIT 307 (BK/YE) FOR OPEN Key Off ABS Module C135 Brake Pressure Switch C1025 Connect the breakout box. Measure the resistance between the suspect BPS connector terminal and the breakout box pin 13.
• Is the resistance less than 5 ohms? Yes INSTALL a new brake pressure switch and REPEAT the self-test. No REPAIR circuit 307 (BK/YE) and REPEAT the self-test. G7 CHECK FOR SHORT TO POWER Key Off ABSe Module C135 Brake Pressure Switch C1025 Connect the breakout box. KOEO Measure the voltage between the breakout box pin 13 and ground.
• Is voltage present? Yes REPAIR circuit 307 (BK/YE) and RETEST. No INSTALL a new brake pressure switch. PINPOINT TEST H: YELLOW ABS LIGHT ALWAYS ON, NO DTCS CONDITIONS DETAILS/RESULTS/ACTIONS H1 CHECK THE MODULE ABS Module C135 • Does the yellow ABS light illuminate? Yes GO to H2. No GO to F1. H2 CHECK CIRCUIT 603 (DG) FOR SHORT TO GROUND
At the ABS module connector, press the shorting bar. • Is the yellow ABS light off? Yes REPEAT the connector. If light remains on, INSTALL a new ABS module. No REPAIR circuit 603 (DG). REPEAT the self-test.
SECTION 206-09: Anti-Lock Control REMOVAL AND INSTALLATION 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Hydraulic Control Unit Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plaster surface, immediately wash it with water. 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector by lifting up on the release tab. 3. Disconnect the brake lines from the hydraulic control unit (HCU). 4. Remove the HCU. 1. Remove the bolts. 2. Remove the HCU.
5. If necessary, remove the anti-lock brake control module. Installation 1. CAUTION: After the electronic hydraulic control unit is installed, it is necessary to bleed the hydraulic brake system; refer to Section 206-00. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure.
SECTION 206-09: Anti-Lock Control REMOVAL AND INSTALLATION Anti-Lock Brake System (ABS) Module Removal 1. Disconnect the battery ground cable. 2. Remove the hydraulic control unit bolts. 3. Disconnect the electrical connectors. 4. Remove the anti-lock brake control module. 1. Remove the bolts. 2. Remove the anti-lock brake control module. Installation 2001 Ranger Workshop Manual Procedure revision date: 02/13/2003
1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. SECTION 206-09: Anti-Lock Control 2001 Ranger Workshop Manual
REMOVAL AND INSTALLATION Procedure revision date: 06/26/2000 Sensor — Front 4x2 Material Item High-Temperature 4x4 Front Axle and Wheel Bearing Grease Specification ESA-M1C198A Removal and Installation Raise and support the vehicle. For additional information, refer to Section 100-02. Disconnect the front anti-lock brake sensor wire from the vehicle frame. Disconnect the electrical connector. Unclip the front anti-lock brake sensor wire from the vehicle frame. Remove the front anti-lock brake sensor. Remove the bolt. Remove the front anti-lock brake sensor. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply grease. To install, reverse the removal procedure.
SECTION 206-09: Anti-Lock Control REMOVAL AND INSTALLATION 2001 Ranger Workshop Manual Procedure revision date: 03/08/2004 Sensor — Front 4x4 Removal and Installation Remove the rotor shield. For additional information, refer to Section 205-03. Disconnect the electrical connector. Unclip the wire from the vehicle frame. Remove the bolt. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford Specification ESA-M1C198-A. Remove the front wheel speed sensor. Remove the bolt and the sensor.
To install, reverse the removal procedure.
SECTION 206-09: Anti-Lock Control REMOVAL AND INSTALLATION 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Sensor — Rear Material Item Specification SAE 75W-140 High WSL-M2C192Performance Rear Axle A Lubricant XY-75W140-QL or equivalent Removal and Installation Raise and support vehicle. For additional information, refer to Section 100-02. NOTE: Clean off dirt and foreign material that may have collected around the rear antilock brake sensor before removal. Remove the rear anti-lock brake system (ABS) sensor. Disconnect the electrical connector. Remove the bolt. Remove the sensor. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the Oring with axle lubricant. To install, reverse the removal procedure. SECTION 206-09: Anti-Lock Control 2001 Ranger Workshop Manual
REMOVAL AND INSTALLATION Procedure revision date: 06/26/2000 Sensor Indicator — Front 4x2 Removal and Installation For additional information, refer to Section 206-03. SECTION 206-09: Anti-Lock Control 2001 Ranger Workshop Manual
REMOVAL AND INSTALLATION Procedure revision date: 06/26/2000 Sensor Indicator — Front 4x4 Removal and Installation For additional information, refer to Section 204-01B. SECTION 206-09: Anti-Lock Control 2001 Ranger Workshop Manual
REMOVAL AND INSTALLATION Procedure revision date: 06/26/2000 Sensor Indicator — Rear Removal and Installation NOTE: The rear anti-lock brake sensor indicator is attached to the differential case. For additional information, refer to Section 205-02A.For additional information, refer to Section 205-02B.
SECTION 303-01D: Engine — 2.3L IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 12/03/2003 Timing Drive Components Special Tool(s) Alignment Plate, Camshaft 303-465 (T949-6256-CH) Removal CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe damage can occur. 1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section. 2. Remove the timing chain tensioner. 1. Compress the timing chain tensioner, and insert a paper clip into the hole. 2. Remove the bolts and timing chain tensioner. 3. Remove the RH timing chain guide.
4. Remove the timing chain. 5. Remove the bolts and the LH timing chain guide.
6. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur. If necessary, remove the bolts and the camshaft sprockets. • Use the flats on the camshaft to prevent camshaft rotation. Installation 1. Remove the special tool. 2. CAUTION: Do not rotate the camshafts. Damage to the valves and pistons can occur. If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft rotation and loosen the sprocket bolts.
3. If removed, install the camshaft sprockets and the bolts. Do not tighten the bolts at this time. 4. Install the LH timing chain guide and bolts. 5. Install the timing chain. 6. Install the RH timing chain guide.
7. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. 8. Install the special tool. 9. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshafts can result.
Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. 10. Install the front cover. For additional information, refer to Engine Front Cover in this section.
SECTION 303-01C: Engine — 4.0L SOHC SPECIFICATIONS DESCRIPTION AND OPERATION Engine DIAGNOSIS AND TESTING Engine IN-VEHICLE REPAIR Intake Manifold Valve Cover — RH Valve Cover — LH Crankshaft Pulley Crankshaft Front Oil Seal Engine Front Cover Timing Drive Components — Camshaft Timing Timing Drive Components — Hydraulic Chain Tensioner, RH Timing Drive Components — Hydraulic Chain Tensioner, LH Timing Drive Components — Camshaft Drive Cassette, LH Valve — Valve Spring Valve — Valve Seals Hydraulic Lash Adjusters Roller Followers Camshaft — LH Camshaft — RH Exhaust Manifold LH Exhaust Manifold — RH Cylinder Head — LH Cylinder Head RH Oil Pan Oil Pump Screen and Pickup Tube Flywheel Flexplate Crankshaft Rear Oil Seal Cylinder Block Cradle Engine Support Insulators
REMOVAL Engine DISASSEMBLY Engine DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Head Piston ASSEMBLY Engine INSTALLATION Engine
SECTION 303-01C: Engine — 4.0L SOHC SPECIFICATIONS 2001 Ranger Workshop Manual Procedure revision date: 12/18/2003 General Specifications Item Specification Lubricants and Sealants Super Premium SAE 5W-30 Motor Oil XO-5W30QSP or equivalent WSS-M2C205-A Metal Surface Cleaner F4AZ-19A536-RA or equivalent WSE-M5B392-A Silicone Gasket and Sealant F7AZ-19554-EA or equivalent Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent WSE-M4G323-A4 ESA-M1C171-A Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent a ESE-M97B44-A (green color) Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent a b WSS-M97B51-A1 (yellow color) Engine — 4.0L SOHC Displacement liters (cubic inch) Number of cylinders Bore mm (inch) 4.0L (244) 6 100.4 (3.953) Stroke mm (inch) 84.4 (3.31) Firing order 1-4-2-5-3-6 Minimum oil pressure at 2,000 rpm (engine at normal operating temperature) kPa (psi) Oil capacity liters/quarts 103 (15) 3.8 (4) with filter Cylinder Head and Valve Train Cylinder head gasket surface flatness mm (inch) 0.08 (0.003) Total Combustion chamber volume (cc) 65.197 ± 2.068-2.018 Valve arrangement (front to rear) LH=I-E-I-E-I-E RH=E-I-E-I-E-I Valve guide bore diameter mm (inch) 7.00-7.018 (0.276) Valve stem diameter intake mm (inch) 6.965-6.98 (0.274-0.275) Valve stem diameter exhaust mm (inch) 6.95-6.965 (0.274) Valve stem-to-guide clearance exhaust mm (inch) 0.035-0.068 (0.001-0.003) Valve stem-to-guide clearance intake mm (inch) 0.020-0.053 (0.001-0.002) Valve head diameter intake mm (inch) 45.9-46.1 (1.807-1.815) Valve head diameter exhaust mm (inch) 38.9-39.1 (1.531-1.539) Valve face runout Valve face angle (degrees) Valve seat width (exhaust and intake) mm (inch) 0.03 (0.001) 45° 1.556-2.404 (0.06-0.094) 1.273-2.121 (0.05-0.083)
Valve seat runout (TIR maximum) mm (inch) Valve seat angle (degrees) 0.059 (0.002) 45° Valve spring free length intake mm (inch) 43.1 (1.7) Valve spring free length exhaust mm (inch) 43.1 (1.7) Valve spring squareness — Valve spring compression pressure intake (at specified height) (lb) 275-305 Nm at 35.9-36.7 mm (202.84224.968 lb-ft at 1.413-1.445 inch) Valve spring compression pressure exhaust (at specified height) (lb) 275-305 Nm at 35.9-36.7 mm (202.84224.968 lb-ft at 1.413-1.445 inch) Valve spring installed height intake mm (inch) 39.86-40.86 (1.569-1.601) Valve spring installed height exhaust mm (inch) 39.86-40.68 (1.569-1.601) Valve spring installed pressure — Roller follower ratio — Camshaft Theoretical valve lift @ 0 lash — Lobe lift intake mm (inch) 6.584 (0.259) Lobe lift exhaust mm (inch) 6.584 (0.259) Allowable lobe lift loss mm (inch) 0.127 (0.005) Journal diameter mm (inch) 27.935-27.96 (1.099-1.101) Journal bore inside diameter mm (inch) Journal to bearing clearance mm (inch) 28.0-28.03 (1.102-1.104) c Runout mm (inch) End play mm (inch) 0.04-0.095 (0.002-0.004) 0.05 (0.002) 0.075-0.185 (0.0003-0.007) Cylinder Block Cylinder bore diameter mm (inch) 100.4 (3.953) Cylinder bore maximum taper mm (inch) 0.025 (0.001) Cylinder bore maximum out-of-round mm (inch) 0.025 (0.001) Main bearing bore inside diameter mm (inch) Head gasket surface flatness mm (inch) Head gasket surface finish (RMS) 60.634-60.620 (2.387-2.387) 0.1 (0.004) overall 60-150 Crankshaft Main bearing journal diameter mm (inch) 56.980-57.0 (2.243-2.244) Main bearing journal maximum taper mm (inch) 0.008 (0.0003) Main bearing journal maximum out-of-round mm (inch) 0.008 (0.0003) Main bearing journal-to-cylinder block clearance mm (inch) — Connecting rod journal diameter mm (inch) 53.98-54.0 (2.125-2.126) Connecting rod journal maximum taper mm (inch) 0.008 (0.0003) Connecting rod journal maximum out-of-round mm (inch) 0.008 (0.0003) Crankshaft maximum end play mm (inch) Main Bearings 0.05-0.32 (0.002-0.0126)
Clearance to crankshaft mm (inch) 0.021-0.039 (0.0008-0.0015) Clearance to crankshaft allowable mm (inch) 0.013-0.048 (0.0005-0.002) Bearing wall thickness mm (inch) 1.8-1.806 (0.0709-0.0711) Piston and Connecting Rod Piston diameter — coded STD mm (inch) 100.380-100.400 (3.952-3.9528) Piston diameter — coded 0.5 mm (inch) 100.880-100.900 (3.972) Piston diameter — coded 1.0 mm (inch) 101.350-101.370 (3.990-3.991) Piston-to-cylinder bore clearance mm (inch) 0.030-0.060 (0.0012-0.002) Piston top ring end gap mm (inch) 0.200-0.450 (0.008-0.018) Piston bottom ring end gap mm (inch) 0.450-0.700 (0.018-0.028) Piston top ring groove width mm (inch) 1.64-1.66 (0.0645-0.0654) Piston bottom ring groove width mm (inch) 1.79-1.81 (0.0705-0.0713) Piston oil ring groove width mm (inch) 3.5-3.53 (0.1378-0.1399) Piston top ring width mm (inch) 1.578-1.598 (0.062-0.063) Piston bottom ring width mm (inch) 1.728-1.74 (0.068-0.069) Piston top ring-to-groove clearance mm (inch) 0.050-0.082 (0.002-0.0003) Piston bottom ring-to-groove clearance mm (inch) 0.050-0.082 (0.002-0.003) Piston pin bore diameter (red) mm (inch) 24.007-24.010 (0.945) Piston pin bore diameter (blue) mm (inch) 24.010-24.013 (0.945) Piston pin diameter (red) mm (inch) 23.994-23.997 (0.9446-0.9447) Piston pin diameter (blue) mm (inch) 23.997-24.000 (0.9447-0.9449) Piston pin length mm (inch) 72.0-72.8 (2.835-2.866) Piston pin-to-piston pin fit mm (inch) Piston pin-to-connecting rod clearance mm (inch) 0.01-0.016 (0.0004-0.0006) Press Fit -0.018 to -0.042 (-0.0007 to 0.0017) Connecting rod pin bore diameter mm (inch) 23.958-23.976 (0.943-0.944) Connecting rod length mm (inch) 145.965-146.035 (5.746-5.749) Connecting rod maximum allowed bend mm (inch) 0.0125 (0.00049) per 25.4 mm (1.000) Connecting rod maximum allowed twist mm (inch) 0.038 (0.0015) per 25.4 mm (1.000) Connecting rod bearing bore diameter mm (inch) 56.82-56.84 (2.237) Connecting rod bearing-to-crankshaft clearance mm (inch) 0.013-0.048 (0.005-0.002) Connecting rod side clearance (assembled to crankshaft) mm (inch) 0.092-0.268 (0.0036-0.0106) a Use the same type of coolant that was drained from the cooling system. Do not mix coolant types. b The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan. c Tighten camshaft bearing cap bolts to 15 Nm (11 lb-ft) when measuring journal clearance. Torque Specifications Description A/C compressor manifold bolt Nm lb-ft lb-in 20 15 —
A/C line bracket nut 20 15 — Accelerator control splash shield bolts 4 — 35 Balance shaft bolts 26-28 19-21 Balance shaft chain guide 9-11 Balance shaft tensioner bolts 28-30 21-22 — — 80-97 — Camshaft bearing cap bolts (a) — — Camshaft sprocket bolt 85 63 — 61 45 — — — — — — — — — — — — — — — — — — — Accessory bracket bolts 42 31 — Engine electrical connector 6 — 53 Engine front cover bolts 19 14 — Engine lifting eye bolts 28 21 — Electrical harness retainer bolt 10 — 89 Lower engine mount bracket nuts 80 59 — Fuel line bracket bolt 10 — 89 EGR valve tube fittings 34 25 — Exhaust manifold nuts 22 16 — Exhaust manifold to exhaust pipe bolts 40 30 — a — — 19 14 — — — — Fuel injection supply manifold bolts 23 17 — Generator bracket bolts 42 31 — Ground wire bolt 10 — 89 Camshaft sprocket bolt (w/sst) Cassette and sprocket to jackshaft bolt Cassette bolt, LH a Cassette bolt, RH a Connecting rod bolts a Crankshaft pulley bolts Cylinder head bolts a a Flywheel bolts Front cassette bolt Front cylinder head bolts a Heater hose bracket bolts a 23 17 — Hydraulic camshaft tensioner, RH a — — — Hydraulic camshaft tensioner, LH a — — — Intake manifold bolts 10 — 89 Jackshaft chain guide bolts 19 14 — 9 — 80 — — — — — — Jackshaft thrust plate bolts 11 8 — Knock sensor bolt 25 18 — Ladder frame bolts and nuts (outside) 10 — 89 Jackshaft chain tensioner bolts Jackshaft rear sprocket bolt Jackshaft front sprocket bolt a a
Ladder frame bolts (inside) a — — — Ladder frame Torx® bolts 8 — 71 Ladder frame inserts 3 — 27 Main bearing cap bolts 97 72 — Oil bypass filter 13 10 — Oil filter adapter bolt 57 42 — Oil level indicator tube bracket bolt 25 18 — Oil pan bolts 9 — 80 Oil pan drain plug 25 18 — Oil pressure sensor 11-16 9-11 — Oil pump bolts 19 14 — Oil pump drive assembly 19 14 — Oil pump screen cover and tube bolts 10 — 89 Powertrain control module (PCM) bolt 6 — 53 Powertrain control module (PCM) ground wire nut 10 — 89 Power steering pressure line nut 18 13 — Rear cassette bolt 18 13 — Spark plug 20 15 — Thermostat housing bolts 11 8 — Transmission cooler line bracket bolt 47 35 — Transmission to engine bolts 47 35 — Torque converter to flywheel nuts 47 35 — Upper engine mount bracket nuts 110 81 — Lower engine mount bracket bolts 80 59 — Valve cover bolts 10 — 89 Vapor management valve (VMV) hose bracket 15 11 — Water pump bolts 10 — 89 Water temperature indicator sender unit 10 — 89 Wiring harness retainer nuts 10 — 89 a Refer to the procedure.
SECTION 303-01C: Engine — 4.0L SOHC DESCRIPTION AND OPERATION 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Engine The 4.0L SOHC engine consists of the following: • single overhead camshafts • sequential multiport fuel injection (SFI) • distributorless ignition system • aluminum cylinder heads • cast iron, 60-degree V cylinder block • balance shaft (4x4 vehicles) • jackshaft • unique engine timing configuration For quick identification, refer to the vehicle control information decal mounted under the hood. • For additional information, refer to Section 100-01 . An engine identification label is attached to the engine. The label: • identifies the symbol code for determining parts usage. For additional information, refer to Section 100-01 . Lower Components—4.0L SOHC Engine
Item Part Number Description 1 6U000 Bolt 2 6M290 Camshaft drive cassette RH 3 12A699 Knock sensor 4 6A364 Balance shaft chain (4x4 only) 5 W702523 Bolt (4x4 only) 6 W702979 Crankshaft key 7 6306 Sprocket 8 6K350 Sprocket
9 6329 Crankshaft front main bearing cap 10 6345 Bolt (8 req'd) 11 W709211 Stud (2 req'd) 12 6F092 Cylinder block cradle 13 W503275 Bolt (20 req'd) 14 E822125 Nut 15 6734 Gasket 16 W702323 Bolt 17 E802185 Bolt 18 6675 Oil pan 19 W702323 Bolt (6 req'd) 20 6617 Oil pump screen and pickup tube 21 W709198 Bolt 22 E804588 Bolt 23 6C629 Spacer 24 6710 Gasket 25 6334 Crankshaft front intermediate main bearing cap 26 E804553 Screw (3 req'd) 27 6K790 Oil pickup adapter 28 W708582 Bolt (2 req'd) 29 6600 Oil pump 30 6A605 Oil pump intermediate shaft 31 6325 Crankshaft rear main bearing cap 32 6330 Crankshaft center main bearing cap 33 6A338 Crankshaft lower main bearing (3 req'd) 34 6A339 Crankshaft lower center main bearing 35 6303 Crankshaft 36 6333 Crankshaft upper main bearing (3 req'd) 37 6337 Crankshaft upper center main bearing 38 6K355 Balance shaft tensioner assembly (4x4 only) 39 6A311 Balance shaft (4x4 only) 40 6010 Block 41 9278 Oil pressure sensor 42 W701473 Nut (12 req'd) 43 6210 Connecting rod bearing cap (6 req'd) 44 6211 Connecting rod bearings 45 6200 Connecting rod 46 6135 Piston pin 47 6159 Piston ring, oil control (2 req'd) 48 6152 Piston ring, lower compression
49 6214 Bolt (2 req'd) 50 6110 Piston 51 6161 Piston ring, oil control spacer 52 6150 Piston ring, upper compression 53 6754 Oil level indicator tube 54 W701723 Bolt 55 6750 Oil level indicator 56 W500024 Bolt 57 12270 Clamp 58 6846 Oil pump drive assembly 59 6M289 Camshaft drive cassette LH 60 6M276 Bolt 61 W500110 Bolt 62 W703167 Bolt 63 6U001 Bolt 64 W500225 Bolt 65 6M276 Bolt Front and Rear Components—4.0L SOHC Engine
Item Part Number Description 1 6L621 Gasket 2 6884 Oil filter adapter 3 6895 Bolt 4 E853188 O-ring 5 6890 Adapter 6 6714 Oil filter 7 6M272 Jackshaft chain guide 8 6M278 Jackshaft thrust plate 9 6M263 Jackshaft 10 6C524 Jackshaft sprocket 11 6M276 Bolt 12 6M270 Jackshaft chain 13 W500012 Bolt (2 req'd) 14 6M271 Jackshaft chain tensioner 15 W702125 Bolt (2 req'd)
16 W500110 Bolt (2 req'd) 17 W500014 Bolt (2 req'd) 18 6K357 Balance shaft chain guide (4x4 only) 19 W500024 Bolt (5 req'd) 20 W702501 Stud 21 8507 Gasket 22 W500014 Bolt (12 req'd) 23 W500213 Bolt (2 req'd) 24 E800511 Bolt 25 6B321 Crankshaft pulley 26 6C315 Crankshaft position sensor 27 8501 Water pump 28 6700 Crankshaft front seal 29 E804541 Stud (4 req'd) 30 6019 Front cover 31 6020 Gasket 32 6379 Bolt (8 req'd) 33 6375 Flexplate 34 6434 Spacer 35 6701 Crankshaft rear seal Upper Components—4.0L SOHC Engine
Item Part Number Description 1 W708086 Bolt (2 req'd) 2 9F775 Fuel injection pulse damper 3 9G756 Fuel pressure/temperature sensor 4 W709515 Bolt (2 req'd) 5 W500023 Bolt (4 req'd) 6 W500204 Bolt 7 9E964 Fuel supply tube 8 W708086 Bolt (4 req'd) 9 9D280 Fuel injection supply manifold LH 10 9F593 Fuel injector (6 req'd) 11 9G512 Fuel injector adapter (6 req'd) 12 W500213 Bolt 13 9G271 Fuel vapor tube 14 9K479 Intake manifold
15 W708086 Bolt (2 req'd) 16 9G624 Cover 17 9D280 Fuel injection supply manifold RH 18 6763 Oil filler pipe 19 6582 Valve cover RH 20 6578 Oil supply tube RH 21 6A258 Camshaft bearing cap (3 req'd) 22 6250 Camshaft RH 23 6A258 Camshaft bearing cap 24 18465 Heated PCV coolant hose 25 18696 Heater water inlet tube assembly 26 W500023 Bolt 27 17A084 Lifting eye RH 28 W500041 Bolt (2 req'd) 29 W701706 Nut (6 req'd) 30 9430 Exhaust manifold RH 31 9448 Exhaust manifold gasket RH 32 6K254 Timing chain tensioner RH 33 W703974 Spacer 34 W705495 Stud (6 req'd) 35 6051 Cylinder head gasket RH 36 6049 Cylinder head RH 37 W525966 Clamp (2 req'd) 38 8548 Coolant hose 39 8A586 Thermostat housing 40 W702527 Bolt (3 req'd) 41 W702341 Bolt (16 req'd) 42 6049 Camshaft bearing cap 43 6A274 Camshaft LH 44 6K254 Timing chain tensioner LH 45 6N091 Oil volume reduction plug 46 6U000 Bolt 47 12405 Spark plug (6 req'd) 48 6505 Exhaust valve (6 req'd) 49 6083 Cylinder head gasket LH 50 6507 Intake valve (6 req'd) 51 9J433 Differential pressure feedback exhaust gas recirculation system 52 9E469 EGR tube 53 9G485 Adapter 54 9431 Exhaust manifold LH
55 W701706 Nut (6 req'd) 56 W500023 Bolt 57 9448 Exhaust manifold gasket LH 58 W705495 Stud (6 req'd) 59 W500041 Bolt (2 req'd) 60 17A084 Lifting eye LH 61 12A310 Ignition coil assembly 62 W500214 Bolt (2 req'd) 63 6571 Valve stem seal (12 req'd) 64 6513 Valve spring (12 req'd) 65 6C501 Lash adjuster (12 req'd) 66 6518 Valve spring retainer key (24 req'd) 67 6529 Roller follower (12 req'd) 68 6065 Cylinder head bolts (16 req'd) 69 6A536 Valve spring retainer seat (12 req'd) 70 6A258 Camshaft bearing cap (3 req'd) 71 6578 Oil supply tube LH 72 6A505 Valve cover LH 73 14A004 Bracket 74 W500204 Bolt 75 W500204 Bolt 76 6B288 Camshaft position sensor
SECTION 303-01C: Engine — 4.0L SOHC DIAGNOSIS AND TESTING Engine Refer to Section 303-00 . 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Intake Manifold Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 . 2. Remove the bolts and the shield. 3. Remove the air cleaner outlet pipe. • Disconnect the tube. • Detach the mass airflow (MAF) sensor wiring pushpin. • Loosen the clamps and remove the pipe. 4. Disconnect the idle air control (IAC) valve and the throttle position sensor (TPS) electrical connectors. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose. 5. Disconnect the accelerator and speed control cables. 1. Detach the accelerator and speed control cables from the throttle body.
2. Detach the accelerator and speed control cables from the bracket, and position the cables aside. 6. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube. 7. Disconnect the EGR valve vacuum regulator electrical connector and vacuum hoses. 8. Disconnect the hose. 9. Loosen the clamp and disconnect the brake booster vacuum hose.
10. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Disconnect the RH spark plug wires from coil. Remove spark plug wire routing clip pushpin and position the wires aside. 11. Remove wiring harness bracket retainer, then position wiring harness aside. 12. Remove accelerator cable routing clip pushpin and wiring harness pushpin. 13. Remove the bolts.
14. Remove the bolt and position the coil and bracket aside. 15. Disconnect the vacuum hoses. 16. Remove the nut. 17. Disconnect the powertrain control module (PCM) electrical connector.
18. Disconnect the ground wires and position the wiring harness aside. 19. Detach the electrical connector retainer. 20. Remove the intake manifold bolts and lift up the intake manifold.
21. Remove the heated PCV hose retainers and remove the heated PCV fitting. 22. Remove the intake manifold. 23. To install, reverse the removal procedure.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 04/01/2003 Valve Cover — RH Removal and Installation All vehicles 1. Drain the cooling system. For additional information, refer to Section 303-03 . 2. Remove the air cleaner outlet pipe. • Disconnect the tube. • Detach the mass airflow (MAF) sensor wiring pushpin. • Loosen the clamps and remove the pipe. 3. Release hose clamps and remove hose. 4. Remove hose.
5. Disconnect the vacuum hose. 6. Loosen hose clamps and disconnect hoses. 7. Release hose clamps and disconnect hoses. 8. Release hose clamp and disconnect hose.
9. Release hose clamp and disconnect hose. Position hose aside. Vehicles with automatic transmission 10. Remove the nut and position the transmission fluid level indicator and tube assembly aside. All vehicles 11. Remove the bolts. 12. Detach the wiring harness retainer. • Remove the heater tube and bracket assembly. 13. Disconnect MAF sensor connector and wiring pushpin. Position wiring aside.
14. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Position the spark plug wires aside. 1. Disconnect the spark plug wires. 2. Disconnect the spark plug wire retainer and position the wires aside. 15. Disconnect fuel injector electrical connectors. Position wiring aside. 16. Remove the bolts and the valve cover.
17. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean and inspect the sealing surfaces. Install a new gasket if necessary. 18. To install, reverse the removal procedure.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Valve Cover — LH Special Tool(s) Disconnect Tool, Spring Lock Coupling (5/8") 412-038 (T83P-19623-C) Removal and Installation 1. Disconnect the battery negative cable. For additional information, refer to Section 414-01 . 2. Detach the accelerator and speed control cables. 1. Detach the accelerator and speed control cables from the throttle body. 2. Detach the accelerator and speed control cables from the bracket, and position the cables aside. 3. Detach the spark plug wire retainer. 4. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Disconnect the spark plug wires.
5. Remove the bolts. 6. Remove the bolt. 7. Disconnect the coil electrical connector. 8. Disconnect the radio interference capacitor electrical connector and position the coil aside.
9. Loosen the bolt and disconnect the electrical connector. 10. Disconnect the following: 1. Exhaust gas recirculation (EGR) valve vacuum hose. 2. EGR valve vacuum regulator solenoid vacuum hoses. 3. EGR valve vacuum regulator solenoid electrical connector. 4. Camshaft position sensor electrical connector. 5. Differential pressure feedback electrical connector. 11. Disconnect fuel injector electrical connectors. Position wiring aside. 12. Detach the spark plug wire retainer.
13. Disconnect the fuel vapor hose and the vacuum hose. 14. Remove the bolt and position the electrical connector and bracket aside. 15. Remove the screws and the EGR valve vacuum regulator solenoid. 16. Remove the differential pressure feedback with the hoses from the exhaust manifold-to-EGR valve tube.
17. Relieve the fuel system pressure. For additional information, refer to Section 310-00 . 18. Detach the clip. 19. Using the special tool, disconnect the fuel supply line. 20. Remove the bolt and position the lower fuel line bracket aside. 21. Remove the bolt and position the fuel supply line aside.
22. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube. 23. Disconnect the hose. 24. Unscrew the fitting. 25. Remove the bolts and the valve cover.
26. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean and inspect the sealing surfaces. Install a new gasket if necessary. 27. To install, reverse removal procedure.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 05/27/2003 Crankshaft Pulley Special Tool(s) Crankshaft Vibration Damper Remover 303-101 (T74P-6316-A) Installer, Crankshaft Vibration Damper Replacer 303-102 (T74P-6316-B) Strap Wrench 303-D055 (D85L-6000-A) or equivalent Material Item Specification Motorcraft Silicone Gasket Remover ZC-30 — Motorcraft Metal Surface Prep ZC-31 — Silicone Gasket and Sealant F7AZ-19554-EA WSE-M4G323A4 Removal 1. Remove the fan shroud. For additional information, refer to Section 303-03 . 2. Remove the accessory drive belt. For additional information, refer to Section 30305 . 3. CAUTION: This bolt is a torque-to-yield design and cannot be reused. Using the special tool, remove the crankshaft pulley bolt.
4. Using the special tool, remove the crankshaft pulley. Installation 1. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. 2. Using the special tool, install the crankshaft pulley. 3. Using the special tool, install a new crankshaft pulley bolt. • Tighten the bolt in two stages: • Stage 1: Tighten the bolt to 50 Nm (37 lb-ft). • Stage 2: Tighten the bolt an additional 90 degrees.
4. Install the accessory drive belt. For additional information, refer to Section 30305 . 5. Install the fan shroud. For additional information, refer to Section 303-03 .
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Crankshaft Front Oil Seal Special Tool(s) Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Aligner, Front Cover 303-093 (T74P-6019-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Material Item Specification Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C205A Removal 1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section. 2. Using the special tool, remove the crankshaft front oil seal. Installation 1. NOTE: Lubricate the seal lip with clean engine oil. Using the special tools, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 04/15/2003 Engine Front Cover Material Item Specification Silicone Gasket and Sealant F7AZ-19554-EA or equivalent WSS-M4G323A4 Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C153G Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 . 2. Remove the crankshaft front oil seal. For additional information, refer to Crankshaft Front Oil Seal . 3. Drain the cooling system. For additional information, refer to Section 303-03 . 4. On A/C equipped vehicles, remove the A/C line bracket bolt and position the A/C line aside. 5. Remove the lower cylinder block cradle-to-engine front cover bolts. 6. Lower the vehicle. 7. Remove the bolt and the wiring harness routing clip.
8. Remove the accessory bracket bolts and position the bracket aside. 9. Remove the drivebelt tensioner. 10. Disconnect the generator wiring and position the wiring aside. 11. Remove the generator mounting bracket.
12. Disconnect the crankshaft position (CKP) sensor electrical connector. 13. Remove the wiring anchors and position the wiring aside. 14. Remove the wiring harness retainer and position the wiring aside. 15. Move the lower bypass hose clamp off of the coolant pump outlet.
16. Release the hose clamp and remove the lower heater water hose. 17. Release the hose clamp and remove the lower radiator hose. 18. NOTE: The water pump is removed for clarity. Remove the bolts and the engine front cover. • Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause gouges which make leak paths. Clean and inspect the sealing surfaces. Install a new gasket.
2. Apply silicone gasket and sealant to the oil pan and the engine block mating surfaces. 3. Apply silicone gasket and sealant to the front cover in two places. 4. Install the engine front cover. 5. Connect the coolant bypass hose clamp. 6. Install the lower radiator hose and clamp.
7. Install the lower heater water hose and clamp. 8. Position the wiring harness and install the bolt. 9. Secure the wiring anchors. 10. Connect the CKP sensor electrical connector.
11. Install the generator mounting bracket. 12. Connect the generator wiring. 13. Install the drivebelt tensioner. 14. Install the accessory bracket bolts.
15. Install the routing clip and bolt. 16. Raise and support the vehicle. For additional information, refer to Section 10002 . 17. Install the cylinder block cradle-to-engine front cover bolts. 18. On A/C equipped vehicles, install the A/C line bracket and bolt. 19. NOTE: Install the drain plug when finished draining. Drain the engine oil.
20. Lower the vehicle. 21. Install crankshaft front oil seal. For additional information, refer to Crankshaft Front Oil Seal in this section. 22. Fill the engine with clean engine oil. 23. Connect the battery ground cable. For additional information, refer to Section 414-01 . 24. Fill the engine with coolant. For additional information, refer to Section 303-03 .
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Timing Drive Components — Camshaft Timing Special Tool(s) Tensioner, Timing Chain 303-571 (T97T-6K254-A) Extension, Torque Wrench 303-575 (T97T-6256-F) Socket, Camshaft Sprocket Nut 303-565 (T97T-6256-G) Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) Adapter for 303-564 303-578 (T97T-6256-A) Holding Tool, Camshaft 303-577 (T97T-6256-C) Timing Tool, Crankshaft TDC 303-573 (T97T-6303-A)
Adapter for 303-577 303-576 (T97T-6256-D) 1. Remove the valve covers. For additional information, refer to Valve Cover — RH Valve Cover — LH and in this section. 2. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 3. Remove the fuel supply manifold. For additional information, refer to Section 30304C . 4. Remove the accessory drive belt. For additional information, refer to Section 30305 . 5. Remove the thermostat housing. For additional information, refer to Section 30303 . 6. Remove the roller followers. For additional information, refer to Roller Followers in this section. 7. NOTE: You must retime the LH and RH camshafts when either camshaft is disturbed. Turn the crankshaft clockwise to position the number one cylinder at TDC. 8. NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at top dead center (TDC). Install the special tool. 9. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt. Using the special tool, loosen the RH camshaft sprocket bolt. 10. NOTE: The camshaft timing slots are off-center. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools and install the special tools on the front of the RH cylinder head.
11. Raise and support the vehicle. For additional information, refer to Section 10002 . 12. Remove the RH wheel and tire. For additional information, refer to Section 20404 . 13. Remove the RH lower splash shield. 14. Remove the RH camshaft tensioner. 15. Lower the vehicle. 16. NOTE: Leave the top two special tool clamp bolts loose. Install the special tools on the rear of the RH cylinder head. 17. Install the special tool.
18. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt. Tighten the bolts. 1. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). 2. Tighten the camshaft bolt. 19. Remove the special tool. 20. Install the RH camshaft tensioner. 21. Raise the vehicle. 22. Install the RH lower splash shield.
23. Install the RH wheel and tire. For additional information, refer to Section 204-04 . 24. Lower the vehicle. 25. Remove the special tools from the RH cylinder head. 26. Remove the LH camshaft tensioner. 27. Install the special tools on the front of the LH cylinder head and tighten the top two clamp bolts to 10 Nm (89 lb-in). 28. Loosen the LH camshaft sprocket bolt. 29. Loosen the top two clamp bolts on the special tool to allow the camshaft sprocket to rotate freely. 30. NOTE: The camshaft timing slots are off-center.
Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the rear of the LH cylinder head. 31. Install the special tool. 32. Tighten the bolts. 1. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). 2. Tighten the camshaft bolt. 33. Remove the special tool. 34. Install the LH camshaft tensioner.
35. Remove all of the special tools. 36. Install the roller followers. For additional information, refer to Roller Followers in this section. 37. Install the thermostat housing. For additional information, refer to Section 30303 . 38. Install the accessory drive belt. For additional information, refer to Section 30305 . 39. Install the fuel supply manifold. For additional information, refer to Section 30304C . 40. Install the lower intake manifold. For additional information, refer to Intake Manifold in this section. 41. Install the valve covers. For additional information, refer to Valve Cover — LH and Valve Cover — RH in this section.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Timing Drive Components — Hydraulic Chain Tensioner, RH Removal and Installation 1. Remove the wheel and tire. For additional information, refer to Section 204-04 . 2. Remove the lower splash shield. 3. Remove the RH camshaft tensioner. 4. To install, reverse the removal procedure.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Timing Drive Components — Hydraulic Chain Tensioner, LH Removal and Installation 1. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 2. Remove the thermostat housing. For additional information, refer to Section 30303 . 3. Remove the LH camshaft tensioner. 4. To install, reverse the removal procedure.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Timing Drive Components — Camshaft Drive Cassette, LH Removal 1. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 2. Remove valve covers. For additional information, refer to Valve Cover — RH and Valve Cover — LH in this section. 3. Remove the fuel supply manifold. For additional information, refer to Section 30304C . 4. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section. 5. Remove the thermostat housing. For additional information, refer to Section 30303 . 6. Remove all of the roller followers. For additional information, refer to Roller Followers in this section. 7. NOTE: You must retime the LH and RH camshafts when either camshaft is disturbed. Turn the crankshaft clockwise to position number one cylinder at TDC. 8. Remove the LH camshaft chain tensioner. 9. Remove the LH camshaft sprocket bolt. • Install the special tools to hold the camshaft sprocket. • Loosen but do not remove the bolt.
10. Remove the tool and bolt. 11. Hold the crankshaft from turning and loosen the jackshaft sprocket bolt.
12. Remove the primary chain tensioner. 13. Remove the primary chain and sprocket.
14. Remove the camshaft drive cassette. 1. Remove the chain guide bolts. 2. Remove the sprockets. 3. Lift the chain and guide up and out of the cylinder head. 15. Clean all surfaces. Clean all debris from engine.
Installation 1. Install the chain guide through the cylinder head. 2. Install the chain.
3. Install the new chain guide bolts. 4. NOTE: The camshaft chain sprockets must be orientated correctly. Install the lower chain sprocket and the camshaft sprocket.
5. Install, but do not tighten the camshaft sprocket bolt. 6. Install the primary chain and gear.
7. Install the primary drive chain tensioner. 8. Hold the crankshaft from turning and tighten the jackshaft sprocket bolt in two stages. • Stage 1: Tighten bolts to 45 Nm (33 lb-ft). • Stage 2: Tighten bolts an additional 90 degrees. 9. Install the engine front cover. For additional information, refer to Engine Front Cover in this section. 10. Time the engine. For additional information, refer to Timing Drive Components — Camshaft Timing in this section.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Valve — Valve Spring Special Tool(s) Valve Spring Compressor 303-581 (T97T-6565-A) Spacer, Valve Spring Compressor 303-382 (T91P-6565-AH) Removal 1. Remove the camshaft roller followers. For additional information, refer to Roller Followers in this section. 2. Position the piston at top dead center (TDC). 3. Remove the spark plug and apply compressed air in the cylinder to hold both valves in position. 4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. Using the special tool to compress the valve spring, remove the valve spring retainer keys, the valve spring and the retainer. 5. Inspect the components. For additional information, refer to Section 303-00 .
Installation 1. Position the valve spring and the valve spring retainer. 2. Install the special tool between the valve spring coil to prevent valve stem seal damage. 3. Using the special tool to compress the valve spring, install the valve spring retainer keys. 4. Install the camshaft roller followers. For additional information, refer to Roller Followers in this section. 5. Install the spark plug. 6. Repeat all steps for each cylinder being serviced.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Valve — Valve Seals Special Tool(s) Installer, Valve Stem Oil Seal 303-370 (T90T-6571-A) Material Item Specification Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C205A Removal 1. Remove the valve springs. For additional information, refer to Valve — Valve Spring in this section. 2. Remove the valve stem seals. Installation 1. NOTE: Lubricate parts with clean engine oil prior to installing. Using the special tool, install the valve stem seals. 2. Install the valve springs. For additional information, refer to Valve — Valve Spring in this section.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Hydraulic Lash Adjusters Material Item Specification Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C205A Removal and Installation 1. Remove the camshaft roller followers. For additional information, refer to Roller Followers in this section. 2. Remove the hydraulic lash adjusters. 3. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Roller Followers Special Tool(s) Compressor, Valve Spring 303-581 (T97T-6565-A) Material Item Specification Super Premium SAE SW-30 Motor Oil WSS-M2C153XO-5W30-QSP or G equivalent Removal 1. Remove the valve covers. For additional information, refer to Valve Cover — LH or Valve Cover — RH in this section. 2. Remove the fuel supply manifold. For additional information, refer to Section 30304C . 3. NOTE: Mark each camshaft roller follower to ensure its original position during reassembly. Using the special tool, remove the camshaft roller followers. 4. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Camshaft — LH Material Item Specification Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C205A Removal 1. Remove the camshaft roller followers. For additional information, refer to Roller Followers in this section. 2. Remove the LH camshaft chain tensioner. For additional information, refer to Timing Drive Components — Hydraulic Chain Tensioner, LH in this section. 3. Remove the bolt and the camshaft sprocket. 4. NOTE: Mark the position of the camshaft bearing caps so they can be installed in their original position. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube. 5. Remove the camshaft.
Installation 1. NOTE: Lubricate the parts with clean engine oil before installing. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in the original position. Position the camshaft bearing caps, the oil supply tube, and the bolts. 3. NOTE: After installing the bolts, check the camshaft for free rotation. Tighten the camshaft bearing cap bolts in two stages in the sequence shown. 1. Stage 1: Tighten the bolts to 6 Nm (53 lb-in). 2. Stage 2: Tighten the bolts to 16 Nm (12 lb-ft). 4. Retime both camshafts. For additional information, refer to Timing Drive Components — Camshaft Timing in this section.
5. Install the camshaft roller followers. For additional information, refer to Roller Followers in this section.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Camshaft — RH Special Tool(s) Extension, Torque Wrench 303–575 (T97T-6256-F) Material Item Specification Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C205A Removal 1. Remove the camshaft roller followers. For additional information, refer to Roller Followers in this section. 2. Remove the RH camshaft chain tensioner. For additional information, refer to Timing Drive Components — Hydraulic Chain Tensioner, RH in this section. 3. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt. Using the special tool, remove the bolt and the camshaft sprocket. 4. NOTE: Mark the position of the camshaft bearing caps so they can be installed in their original position. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube.
5. Remove the camshaft. Installation 1. NOTE: Lubricate the parts with clean engine oil before installing. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in their original position. Position the camshaft bearing caps, the oil supply tube, and the bolts. 3. NOTE: After installing the bolts, check the camshaft for free rotation. Tighten the camshaft bearing cap bolts in two stages in the sequence shown. 1. Stage 1: Tighten the bolts to 6 Nm (53 lb-in). 2. Stage 2: Tighten the bolts to 16 Nm (12 lb-ft).
4. Retime both camshafts. For additional information, refer to Timing Drive Components — Camshaft Timing in this section. 5. Install the camshaft roller followers. For additional information, refer to Roller Followers in this section.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 12/18/2003 Exhaust Manifold LH Removal and Installation 1. With the vehicle in neutral, position it on a hoist. For additional information, refer to Section 100-02 . 2. Remove the exhaust pipe-to-exhaust manifold nuts. 3. Remove the exhaust gas recirculation (EGR) tube. • Disconnect the differential pressure feedback EGR system from the EGR tube. • Disconnect the EGR tube from the EGR valve and the exhaust manifold. 4. Remove the retainers and the LH exhaust manifold. 5. NOTE: Use new exhaust manifold gaskets and retaining nuts. To install, reverse the removal procedure.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 12/18/2003 Exhaust Manifold — RH Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100-02 . 2. Remove the nuts. 3. Lower the vehicle. 4. Remove the RH exhaust manifold. 5. NOTE: Use new exhaust manifold gaskets and nuts. To install, reverse the removal procedure.
SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 12/18/2003 Cylinder Head — LH Removal CAUTION: If the fuel supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold. 1. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 2. Remove the roller followers. For additional information, refer to Roller Followers in this section. 3. Remove the fan shroud. For additional information, refer to Section 303-03 . 4. Remove the accessory drive belt. For additional information, refer to Section 30305 . 5. Disconnect the generator wiring. 6. Remove drivebelt tensioner. For additional information, refer to Section 303-05 . 7. Remove the generator mounting bracket. 8. Remove the bolt and the wiring harness routing clip.
9. Remove the bolts and position the accessory bracket aside. 10. Disconnect the crankshaft position (CKP) sensor electrical connector. 11. Remove the electrical harness retainer. 12. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
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manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001
manual de taller ranger (ford) a partir del 2001

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  • 1.
  • 2. Table of Contents 1: General Information 00: Service Information 2: Chassis 04: Suspension 05: Driveline 06: Brake System 11: Steering System 3: Powertrain 03: Engine 07: Automatic Transmission 08: Manual Transmission, Clutch and Transfer Case 09: Exhaust System 10: Fuel System 4: Electrical 12: Climate Control System 13: Instrumentation and Warning Systems 14: Battery and Charging System 15: Audio Systems 17: Lighting 18: Electrical Distribution 19: Electronic Feature Group 5: Body and Paint 01: Body 02: Frame and Mounting
  • 3. Diagnostic Trouble Code Chart Diagnostic Trouble Code (DTC) Chart DTC Description Source Action B1213 Anti-Theft Number of Programmed Keys is Below Minimum PCM REFER to Section 419-01. RCM REFER to Section 501-20B. B1231 Longitudinal Acceleration Threshold Exceeded B1309 Power Door Lock Circuit Short to Ground Central security module REFER to Section 501-14. B1313 Battery Saver Relay Coil Circuit Open, Short to Ground GEM REFER to Section 417-02. GEM REFER to Section 417-02. B1315 Battery Saver Relay Circuit Short to Battery B1317 Battery Voltage High 4WD control module REFER to Section 414-00. B1317 Battery Voltage High GEM REFER to Section 414-00. B1318 Battery Voltage Low 4WD control module REFER to Section 414-00. B1318 Battery Voltage Low RCM REFER to Section 414-00. B1318 Battery Voltage Low GEM REFER to Section 414-00. B1322 Driver Door Ajar Circuit Short to Ground GEM REFER to Section 417-02. B1323 Door Ajar Lamp Circuit Failure GEM REFER to Section 413-01. B1325 Door Ajar Lamp Circuit Short to Battery GEM REFER to Section 413-01. B1330 RF Door Ajar Circuit Short to Ground GEM REFER to Section 417-02. B1334 Decklid Ajar Rear Door Circuit Short to Ground GEM REFER to Section 417-02. B1340 Chime Input Request Circuit Short to Ground GEM REFER to Section 413-09. B1341 Power Door Unlock Circuit Short to Ground Central security module REFER to Section 501-14. B1342 ECU is Defective ABS module CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved, INSTALL a new ABS module. REFER to Section 206-09. CLEAR the DTCs. REPEAT the self-test. B1342 ECU is Defective Central security module CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved, INSTALL a new central security module. REFER to Vehicle Security Module in this section. CLEAR the DTCs. REPEAT the self-test. B1342 ECU is Defective 4WD CLEAR the DTCs. REPEAT the self-test. If DTC
  • 4. control module B1342 is retrieved, INSTALL a new 4WD Control Module. REFER to Section 308-07A . CLEAR the DTCs. REPEAT the self-test. B1342 ECU is Defective GEM CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved, INSTALL a new GEM. REFER to Generic Electronic Module (GEM) in this section. CLEAR the DTCs. REPEAT the self-test. B1342 ECU is Defective RCM CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved, INSTALL a new RCM. REFER to Section 501-20B . CLEAR the DTCs. REPEAT the self-test. B1345 Heated Backlite Input Circuit Short to Ground GEM REFER to Section 501-11. B1347 Heated Backlite Relay Circuit Failure GEM REFER to Section 501-11. B1349 Heated Backlite Relay Short to Battery GEM REFER to Section 501-11. B1352 Ignition Key-In Circuit Failure GEM REFER to Section 413-09. B1355 Ignition Run Circuit Failure 4WD control module REFER to Section 211-05. B1355 Ignition Run Circuit Failure GEM REFER to Section 211-05. B1359 Ignition Run/Acc Circuit Failure GEM REFER to Section 211-05. B1365 Ignition Start Circuit Failure GEM REFER to Section 211-05. B1371 Illuminated Entry Relay Circuit Failure GEM REFER to Section 417-02. B1373 Illuminated Entry Relay Short to Battery GEM REFER to Section 417-02. B1398 LF Power Window One Touch Window Relay Circuit Failure GEM REFER to Section 501-11. B1400 LF Power Window One Touch Window Relay Circuit Short to Battery GEM REFER to Section 501-11. B1405 LF Power Window Down Circuit Short to Battery GEM REFER to Section 501-11. B1408 GEM REFER to Section 501-11. B1410 LF Power Window Motor Circuit Failure GEM REFER to Section 501-11. B1426 Safety Belt Lamp Circuit Short to Battery GEM REFER to Section 413-01. B1428 Safety Belt Lamp Circuit Failure GEM REFER to Section 413-01. B1431 Wiper Brake/Run Relay Circuit Failure GEM REFER to Section 501-16. B1432 Wiper Brake/Run Relay GEM REFER to Section 501-16. LF Power Window Up Circuit Short to Battery
  • 5. Circuit Short to Battery B1434 Wiper Hi/Low Speed Relay Circuit Failure GEM REFER to Section 501-16. B1436 Wiper Hi/Low Speed Relay Circuit Short to Battery GEM REFER to Section 501-16. B1438 Wiper Mode Select Switch Circuit Failure GEM REFER to Section 501-16. B1441 Wiper Mode Select Switch Circuit Short to Ground GEM REFER to Section 501-16. B1446 Wiper Park Sense Circuit Failure GEM REFER to Section 501-16. B1450 Wiper Wash/Delay Switch Circuit Failure GEM REFER to Section 501-16. B1453 Wiper Wash/Delay Switch Circuit Short to Ground GEM REFER to Section 501-16. B1458 Wiper Washer Pump Motor Relay Circuit Failure GEM REFER to Section 501-16. B1460 Wiper Washer Pump Motor Relay Circuit Short to Battery GEM REFER to Section 501-16. B1462 Safety Belt Switch Circuit Failure GEM REFER to Section 413-09. B1466 Wiper Hi/Low Speed Not Switching GEM REFER to Section 501-16. B1473 Wiper Low Speed Circuit Motor Failure GEM REFER to Section 501-16. B1476 Wiper High Speed Circuit Motor Failure GEM REFER to Section 501-16. B1483 Brake Pedal Input Circuit Failure GEM REFER to Section 308-07A. B1485 Brake Pedal Input Circuit Short to Battery 4WD control module REFER to Section 308-07A. B1485 Brake Pedal Input Circuit Short to Battery ABS module REFER to Section 308-07A. B1485 Brake Pedal Input Circuit Short to Battery Central security module REFER to Section 308-07A. B1526 Keyless Entry Circuit Short to Ground Central security module REFER to Section 501-14. B1555 Ignition Run/Start Circuit Failure 4WD control module REFER to Section 211-05. B1562 Door Lock Cylinder Circuit Short to Ground Central security module REFER to Section 501-14. B1577 Park Lamp Input Circuit Short to Battery GEM REFER to Section 413-09.
  • 6. B1600 PATS Ignition Key Transponder Signal is Not Received PCM REFER to Section 419-01. B1601 PATS Received Incorrect Key-Code From Ignition Key Transponder PCM REFER to Section 419-01. B1602 PATS Received Invalid Format of Key-Code From Ignition Key Transponder PCM REFER to Section 419-01. B1610 Illuminated Entry Input Circuit Short to Ground GEM REFER to Section 417-02. B1629 PRNDL Reverse Input Short to Battery Central security module REFER to Section 501-14. B1676 Battery Pack Voltage Out of Range ABS module REFER to Section 206-09. B1681 PATS Transceiver Module Signal is Not Received PCM REFER to Section 419-01. B1840 Wiper Front Power Circuit Failure GEM REFER to Section 501-16. B1869 Lamp Air Bag Warning Indicator Circuit Open RCM REFER to Section 501-20B. B1870 Lamp Air Bag Warning Indicator Circuit Short to Battery RCM REFER to Section 501-20B. B1871 Passenger Air Bag Deactivate Module Fault RCM REFER to Section 501-20B. B1877 Driver Safety Belt Pretensioner Circuit Open RCM REFER to Section 501-20B. B1878 Driver Safety Belt Pretensioner Circuit Short to Battery RCM REFER to Section 501-20B. B1879 Driver Safety Belt Pretensioner Circuit Short to Ground RCM REFER to Section 501-20B. B1881 Passenger Safety Belt Pretensioner Circuit Open RCM REFER to Section 501-20B. B1882 Passenger Safety Belt Pretensioner Circuit Short to Battery RCM REFER to Section 501-20B. B1883 Passenger Safety Belt Pretensioner Circuit Short to Ground RCM REFER to Section 501-20B. B1884 PAD Warning Lamp Inoperative RCM REFER to Section 501-20B. B1885 Driver Safety Belt Pretensioner Circuit Resistance Low on Squib RCM REFER to Section 501-20B. B1886 Passenger Safety Belt Pretensioner Circuit Resistance Low on Squib RCM REFER to Section 501-20B. B1887 Driver Air Bag Circuit RCM REFER to Section 501-20B.
  • 7. Short to Ground B1888 Passenger Air Bag Circuit Short to Ground RCM REFER to Section 501-20B. B1889 Passenger Air Bag Deactivate Module Sensor Obstructed RCM REFER to Section 501-20B. B1890 PAD Warning Lamp Circuit Short to Battery RCM REFER to Section 501-14. B1891 Air Bag tone Warning Indicator Circuit Short to Battery RCM REFER to Section 501-20B. B1892 Air Bag Tone Warning Indicator Circuit Failure RCM REFER to Section 501-20B. B1901 Air Bag Crash Sensor No. 1 Feed/Return Circuit Short to Ground RCM REFER to Section 501-20B. B1916 Driver Air Bag Circuit Short to Battery RCM REFER to Section 501-20B. B1921 Air Bag Diagnostic Monitor Ground Circuit Open RCM REFER to Section 501-20B. B1925 Passenger Air Bag Circuit Short to Battery RCM REFER to Section 501-20B. B1932 RCM REFER to Section 501-20B. B1933 Passenger Air Bag Circuit Open RCM REFER to Section 501-20B. B1934 Driver Air Bag Inflator Circuit Resistance Low on Squib RCM REFER to Section 501-20B. B1935 Passenger Air Bag Inflator Circuit Resistance Low on Squib RCM REFER to Section 501-20B. B1941 Air Bag Crash Sensor No. 1 Feed/Return Circuit Open RCM REFER to Section 501-20B. B2103 PCM REFER to Section 419-01. B2106 Throttle Position Input Out of Range High 4WD control module REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual.. B2276 Less Than Two Transmitters Programmed Central security module REFER to Section 501-14. B2425 Remote Keyless Entry Out of Synchronization Central security module REFER to Section 501-14. B2431 Transponder Programming Failure PCM REFER to Section 419-01. Central security module REFER to Section 418-01. B2477 Driver Air Bag Circuit Open Antenna Not Connected Module Configuration Failure
  • 8. B2477 Module Configuration Failure GEM REFER to Section 418-01. B2477 Module Configuration Failure RCM REFER to Section 418-01. B9610 Illuminated Entry Input Short Circuit to Ground GEM No Action C1095 ABS Hydraulic Pump Motor Circuit Failure ABS module REFER to Section 206-09. C1145 RF Wheel Speed Sensor Input Circuit Failure ABS module REFER to Section 206-09. C1155 LF Wheel Speed Sensor Input Circuit Failure ABS module REFER to Section 206-09. C1230 Wheel Speed Sensor Rear Center Input Circuit Failure ABS module REFER to Section 206-09. C1233 LF Wheel Speed Input Signal Missing ABS module REFER to Section 206-09. C1234 RF Wheel Speed Input Signal Missing ABS module REFER to Section 206-09. C1237 Rear Wheel Speed Input Signal Missing ABS module REFER to Section 206-09. C1728 Transfer Case Unable to Transition Between 2H and 4H 4WD control module REFER to Section 308-07A. C1729 Transfer Case Unable to Transition Between 4H and 4L 4WD control module REFER to Section 308-07A. C1939 Brake Pressure Switch Input Circuit Failure ABS module REFER to Section 206-09. P0500 Vehicle Speed Sensor (VSS) Malfunction 4WD control module REFER to Section 206-09. P0500 Vehicle Speed Sensor (VSS) Malfunction GEM REFER to Section 308-07A. P1804 Transmission 4-Wheel Drive High Indicator Circuit Failure 4WD control module REFER to Section 308-07A. P1806 Transmission 4-Wheel Drive High Indicator Circuit Short to Battery 4WD control module REFER to Section 308-07A. P1808 Transmission 4-Wheel Drive Low Indicator Circuit Failure 4WD control module REFER to Section 308-07A. P1810 Transmission 4-Wheel Drive Low Indicator Circuit Short to Battery 4WD control module REFER to Section 308-07A. P1812 Transmission 4-Wheel Drive Mode Select Circuit Failure 4WD control module REFER to Section 308-07A. P1815 Transmission 4-Wheel Drive Mode Select Circuit Short to Ground 4WD control module REFER to Section 308-07A.
  • 9. P1816 Transmission Neutral Safety Switch Circuit Failure 4WD control module REFER to Section 308-07A. P1819 Transmission Neutral Safety Switch Circuit Short to Ground 4WD control module REFER to Section 308-07A. P1849 Transmission Transfer Case Contact Plate A Circuit Short to Ground 4WD control module REFER to Section 308-07A. P1853 Transmission Transfer Case Contact Plate B Circuit Short to Ground 4WD control module REFER to Section 308-07A. P1857 Transmission Transfer Case Contact Plate C Circuit Short to Ground 4WD control module REFER to Section 308-07A. P1861 Transmission Transfer Case Contact Plate D Circuit Short to Ground 4WD control module REFER to Section 308-07A. P1867 Transmission Transfer Case Contact Plate General Circuit Failure 4WD control module REFER to Section 308-07A. P1891 Transmission Transfer Case Contact Plate Ground Return Circuit Open 4WD control module REFER to Section 308-07A.
  • 10. 2001 Ranger Contents/Index GROUP 06: Brake System SECTION 206-00: Brake System — General Information SECTION 206-02: Drum Brake SECTION 206-03: Front Disc Brake SECTION 206-05: Parking Brake and Actuation SECTION 206-06: Hydraulic Brake Actuation SECTION 206-07: Power Brake Actuation SECTION 206-09: Anti-Lock Control
  • 11. 2001 Ranger Contents/Index GROUP 06: Brake System SECTION 206-09: Anti-Lock Control SPECIFICATIONS DESCRIPTION AND OPERATION Anti-Lock Control — (4WABS) DIAGNOSIS AND TESTING Anti-Lock Control Principles of Operation Inspection and Verification Symptom Chart Pinpoint Tests REMOVAL AND INSTALLATION Hydraulic Control Unit Anti-Lock Brake System (ABS) Module Sensor — Front 4x2 Sensor — Front 4x4 Sensor — Rear Sensor Indicator — Front 4x2 Sensor Indicator — Front 4x4 Sensor Indicator — Rear
  • 12. SECTION 206-09: Anti-Lock Control SPECIFICATIONS 2001 Ranger Workshop Manual Procedure revision date: 03/08/2004 Torque Specifications Description Nm lb-ft lb-in Battery ground cable bolt 8.5 — 75.5 Anti-lock brake system (ABS) module bolts 2.0 — 18 Hydraulic control unit (HCU) to bracket bolts 9 — 80 Front wheel speed sensor bolt (4x2) 12 8.5 — Front wheel speed sensor bolt (4x4) 8 — 71 Front wheel speed sensor wire retaining bolt (4x4) 8 — 71 Inlet brake line to HCU nuts (M10-1) 23 17 — Outlet brake line to HCU nuts (M12-1) 18 13 — Rear axle speed sensor bolt 27 20 —
  • 13. SECTION 206-09: Anti-Lock Control DESCRIPTION AND OPERATION 2001 Ranger Workshop Manual Procedure revision date: 03/08/2004 Anti-Lock Control — (4WABS) The anti-lock control system consists of the following components: • hydraulic control unit (HCU) • anti-lock brake system (ABS) module • rear axle speed sensor • rear axle speed sensor indicator • front wheel speed sensor • front wheel speed sensor indicator • yellow ABS warning indicator • brake pressure switch
  • 14. SECTION 206-09: Anti-Lock Control DIAGNOSIS AND TESTING 2001 Ranger Workshop Manual Procedure revision date: 03/08/2004 Anti-Lock Control Refer to Wiring Diagrams Section 206-09 for schematic and connector information. Special Tool(s) Digital Analog DMM (Series III) 105-R0057 or equivalent Automotive DMM w/Pickup 105-R0053 or equivalent Breakout Box, EEC-IV Control System 418-005 (014-00322) (T83L-50-EEC-IV) or equivalent Worldwide Diagnostic System (WDS) 418-F224 or equivalent diagnostic tool with appropriate adapter cable Connector, ABS Electrical System 418-063 (T97P-50-ALA) Principles of Operation The anti-lock brake system (ABS) operates as follows: • When the brakes are applied, fluid is forced from the brake master cylinder outlet ports to the hydraulic control unit (HCU) inlet ports. This pressure is transmitted through four normally open solenoid valves contained inside the HCU and then through the outlet ports of the HCU to each wheel. • If the ABS module senses a wheel is about to lock, based on wheel speed sensor data, it closes the normally open solenoid valve for that circuit. This prevents any more fluid from entering that circuit. • The ABS module then looks at the wheel speed sensor signal from the affected wheel(s) again. • If that wheel(s) is still decelerating, it opens the closed solenoid valve for that circuit.
  • 15. • Once the affected wheel comes back up to speed, the ABS module returns the valves to their normal condition, allowing fluid to flow to the affected brake. • The ABS module monitors the electromechanical components of the system. • A malfunction in the ABS will cause the ABS module to shut off or inhibit the system. However, normal power-assisted braking remains. • Malfunctions are indicated by a yellow ABS warning indicator in the instrument cluster (10849). • The ABS is self-monitoring. When the ignition switch is turned to the RUN position, the ABS module will carry out a preliminary self-check on the anti-lock electrical system indicated by a three-second illumination of the yellow ABS warning indicator in the instrument cluster. • During vehicle operation, including normal and anti-lock braking, the ABS module monitors all electrical anti-lock functions and some hydraulic operations. • Each time the vehicle is driven to approximately 32 km/h (20 mph), the ABS module turns on the pump motor for approximately one-half second. At this time, a mechanical noise may be heard. This is a normal function of the self-check by the ABS module. • Pedal pulsation coupled with noise while braking on loose gravel, bumps, wet or snowy roads is normal and indicates correct functioning of the vehicle's ABS system. Hydraulic Control Unit (HCU) The HCU consists of the following components: • brake pressure control valve block • pump motor New brake pressure control valve block and pump motor are installed as an assembly. Anti-Lock Brake System (ABS) Module NOTE: The ABS module is 4x2 and 4x4 specific. Do not interchange modules. The ABS module is mounted to the HCU. It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and the necessary circuitry for their operation. The ABS module monitors system operation during normal driving as well as during anti-lock braking. ABS module operation is as follows: • Under normal driving conditions, the microprocessor produces short test pulses to the solenoid valves that check the electrical system without any mechanical reaction. • Impending wheel lock conditions trigger signals from the ABS module that open and close the appropriate solenoid valves. This results in moderate pulsations in the brake pedal (2455). • The ABS module used in 4x4 application includes a G-sensor. It detects vehicle movements during a brake lockup event that is transferred to other wheels through the powertrain. During normal braking, the brake pedal feel will be identical to a standard brake system. Most faults that occur in the ABS will be stored as a diagnostic trouble code (DTC) in the keep-alive memory of the ABS module. The DTCs can be retrieved by following the on-board diagnostic procedures.
  • 16. Wheel Speed Sensor NOTE: Any time a wheel speed sensor is removed, thoroughly clean the mounting surfaces. On front wheel speed sensors, apply High-Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. The ABS uses three variable-reluctance sensors to determine vehicle speed. The wheel speed sensors operate on magnetic induction principle. As the teeth on the wheel speed sensor indicator rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and sent to the ABS module through a twisted cable and shielded wiring harness. Inspection and Verification 1. Verify the customer concern by applying the brakes under different conditions. 2. Visually inspect for obvious signs of mechanical and electrical damage. Visual Inspection Chart Mechanical Electrical • Parking brake cable • • Tire pressure 14 (10A) • Tire size or mismatched tires 11 (7.5A) Central junction box (CJB) fuse(s): 9 (7.5A) • Battery junction box (BJB) Maxi-Fuse 3 (50A) • BJB Mini-Fuse 7 (30A) • Connectors or connections • Harness routing • Wire chafing • Circuitry open/shorted • Indicator bulb 3. If the fault is not visually evident, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: • check that the program card is correctly installed. • check the connections to the vehicle. • check the ignition switch position. 4. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool manual. 5. Carry out the diagnostic tool data link test. If the diagnostic tool responds with:
  • 17. • SCP or ISO = all electronic control units no response/not equipped, refer to Section 418-00. • No response/not equipped for the ABS module, GO to Pinpoint Test A. • System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the ABS module. 6. If the DTCs retrieved are related to the concern, go to the Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart. Warning Lamp Indicators The ABS uses the yellow ABS warning indicator to alert the driver of malfunctions in the ABS. The yellow ABS warning indicator will come on for numerous reasons. It warns the driver that the ABS has been deactivated due to a symptom that exists in the ABS. Normal power assist braking remains, but wheels can lock during a panic stop while the yellow ABS warning indicator is illuminated. The diagnostic procedures must be followed step-by-step in order to correct the condition. Electronic Brake Distribution (EBD) The electronic brake distribution (EBD) controls rear brake pressure and acts as an electronic proportioning valve. It is controlled by the ABS module. When EBD is disabled, the brake warning indicator will illuminate. Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Index DTC Description Source Action B1342 Anti-Lock Brake Control Module Failure ABS Module INSTALL a new ABS module. REFER to AntiLock Brake System (ABS) Module in this section. REPEAT the self-test. B1485 Brake Pedal Position (BPP) Switch Circuit Failure ABS Module IGNORE the DTC. This DTC applies only to traction control vehicles. B1676 Battery Voltage Out Of Range ABS Module GO to Pinpoint Test B. C1939 Brake Pressure Switch Circuit Failure ABS Module GO to Pinpoint Test G. C1095 Hydraulic Pump Motor Circuit Failure ABS Module GO to Pinpoint Test E. C1145 RF Wheel Speed Sensor Circuit Failure (Static) ABS Module GO to Pinpoint Test C. C1155 LF Wheel Speed Sensor Circuit Failure (Static) ABS Module GO to Pinpoint Test C. C1230 Rear Axle Speed Sensor Circuit Failure (Static) ABS Module GO to Pinpoint Test C. C1233 LF Wheel Speed Sensor Output Failure (Dynamic) ABS Module GO to Pinpoint Test D. C1234 RF Wheel Speed Sensor Output Failure (Dynamic) ABS Module GO to Pinpoint Test D.
  • 18. C1237 Rear Axle Speed Sensor Output Failure (Dynamic) ABS Module GO to Pinpoint Test D. Symptom Chart Symptom Chart Condition • Possible Sources ABS module. • Wheel speed sensor indicator. • Sensor output is weak. Air gap. • Circuitry. • Wheel speed sensor. Maladjusted rear brakes or "grabby" brake shoe or pad linings • Rear brake adjustment. • Linings. Base brake mechanical concern for wheels lockup • Rear brake shoe linings. • Wheel cylinder. Rear brakes. • No communication with the anti-lock brake system (ABS) module Loss of sensor signal during vehicle deceleration or sensor signal drops out at low speed Unwarranted ABS activity Base brake hydraulic concern (soft pedal) • GO to Pinpoint Test A. • GO to Pinpoint Test D. • GO to Pinpoint Test D. • REFER to Section 206-00. • REFER to Section 206-00. Parking brake. • REFER to Section 206-05. • • Circuitry. • • Central junction box (CJB) fuse 14 (10A). • • • • • Battery junction box (BJB) fuse 3 (50A). • • • Action Rear axle seal. • REFER to Section 205-00. • Brake line or hose, fitting, master cylinder, wheel cylinder or caliper. • REFER to Section 206-00. • Air in brake
  • 19. system. Base brake mechanical concern for vehicle pulls Brake line or hose. • Brake line or hose, fitting, master cylinder, wheel cylinder or caliper. Air in brake system. • Vacuum boost. • Wheel cylinder or caliper. Brake line or hose. Brake shoe or pad linings. • Rear brake. • Caliper. • • Wheel cylinder or caliper. • Base brake mechanical concern during medium/hard brake application • • • Base brake hydraulic concern during medium/hard brake application Vacuum boost. • • Base brake mechanical concern (hard pedal) • • • Brake pad or shoe wear. • REFER to Section 206-00. • REFER to Section 206-00. • REFER to Section 206-00. • REFER to Section 206-00. • Base brake hydraulic concern for vehicle pulls • Brake line or hose. • REFER to Section 206-00. • One wheel locks up; no DTCs recorded • Base brake. • REFER to Section 206-00. • Dump valve. • • ISO valve. INSTALL a new hydraulic control unit (HCU). REFER to Hydraulic Control Unit in this section. • Bulb. • • GO to Pinpoint Test F. Circuitry. • Instrument cluster. • The yellow ABS warning indicator does not self-check
  • 20. • • Yellow ABS light always on, no DTC Brake line or hose, fitting, master cylinder, wheel cylinder, wheel cylinder or caliper. Air in brake system. • Soft or excessive brake pedal • • • Anti-lock brake system (ABS) module. Hydraulic control unit (HCU). • Circuitry. • Module. • Section 206-00. • GO to Pinpoint Test H. Pinpoint Tests PINPOINT TEST A: NO COMMUNICATION WITH THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE CONDITIONS DETAILS/RESULTS/ACTIONS A1 CHECK CIRCUIT 601 (LB/PK), 534 (YE/LG) AND 483 (RD) ABS Module C135 Connect the breakout box. Measure the voltage between the breakout box pins and ground as follows: Breakout Box Pin 20 Circuit 601 (LB/PK)
  • 21. 25 9 • 483 (RD) 534 (YE/LG) Are the voltages greater than 10 volts? Yes GO to A2. No REPAIR the circuit(s) in question. TEST the system for normal operation. A2 CHECK CIRCUIT 57 (BK) FOR AN OPEN Measure the resistance between the breakout box pin 8, circuit 57 (BK) and ground; and between the breakout box pin 24, circuit 57 (BK) and ground. • Are the resistances less than 5 ohms? Yes REFER to Section 418-00. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. PINPOINT TEST B: DTC B1676 — BATTERY VOLTAGE OUT OF RANGE
  • 22. NOTE: DTC B1676 is generated when the ABS module detects system voltage is less than 9 volts or greater than 19 volts for more than 8 seconds. CONDITIONS DETAILS/RESULTS/ACTIONS B1 CHECK RECENT VEHICLE HISTORY Check recent vehicle history. • Has the vehicle been jumpstarted within the past two weeks? Yes The system is OK. CLEAR the DTCs. REPEAT the self-test. No GO to B2. B2 CHECK THE BATTERY VOLTAGE Measure the voltage between the positive and negative battery posts. • Is the voltage between 9 and 19 volts? Yes GO to B3. No REFER to Section 414-00. B3 CHECK CIRCUIT 601 (LB/PK) FOR CORRECT VOLTAGE ABS Module C135 Connect the breakout box. Measure the voltage between the breakout box pin 20, circuit 601 (LB/PK) and ground.
  • 23. • Is the voltage greater than 10 volts? Yes GO to B4. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. B4 CHECK CIRCUIT 483 (RD) FOR AN OPEN Measure the voltage between the breakout box pin 25, circuit 483 (RD) and ground. • Is the voltage greater than 10 volts? Yes GO to B5. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. B5 CHECK CIRCUIT 534 (YE/LG) FOR AN OPEN Measure the voltage between the breakout box pin 9, circuit 534 (YE/LG) and ground.
  • 24. • Is the voltage greater than 10 volts? Yes GO to B6. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. B6 CHECK CIRCUIT 57 (BK) FOR AN OPEN Measure the resistance between the breakout box pin 8, circuit 57 (BK) and ground; and between the breakout box pin 24, circuit 57 (BK) and ground. • Are the resistances less than 5 ohms? Yes INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. REPEAT the self-test. No REPAIR the circuit. CLEAR the DTCs. PINPOINT TEST C: DTCS C1145, C1155, AND C1230 — ANTI-LOCK BRAKE SENSOR CIRCUIT FAILURE CONDITIONS DETAILS/RESULTS/ACTIONS
  • 25. C1 CHECK THE WHEEL SPEED SENSOR RESISTANCE AT BREAKOUT BOX ABS Module C135 Connect EEC-IV 60-Pin Breakout Box. Measure the resistance between EEC-IV 60-Pin Breakout Box pins for the suspect wheel speed sensor as follows: Wheel Speed Sensor EEC-IV 60-Pin Breakout Box Positive Negative Probe Probe LF 18 RF 3 4 Rear • 17 22 21 Is the resistance between 800 and 1400 ohms (front 4x2), 800 and 2500 ohms (rear), or 380 and 480 ohms (front 4x4)? Yes GO to C5. No GO to C2. C2 CHECK WHEEL SPEED SENSOR RESISTANCE Suspect Wheel Speed Sensor Measure the resistance between suspect wheel speed sensor terminals.
  • 26. • Is the resistance between 800 and 1400 ohms (front 4x2), 800 and 3500 ohms (rear), or 380 and 480 ohms (front 4x4)? Yes GO to C3. No INSTALL a new wheel speed sensor. If the front wheel speed sensor (4x4), REFER to Sensor — Front 4x4 in this section. CLEAR the DTCs. REPEAT the self-test. If the front wheel speed sensor (4x2), REFER to Sensor — Front 4x2 in this section. CLEAR the DTCs. REPEAT the self-test. If the rear axle speed sensor, REFER to Sensor — Rear in this section. CLEAR the DTCs. REPEAT the self-test. C3 CHECK CIRCUIT 521 (TN/OG), 514 (YE/RD), OR 523 (RD/PK) Measure the resistance between the suspect wheel speed sensor and EEC-IV 60-Pin Breakout Box; and between the suspect wheel speed sensor and ground as follows:
  • 27. AntiSensor EEC-IV Lock Connector 60-Pin Brake and Breakout Box Sensor Circuit LF 17 RF C158 Pin 2, Circuit 514 (YE/RD) 3 Rear • C151 Pin 2, Circuit 521 (TN/OG) C421 Pin 2, Circuit 523 (RD/PK) 21 Is the resistance between the suspect wheel speed sensor and EEC-IV 60-Pin Breakout Box less than 5 ohms; and between the suspect wheel speed sensor and ground greater than 10,000 ohms? Yes GO to C4. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. C4 CHECK CIRCUIT 522 (TN/BK), 516 (YE/BK) OR 519 (LG/BK) Measure the resistance between the suspect wheel speed sensor and EEC-IV 60-Pin Breakout Box; and between the suspect wheel speed sensor and ground as follows: AntiSensor EEC-IV Lock Connector 60-Pin Brake and Breakout Sensor Circuit Box LF C151 Pin 1, Circuit 522 (TN/BK) 18
  • 28. RF 19 Rear • C158 Pin 1, Circuit 516 (YE/BK) C421 Pin 1, Circuit 519 (LG/BK) 22 Is the resistance between the suspect wheel speed sensor and EEC-IV 60-Pin Breakout Box less than 5 ohms; and between the suspect wheel speed sensor and ground greater than 10,000 ohms? Yes GO to C8. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. C5 CHECK THE SUSPECT WHEEL SPEED SENSOR CIRCUIT FOR SHORT TO POWER Suspect Wheel Speed Sensor Measure the voltage between the suspect EEC-IV 60-Pin Breakout Box pins and ground as follows: Wheel Speed Sensor EEC-IV 60-Pin Breakout Box
  • 29. LF RF 3 Rear • 17 22 Is voltage present? Yes REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. No GO to C6. C6 CHECK CIRCUIT 521 (TN/OG), 514 (YE/RD) or 523 (RD/PK) FOR SHORT TO GROUND Measure the resistance between EEC-IV 60-Pin Breakout Box and ground for the suspect wheel speed sensor as follows: Wheel Speed Sensor LF 17 RF 3 Rear • EEC-IV 60-Pin Breakout Box 21 Is the resistance greater than 10,000 ohms? Yes GO to C7. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. C7 CHECK CIRCUIT 522 (TN/BK), 516 (YE/BK) OR 519 (LG/BK) FOR SHORT TO GROUND Measure the resistance between EEC-IV 60-Pin Breakout Box and ground as follows: Wheel Speed Sensor EEC-IV 60-Pin Breakout Box
  • 30. LF RF 4 Rear • 18 22 Is the resistance greater than 10,000 ohms? Yes GO to C8. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. C8 CHECK FOR SHORT TO SPINDLE If front wheel speed sensor is suspected, measure the resistance between the spindle near the sensor and both terminals of the wheel speed sensor. If the rear axle speed sensor is suspected, measure the resistance between the rear axle housing near the sensor and both terminals of the wheel speed sensor. • Yes Is the resistance greater than 10,000 ohms?
  • 31. GO to C9. No INSTALL a new wheel speed sensor. If the front wheel speed sensor (4x4), REFER to Sensor — Front 4x4 in this section. CLEAR the DTCs. REPEAT the self-test. If the front wheel speed sensor (4x2), REFER to Sensor — Front 4x2 in this section. CLEAR the DTCs. REPEAT the self-test. If the rear axle speed sensor, REFER to Sensor — Rear in this section. CLEAR the DTCs. REPEAT the self-test. C9 CHECK WHEEL END ROUTING FOR DAMAGE Inspect the wheel speed sensor cable at the affected wheel end for chafing or other wiring damage. • Is damage found? Yes INSTALL a new wheel speed sensor. If the front wheel speed sensor (4x4), REFER to Sensor — Front 4x4 in this section. CLEAR the DTCs. REPEAT the self-test. If the front wheel speed sensor (4x2), REFER to Sensor — Front 4x2 in this section. CLEAR the DTCs. REPEAT the self-test. If the rear axle speed sensor, REFER to Sensor — Rear in this section. CLEAR the DTCs. REPEAT the self-test. No INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. REPEAT the self-test. PINPOINT TEST D: DTCS C1233, C1234, AND C1237 WHEEL SPEED SENSOR OUTPUT FAILURE NOTE: Any time a wheel speed sensor is removed, thoroughly clean the mounting surfaces. On front wheel speed sensors, apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590A or equivalent meeting Ford specification ESA-M1C198-A. CONDITIONS DETAILS/RESULTS/ACTIONS D1 CHECK THE DTCs FROM THE SELF-TEST Using the recorded results from the ABS self-test:
  • 32. • Are DTCs C1145, C1155 or C1230 present? Yes GO to Pinpoint Test C. No GO to D2. D2 MONITOR THE WHEEL SPEED PIDS ABS Module PIDs Use the diagnostic tool to monitor the ABS module wheel speed sensor PIDs while driving the vehicle at a constant speed. • Are all the wheel speed sensor PID values similar? Yes CLEAR the DTCs. DRIVE the vehicle. RETRIEVE the DTCs. If DTC C1233, C1234 or C1237 is present, GO to D10. No GO to D3. D3 INSPECT THE WHEEL SPEED SENSOR MOUNTING Raise and support the vehicle. Refer to Section 100-04. Inspect the wheel speed sensor for looseness. • Is the wheel speed sensor
  • 33. loose? Yes TORQUE the wheel speed sensor to specification. CLEAR the DTCs. GO to D4. No GO to D5. D4 RECHECK THE WHEEL SPEED PIDS ABS Module PIDs Use the diagnostic tool to monitor the ABS module wheel speed sensor PIDs while driving the vehicle at a constant speed. • Are all the wheel speed sensor PID values similar? Yes The vehicle is OK. Concern may have been caused by a loose wheel speed sensor. No GO to D5. D5 CHECK THE WHEEL SPEED SENSOR FOR DAMAGE Raise and support the vehicle. Refer to Section 100-04. CAUTION: Examine the wheel speed sensor wire carefully with a good light source. Failure to verify damage in the wheel speed sensor wire can lead to unnecessary installation of a new component.
  • 34. Inspect the wheel speed sensor for general damage. • Is the wheel speed sensor OK? Yes GO to D6. No INSTALL a new wheel speed sensor. REFER to Sensor — Front 4x2, Sensor — Front 4x4 or Sensor — Rear in this section. CLEAR the DTCs. TEST the system for normal operation. D6 CHECK FOR WHEEL SPEED SENSOR RING DAMAGE Remove the wheel speed sensor. Refer to Sensor — Front 4x2, Sensor — Front 4x4 or Sensor — Rear in this section. Inspect the wheel speed sensor ring for damaged or missing teeth. Rotate the wheel to verify that no teeth are missing. • Is the wheel speed sensor ring OK? Yes GO to D7. No INSTALL a new hub and bearing (front wheel), rear halfshaft (rear wheel) or ring gear. REFER to Section 204-00 or Section 205-00 respectively. CLEAR the DTCs. REPEAT the self-test. D7 CHECK FOR BEARING DAMAGE Inspect the wheel bearings for damage. • Are the wheel bearings OK? Yes GO to D8. No INSTALL a new wheel bearing as necessary. REFER to Section 20400. CLEAR the DTCs. REPEAT the self-test. D8 CHECK WHEEL SPEED SENSOR OUTPUT AT EEC-IV 60-PIN BREAKOUT BOX
  • 35. Raise the vehicle so that all wheels are free to spin. ABS Module C135 Connect EEC-IV 60-Pin Breakout Box. While spinning the suspect wheel at a constant speed, measure the AC voltage of the suspect wheel speed sensor between EEC-IV 60-Pin Breakout Box pins as follows: EEC-IV 60-Pin Breakout Box Wheel Speed Positive Negative Sensor Probe Probe LF 18 RF 3 4 Rear • 17 22 21 Is there any voltage present? Yes INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. REPEAT the self-test. No GO to D9. D9 CHECK THE WHEEL SPEED SENSOR OUTPUT Suspect Wheel Speed Sensor While spinning the suspect wheel at a constant speed, measure the AC voltage between the suspect wheel speed sensor terminals.
  • 36. • Is there any voltage present? Yes REPAIR the suspect wheel speed sensor circuit(s) in question. CLEAR the DTCs. REPEAT the self-test. No INSTALL a new wheel speed sensor. If front wheel speed sensor (4x4), REFER to Sensor — Front 4x4 in this section. CLEAR the DTCs. REPEAT the self-test. If front wheel speed sensor (4x2), REFER to Sensor — Front 4x2 in this section. CLEAR the DTC's. REPEAT the self-test. If rear wheel speed sensor; REFER to Sensor — Rear in this section. D10 CHECK FOR CORRECT ABS MODULE OPERATION Disconnect all ABS connectors. Check for: • corrosion • pushed-out pins
  • 37. Connect all ABS connectors and make sure they seat correctly. Operate the system and verify the concern is still present. • Is the concern still present? Yes INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. TEST the system for normal operation. No The system is operating correctly at this time. Concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. PINPOINT TEST E: DTC C1095 — HYDRAULIC PUMP MOTOR CIRCUIT FAILURE CONDITIONS DETAILS/RESULTS/ACTIONS E1 CHECK THE ABS PUMP MOTOR • Is the pump motor on constantly? Yes INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. CLEAR the DTCs. REPEAT the self-test. No GO to E2. E2 CHECK THE PUMP MOTOR OPERATION Diagnostic Tool
  • 38. Trigger the ABS module active command PMP MOTOR ON. • Does the pump motor operate? Yes CLEAR the DTC. CHECK the yellow ABS warning indicator while driving the vehicle above 40 km/h (25 mph). If the yellow ABS warning indicator illuminates, INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. CLEAR the DTCs. REPEAT the selftest. If the yellow ABS warning indicator does not illuminate, CLEAR the DTCs. REPEAT the self-test. No GO to E3. E3 CHECK THE PUMP MOTOR Pump Motor Connector Connect a fused 30A jumper wire between the positive battery terminal and red ABS pump motor terminal. Connect a jumper wire between the negative battery terminal and brown ABS pump motor terminal. • Is the ABS pump motor
  • 39. running? Yes GO to E4. No INSTALL a new HCU. REFER to Hydraulic Control Unit in this section. REPEAT the self-test. E4 CHECK CIRCUIT 534 (YE/LG) AND CIRCUIT 601 (LB/PK) FOR AN OPEN ABS Module C135 Connect the breakout box. Measure the voltage between the breakout box pin 9, circuit 534 (YE/LG) and ground; and between the breakout box pin 20, circuit 601 (LB/PK) and ground. • Are the voltages greater than 10 volts? Yes GO to E5. No REPAIR the circuit(s) in question. CLEAR the DTCs. REPEAT the selftest. E5 CHECK CIRCUIT 57 (BK) FOR AN OPEN
  • 40. Measure the resistance between the breakout box pin 8, circuit 57 (BK) and ground; and between the breakout box pin 24, circuit 57 (BK), and ground. • Are the resistances less than 5 ohms? Yes INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. REPEAT the self-test. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. PINPOINT TEST F: THE YELLOW ABS WARNING INDICATOR DOES NOT SELF-CHECK CONDITIONS DETAILS/RESULTS/ACTIONS F1 CHECK THE ABS MODULE ABS Module C135 Connect the breakout box. Connect a fused (10A) jumper
  • 41. between the breakout box pin 16, circuit 603 (DG) and ground. • Does the yellow ABS warning indicator illuminate? Yes VERIFY that all repair procedures have been carried out and DTCs have been repaired. INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section. REPEAT the self-test. No GO to F2. F2 CHECK CIRCUIT 603 (DG) FOR AN OPEN Instrument Cluster C288 Measure the resistance between the breakout box pin 16, circuit 603 (DG) and instrument cluster C288 pin 6, circuit 603 (DG). • Is the resistance less than 5 ohms? Yes INSTALL a new instrument cluster printed circuit. REFER to Section 413-01. TEST the system for normal
  • 42. operation. No REPAIR the circuit. TEST the system for normal operation. PINPOINT TEST G: DTC C1939: BRAKE PRESSURE SWITCH (BPS) CIRCUIT FAILURE CONDITIONS DETAILS/RESULTS/ACTIONS G1 VERIFY DTC Clear DTC. Road Test. Repeat the self-test. • Does code repeat? Yes GO to G2. No REVERIFY. G2 MONITOR BRAKE PRESSURE SWITCH (BPS) PID • With foot off brake pedal, is battery voltage present?
  • 43. Yes GO to G3. No GO to G4. G3 MONITOR BPS • While applying the brake pedal, is battery voltage present? Yes INSTALL a new ABS module. No GO to G7. G4 CHECK VOLTAGE TO BPS Brake Pressure Switch C1025 Measure the voltage between BPS C1025, circuit 276 (BN) and ground.
  • 44. • Is the voltage greater than 10 volts? Yes GO to G5. No REPAIR the circuit and RETEST. REPAIR/INSTALL new as necessary. G5 CHECK CIRCUIT 307 (BK/YE) FOR SHORT TO GROUND ABS Module C135 Brake Pressure Switch C1025 Connect the breakout box. Measure the resistance between breakout box pin 13 and ground.
  • 45. • Is the resistance greater than 10,000 ohms? Yes GO to G6. No REPAIR circuit 307 (BK/YE) and REPEAT the self-test. G6 CHECK CIRCUIT 307 (BK/YE) FOR OPEN Key Off ABS Module C135 Brake Pressure Switch C1025 Connect the breakout box. Measure the resistance between the suspect BPS connector terminal and the breakout box pin 13.
  • 46. • Is the resistance less than 5 ohms? Yes INSTALL a new brake pressure switch and REPEAT the self-test. No REPAIR circuit 307 (BK/YE) and REPEAT the self-test. G7 CHECK FOR SHORT TO POWER Key Off ABSe Module C135 Brake Pressure Switch C1025 Connect the breakout box. KOEO Measure the voltage between the breakout box pin 13 and ground.
  • 47. • Is voltage present? Yes REPAIR circuit 307 (BK/YE) and RETEST. No INSTALL a new brake pressure switch. PINPOINT TEST H: YELLOW ABS LIGHT ALWAYS ON, NO DTCS CONDITIONS DETAILS/RESULTS/ACTIONS H1 CHECK THE MODULE ABS Module C135 • Does the yellow ABS light illuminate? Yes GO to H2. No GO to F1. H2 CHECK CIRCUIT 603 (DG) FOR SHORT TO GROUND
  • 48. At the ABS module connector, press the shorting bar. • Is the yellow ABS light off? Yes REPEAT the connector. If light remains on, INSTALL a new ABS module. No REPAIR circuit 603 (DG). REPEAT the self-test.
  • 49. SECTION 206-09: Anti-Lock Control REMOVAL AND INSTALLATION 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Hydraulic Control Unit Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plaster surface, immediately wash it with water. 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector by lifting up on the release tab. 3. Disconnect the brake lines from the hydraulic control unit (HCU). 4. Remove the HCU. 1. Remove the bolts. 2. Remove the HCU.
  • 50. 5. If necessary, remove the anti-lock brake control module. Installation 1. CAUTION: After the electronic hydraulic control unit is installed, it is necessary to bleed the hydraulic brake system; refer to Section 206-00. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure.
  • 51. SECTION 206-09: Anti-Lock Control REMOVAL AND INSTALLATION Anti-Lock Brake System (ABS) Module Removal 1. Disconnect the battery ground cable. 2. Remove the hydraulic control unit bolts. 3. Disconnect the electrical connectors. 4. Remove the anti-lock brake control module. 1. Remove the bolts. 2. Remove the anti-lock brake control module. Installation 2001 Ranger Workshop Manual Procedure revision date: 02/13/2003
  • 52. 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. SECTION 206-09: Anti-Lock Control 2001 Ranger Workshop Manual
  • 53. REMOVAL AND INSTALLATION Procedure revision date: 06/26/2000 Sensor — Front 4x2 Material Item High-Temperature 4x4 Front Axle and Wheel Bearing Grease Specification ESA-M1C198A Removal and Installation Raise and support the vehicle. For additional information, refer to Section 100-02. Disconnect the front anti-lock brake sensor wire from the vehicle frame. Disconnect the electrical connector. Unclip the front anti-lock brake sensor wire from the vehicle frame. Remove the front anti-lock brake sensor. Remove the bolt. Remove the front anti-lock brake sensor. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply grease. To install, reverse the removal procedure.
  • 54.
  • 55. SECTION 206-09: Anti-Lock Control REMOVAL AND INSTALLATION 2001 Ranger Workshop Manual Procedure revision date: 03/08/2004 Sensor — Front 4x4 Removal and Installation Remove the rotor shield. For additional information, refer to Section 205-03. Disconnect the electrical connector. Unclip the wire from the vehicle frame. Remove the bolt. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford Specification ESA-M1C198-A. Remove the front wheel speed sensor. Remove the bolt and the sensor.
  • 56. To install, reverse the removal procedure.
  • 57. SECTION 206-09: Anti-Lock Control REMOVAL AND INSTALLATION 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Sensor — Rear Material Item Specification SAE 75W-140 High WSL-M2C192Performance Rear Axle A Lubricant XY-75W140-QL or equivalent Removal and Installation Raise and support vehicle. For additional information, refer to Section 100-02. NOTE: Clean off dirt and foreign material that may have collected around the rear antilock brake sensor before removal. Remove the rear anti-lock brake system (ABS) sensor. Disconnect the electrical connector. Remove the bolt. Remove the sensor. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the Oring with axle lubricant. To install, reverse the removal procedure. SECTION 206-09: Anti-Lock Control 2001 Ranger Workshop Manual
  • 58. REMOVAL AND INSTALLATION Procedure revision date: 06/26/2000 Sensor Indicator — Front 4x2 Removal and Installation For additional information, refer to Section 206-03. SECTION 206-09: Anti-Lock Control 2001 Ranger Workshop Manual
  • 59. REMOVAL AND INSTALLATION Procedure revision date: 06/26/2000 Sensor Indicator — Front 4x4 Removal and Installation For additional information, refer to Section 204-01B. SECTION 206-09: Anti-Lock Control 2001 Ranger Workshop Manual
  • 60. REMOVAL AND INSTALLATION Procedure revision date: 06/26/2000 Sensor Indicator — Rear Removal and Installation NOTE: The rear anti-lock brake sensor indicator is attached to the differential case. For additional information, refer to Section 205-02A.For additional information, refer to Section 205-02B.
  • 61. SECTION 303-01D: Engine — 2.3L IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 12/03/2003 Timing Drive Components Special Tool(s) Alignment Plate, Camshaft 303-465 (T949-6256-CH) Removal CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe damage can occur. 1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section. 2. Remove the timing chain tensioner. 1. Compress the timing chain tensioner, and insert a paper clip into the hole. 2. Remove the bolts and timing chain tensioner. 3. Remove the RH timing chain guide.
  • 62. 4. Remove the timing chain. 5. Remove the bolts and the LH timing chain guide.
  • 63. 6. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur. If necessary, remove the bolts and the camshaft sprockets. • Use the flats on the camshaft to prevent camshaft rotation. Installation 1. Remove the special tool. 2. CAUTION: Do not rotate the camshafts. Damage to the valves and pistons can occur. If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft rotation and loosen the sprocket bolts.
  • 64. 3. If removed, install the camshaft sprockets and the bolts. Do not tighten the bolts at this time. 4. Install the LH timing chain guide and bolts. 5. Install the timing chain. 6. Install the RH timing chain guide.
  • 65. 7. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. 8. Install the special tool. 9. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshafts can result.
  • 66. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. 10. Install the front cover. For additional information, refer to Engine Front Cover in this section.
  • 67. SECTION 303-01C: Engine — 4.0L SOHC SPECIFICATIONS DESCRIPTION AND OPERATION Engine DIAGNOSIS AND TESTING Engine IN-VEHICLE REPAIR Intake Manifold Valve Cover — RH Valve Cover — LH Crankshaft Pulley Crankshaft Front Oil Seal Engine Front Cover Timing Drive Components — Camshaft Timing Timing Drive Components — Hydraulic Chain Tensioner, RH Timing Drive Components — Hydraulic Chain Tensioner, LH Timing Drive Components — Camshaft Drive Cassette, LH Valve — Valve Spring Valve — Valve Seals Hydraulic Lash Adjusters Roller Followers Camshaft — LH Camshaft — RH Exhaust Manifold LH Exhaust Manifold — RH Cylinder Head — LH Cylinder Head RH Oil Pan Oil Pump Screen and Pickup Tube Flywheel Flexplate Crankshaft Rear Oil Seal Cylinder Block Cradle Engine Support Insulators
  • 68. REMOVAL Engine DISASSEMBLY Engine DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Head Piston ASSEMBLY Engine INSTALLATION Engine
  • 69. SECTION 303-01C: Engine — 4.0L SOHC SPECIFICATIONS 2001 Ranger Workshop Manual Procedure revision date: 12/18/2003 General Specifications Item Specification Lubricants and Sealants Super Premium SAE 5W-30 Motor Oil XO-5W30QSP or equivalent WSS-M2C205-A Metal Surface Cleaner F4AZ-19A536-RA or equivalent WSE-M5B392-A Silicone Gasket and Sealant F7AZ-19554-EA or equivalent Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent WSE-M4G323-A4 ESA-M1C171-A Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent a ESE-M97B44-A (green color) Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent a b WSS-M97B51-A1 (yellow color) Engine — 4.0L SOHC Displacement liters (cubic inch) Number of cylinders Bore mm (inch) 4.0L (244) 6 100.4 (3.953) Stroke mm (inch) 84.4 (3.31) Firing order 1-4-2-5-3-6 Minimum oil pressure at 2,000 rpm (engine at normal operating temperature) kPa (psi) Oil capacity liters/quarts 103 (15) 3.8 (4) with filter Cylinder Head and Valve Train Cylinder head gasket surface flatness mm (inch) 0.08 (0.003) Total Combustion chamber volume (cc) 65.197 ± 2.068-2.018 Valve arrangement (front to rear) LH=I-E-I-E-I-E RH=E-I-E-I-E-I Valve guide bore diameter mm (inch) 7.00-7.018 (0.276) Valve stem diameter intake mm (inch) 6.965-6.98 (0.274-0.275) Valve stem diameter exhaust mm (inch) 6.95-6.965 (0.274) Valve stem-to-guide clearance exhaust mm (inch) 0.035-0.068 (0.001-0.003) Valve stem-to-guide clearance intake mm (inch) 0.020-0.053 (0.001-0.002) Valve head diameter intake mm (inch) 45.9-46.1 (1.807-1.815) Valve head diameter exhaust mm (inch) 38.9-39.1 (1.531-1.539) Valve face runout Valve face angle (degrees) Valve seat width (exhaust and intake) mm (inch) 0.03 (0.001) 45° 1.556-2.404 (0.06-0.094) 1.273-2.121 (0.05-0.083)
  • 70. Valve seat runout (TIR maximum) mm (inch) Valve seat angle (degrees) 0.059 (0.002) 45° Valve spring free length intake mm (inch) 43.1 (1.7) Valve spring free length exhaust mm (inch) 43.1 (1.7) Valve spring squareness — Valve spring compression pressure intake (at specified height) (lb) 275-305 Nm at 35.9-36.7 mm (202.84224.968 lb-ft at 1.413-1.445 inch) Valve spring compression pressure exhaust (at specified height) (lb) 275-305 Nm at 35.9-36.7 mm (202.84224.968 lb-ft at 1.413-1.445 inch) Valve spring installed height intake mm (inch) 39.86-40.86 (1.569-1.601) Valve spring installed height exhaust mm (inch) 39.86-40.68 (1.569-1.601) Valve spring installed pressure — Roller follower ratio — Camshaft Theoretical valve lift @ 0 lash — Lobe lift intake mm (inch) 6.584 (0.259) Lobe lift exhaust mm (inch) 6.584 (0.259) Allowable lobe lift loss mm (inch) 0.127 (0.005) Journal diameter mm (inch) 27.935-27.96 (1.099-1.101) Journal bore inside diameter mm (inch) Journal to bearing clearance mm (inch) 28.0-28.03 (1.102-1.104) c Runout mm (inch) End play mm (inch) 0.04-0.095 (0.002-0.004) 0.05 (0.002) 0.075-0.185 (0.0003-0.007) Cylinder Block Cylinder bore diameter mm (inch) 100.4 (3.953) Cylinder bore maximum taper mm (inch) 0.025 (0.001) Cylinder bore maximum out-of-round mm (inch) 0.025 (0.001) Main bearing bore inside diameter mm (inch) Head gasket surface flatness mm (inch) Head gasket surface finish (RMS) 60.634-60.620 (2.387-2.387) 0.1 (0.004) overall 60-150 Crankshaft Main bearing journal diameter mm (inch) 56.980-57.0 (2.243-2.244) Main bearing journal maximum taper mm (inch) 0.008 (0.0003) Main bearing journal maximum out-of-round mm (inch) 0.008 (0.0003) Main bearing journal-to-cylinder block clearance mm (inch) — Connecting rod journal diameter mm (inch) 53.98-54.0 (2.125-2.126) Connecting rod journal maximum taper mm (inch) 0.008 (0.0003) Connecting rod journal maximum out-of-round mm (inch) 0.008 (0.0003) Crankshaft maximum end play mm (inch) Main Bearings 0.05-0.32 (0.002-0.0126)
  • 71. Clearance to crankshaft mm (inch) 0.021-0.039 (0.0008-0.0015) Clearance to crankshaft allowable mm (inch) 0.013-0.048 (0.0005-0.002) Bearing wall thickness mm (inch) 1.8-1.806 (0.0709-0.0711) Piston and Connecting Rod Piston diameter — coded STD mm (inch) 100.380-100.400 (3.952-3.9528) Piston diameter — coded 0.5 mm (inch) 100.880-100.900 (3.972) Piston diameter — coded 1.0 mm (inch) 101.350-101.370 (3.990-3.991) Piston-to-cylinder bore clearance mm (inch) 0.030-0.060 (0.0012-0.002) Piston top ring end gap mm (inch) 0.200-0.450 (0.008-0.018) Piston bottom ring end gap mm (inch) 0.450-0.700 (0.018-0.028) Piston top ring groove width mm (inch) 1.64-1.66 (0.0645-0.0654) Piston bottom ring groove width mm (inch) 1.79-1.81 (0.0705-0.0713) Piston oil ring groove width mm (inch) 3.5-3.53 (0.1378-0.1399) Piston top ring width mm (inch) 1.578-1.598 (0.062-0.063) Piston bottom ring width mm (inch) 1.728-1.74 (0.068-0.069) Piston top ring-to-groove clearance mm (inch) 0.050-0.082 (0.002-0.0003) Piston bottom ring-to-groove clearance mm (inch) 0.050-0.082 (0.002-0.003) Piston pin bore diameter (red) mm (inch) 24.007-24.010 (0.945) Piston pin bore diameter (blue) mm (inch) 24.010-24.013 (0.945) Piston pin diameter (red) mm (inch) 23.994-23.997 (0.9446-0.9447) Piston pin diameter (blue) mm (inch) 23.997-24.000 (0.9447-0.9449) Piston pin length mm (inch) 72.0-72.8 (2.835-2.866) Piston pin-to-piston pin fit mm (inch) Piston pin-to-connecting rod clearance mm (inch) 0.01-0.016 (0.0004-0.0006) Press Fit -0.018 to -0.042 (-0.0007 to 0.0017) Connecting rod pin bore diameter mm (inch) 23.958-23.976 (0.943-0.944) Connecting rod length mm (inch) 145.965-146.035 (5.746-5.749) Connecting rod maximum allowed bend mm (inch) 0.0125 (0.00049) per 25.4 mm (1.000) Connecting rod maximum allowed twist mm (inch) 0.038 (0.0015) per 25.4 mm (1.000) Connecting rod bearing bore diameter mm (inch) 56.82-56.84 (2.237) Connecting rod bearing-to-crankshaft clearance mm (inch) 0.013-0.048 (0.005-0.002) Connecting rod side clearance (assembled to crankshaft) mm (inch) 0.092-0.268 (0.0036-0.0106) a Use the same type of coolant that was drained from the cooling system. Do not mix coolant types. b The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan. c Tighten camshaft bearing cap bolts to 15 Nm (11 lb-ft) when measuring journal clearance. Torque Specifications Description A/C compressor manifold bolt Nm lb-ft lb-in 20 15 —
  • 72. A/C line bracket nut 20 15 — Accelerator control splash shield bolts 4 — 35 Balance shaft bolts 26-28 19-21 Balance shaft chain guide 9-11 Balance shaft tensioner bolts 28-30 21-22 — — 80-97 — Camshaft bearing cap bolts (a) — — Camshaft sprocket bolt 85 63 — 61 45 — — — — — — — — — — — — — — — — — — — Accessory bracket bolts 42 31 — Engine electrical connector 6 — 53 Engine front cover bolts 19 14 — Engine lifting eye bolts 28 21 — Electrical harness retainer bolt 10 — 89 Lower engine mount bracket nuts 80 59 — Fuel line bracket bolt 10 — 89 EGR valve tube fittings 34 25 — Exhaust manifold nuts 22 16 — Exhaust manifold to exhaust pipe bolts 40 30 — a — — 19 14 — — — — Fuel injection supply manifold bolts 23 17 — Generator bracket bolts 42 31 — Ground wire bolt 10 — 89 Camshaft sprocket bolt (w/sst) Cassette and sprocket to jackshaft bolt Cassette bolt, LH a Cassette bolt, RH a Connecting rod bolts a Crankshaft pulley bolts Cylinder head bolts a a Flywheel bolts Front cassette bolt Front cylinder head bolts a Heater hose bracket bolts a 23 17 — Hydraulic camshaft tensioner, RH a — — — Hydraulic camshaft tensioner, LH a — — — Intake manifold bolts 10 — 89 Jackshaft chain guide bolts 19 14 — 9 — 80 — — — — — — Jackshaft thrust plate bolts 11 8 — Knock sensor bolt 25 18 — Ladder frame bolts and nuts (outside) 10 — 89 Jackshaft chain tensioner bolts Jackshaft rear sprocket bolt Jackshaft front sprocket bolt a a
  • 73. Ladder frame bolts (inside) a — — — Ladder frame Torx® bolts 8 — 71 Ladder frame inserts 3 — 27 Main bearing cap bolts 97 72 — Oil bypass filter 13 10 — Oil filter adapter bolt 57 42 — Oil level indicator tube bracket bolt 25 18 — Oil pan bolts 9 — 80 Oil pan drain plug 25 18 — Oil pressure sensor 11-16 9-11 — Oil pump bolts 19 14 — Oil pump drive assembly 19 14 — Oil pump screen cover and tube bolts 10 — 89 Powertrain control module (PCM) bolt 6 — 53 Powertrain control module (PCM) ground wire nut 10 — 89 Power steering pressure line nut 18 13 — Rear cassette bolt 18 13 — Spark plug 20 15 — Thermostat housing bolts 11 8 — Transmission cooler line bracket bolt 47 35 — Transmission to engine bolts 47 35 — Torque converter to flywheel nuts 47 35 — Upper engine mount bracket nuts 110 81 — Lower engine mount bracket bolts 80 59 — Valve cover bolts 10 — 89 Vapor management valve (VMV) hose bracket 15 11 — Water pump bolts 10 — 89 Water temperature indicator sender unit 10 — 89 Wiring harness retainer nuts 10 — 89 a Refer to the procedure.
  • 74. SECTION 303-01C: Engine — 4.0L SOHC DESCRIPTION AND OPERATION 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Engine The 4.0L SOHC engine consists of the following: • single overhead camshafts • sequential multiport fuel injection (SFI) • distributorless ignition system • aluminum cylinder heads • cast iron, 60-degree V cylinder block • balance shaft (4x4 vehicles) • jackshaft • unique engine timing configuration For quick identification, refer to the vehicle control information decal mounted under the hood. • For additional information, refer to Section 100-01 . An engine identification label is attached to the engine. The label: • identifies the symbol code for determining parts usage. For additional information, refer to Section 100-01 . Lower Components—4.0L SOHC Engine
  • 75. Item Part Number Description 1 6U000 Bolt 2 6M290 Camshaft drive cassette RH 3 12A699 Knock sensor 4 6A364 Balance shaft chain (4x4 only) 5 W702523 Bolt (4x4 only) 6 W702979 Crankshaft key 7 6306 Sprocket 8 6K350 Sprocket
  • 76. 9 6329 Crankshaft front main bearing cap 10 6345 Bolt (8 req'd) 11 W709211 Stud (2 req'd) 12 6F092 Cylinder block cradle 13 W503275 Bolt (20 req'd) 14 E822125 Nut 15 6734 Gasket 16 W702323 Bolt 17 E802185 Bolt 18 6675 Oil pan 19 W702323 Bolt (6 req'd) 20 6617 Oil pump screen and pickup tube 21 W709198 Bolt 22 E804588 Bolt 23 6C629 Spacer 24 6710 Gasket 25 6334 Crankshaft front intermediate main bearing cap 26 E804553 Screw (3 req'd) 27 6K790 Oil pickup adapter 28 W708582 Bolt (2 req'd) 29 6600 Oil pump 30 6A605 Oil pump intermediate shaft 31 6325 Crankshaft rear main bearing cap 32 6330 Crankshaft center main bearing cap 33 6A338 Crankshaft lower main bearing (3 req'd) 34 6A339 Crankshaft lower center main bearing 35 6303 Crankshaft 36 6333 Crankshaft upper main bearing (3 req'd) 37 6337 Crankshaft upper center main bearing 38 6K355 Balance shaft tensioner assembly (4x4 only) 39 6A311 Balance shaft (4x4 only) 40 6010 Block 41 9278 Oil pressure sensor 42 W701473 Nut (12 req'd) 43 6210 Connecting rod bearing cap (6 req'd) 44 6211 Connecting rod bearings 45 6200 Connecting rod 46 6135 Piston pin 47 6159 Piston ring, oil control (2 req'd) 48 6152 Piston ring, lower compression
  • 77. 49 6214 Bolt (2 req'd) 50 6110 Piston 51 6161 Piston ring, oil control spacer 52 6150 Piston ring, upper compression 53 6754 Oil level indicator tube 54 W701723 Bolt 55 6750 Oil level indicator 56 W500024 Bolt 57 12270 Clamp 58 6846 Oil pump drive assembly 59 6M289 Camshaft drive cassette LH 60 6M276 Bolt 61 W500110 Bolt 62 W703167 Bolt 63 6U001 Bolt 64 W500225 Bolt 65 6M276 Bolt Front and Rear Components—4.0L SOHC Engine
  • 78. Item Part Number Description 1 6L621 Gasket 2 6884 Oil filter adapter 3 6895 Bolt 4 E853188 O-ring 5 6890 Adapter 6 6714 Oil filter 7 6M272 Jackshaft chain guide 8 6M278 Jackshaft thrust plate 9 6M263 Jackshaft 10 6C524 Jackshaft sprocket 11 6M276 Bolt 12 6M270 Jackshaft chain 13 W500012 Bolt (2 req'd) 14 6M271 Jackshaft chain tensioner 15 W702125 Bolt (2 req'd)
  • 79. 16 W500110 Bolt (2 req'd) 17 W500014 Bolt (2 req'd) 18 6K357 Balance shaft chain guide (4x4 only) 19 W500024 Bolt (5 req'd) 20 W702501 Stud 21 8507 Gasket 22 W500014 Bolt (12 req'd) 23 W500213 Bolt (2 req'd) 24 E800511 Bolt 25 6B321 Crankshaft pulley 26 6C315 Crankshaft position sensor 27 8501 Water pump 28 6700 Crankshaft front seal 29 E804541 Stud (4 req'd) 30 6019 Front cover 31 6020 Gasket 32 6379 Bolt (8 req'd) 33 6375 Flexplate 34 6434 Spacer 35 6701 Crankshaft rear seal Upper Components—4.0L SOHC Engine
  • 80. Item Part Number Description 1 W708086 Bolt (2 req'd) 2 9F775 Fuel injection pulse damper 3 9G756 Fuel pressure/temperature sensor 4 W709515 Bolt (2 req'd) 5 W500023 Bolt (4 req'd) 6 W500204 Bolt 7 9E964 Fuel supply tube 8 W708086 Bolt (4 req'd) 9 9D280 Fuel injection supply manifold LH 10 9F593 Fuel injector (6 req'd) 11 9G512 Fuel injector adapter (6 req'd) 12 W500213 Bolt 13 9G271 Fuel vapor tube 14 9K479 Intake manifold
  • 81. 15 W708086 Bolt (2 req'd) 16 9G624 Cover 17 9D280 Fuel injection supply manifold RH 18 6763 Oil filler pipe 19 6582 Valve cover RH 20 6578 Oil supply tube RH 21 6A258 Camshaft bearing cap (3 req'd) 22 6250 Camshaft RH 23 6A258 Camshaft bearing cap 24 18465 Heated PCV coolant hose 25 18696 Heater water inlet tube assembly 26 W500023 Bolt 27 17A084 Lifting eye RH 28 W500041 Bolt (2 req'd) 29 W701706 Nut (6 req'd) 30 9430 Exhaust manifold RH 31 9448 Exhaust manifold gasket RH 32 6K254 Timing chain tensioner RH 33 W703974 Spacer 34 W705495 Stud (6 req'd) 35 6051 Cylinder head gasket RH 36 6049 Cylinder head RH 37 W525966 Clamp (2 req'd) 38 8548 Coolant hose 39 8A586 Thermostat housing 40 W702527 Bolt (3 req'd) 41 W702341 Bolt (16 req'd) 42 6049 Camshaft bearing cap 43 6A274 Camshaft LH 44 6K254 Timing chain tensioner LH 45 6N091 Oil volume reduction plug 46 6U000 Bolt 47 12405 Spark plug (6 req'd) 48 6505 Exhaust valve (6 req'd) 49 6083 Cylinder head gasket LH 50 6507 Intake valve (6 req'd) 51 9J433 Differential pressure feedback exhaust gas recirculation system 52 9E469 EGR tube 53 9G485 Adapter 54 9431 Exhaust manifold LH
  • 82. 55 W701706 Nut (6 req'd) 56 W500023 Bolt 57 9448 Exhaust manifold gasket LH 58 W705495 Stud (6 req'd) 59 W500041 Bolt (2 req'd) 60 17A084 Lifting eye LH 61 12A310 Ignition coil assembly 62 W500214 Bolt (2 req'd) 63 6571 Valve stem seal (12 req'd) 64 6513 Valve spring (12 req'd) 65 6C501 Lash adjuster (12 req'd) 66 6518 Valve spring retainer key (24 req'd) 67 6529 Roller follower (12 req'd) 68 6065 Cylinder head bolts (16 req'd) 69 6A536 Valve spring retainer seat (12 req'd) 70 6A258 Camshaft bearing cap (3 req'd) 71 6578 Oil supply tube LH 72 6A505 Valve cover LH 73 14A004 Bracket 74 W500204 Bolt 75 W500204 Bolt 76 6B288 Camshaft position sensor
  • 83. SECTION 303-01C: Engine — 4.0L SOHC DIAGNOSIS AND TESTING Engine Refer to Section 303-00 . 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000
  • 84. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Intake Manifold Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 . 2. Remove the bolts and the shield. 3. Remove the air cleaner outlet pipe. • Disconnect the tube. • Detach the mass airflow (MAF) sensor wiring pushpin. • Loosen the clamps and remove the pipe. 4. Disconnect the idle air control (IAC) valve and the throttle position sensor (TPS) electrical connectors. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose. 5. Disconnect the accelerator and speed control cables. 1. Detach the accelerator and speed control cables from the throttle body.
  • 85. 2. Detach the accelerator and speed control cables from the bracket, and position the cables aside. 6. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube. 7. Disconnect the EGR valve vacuum regulator electrical connector and vacuum hoses. 8. Disconnect the hose. 9. Loosen the clamp and disconnect the brake booster vacuum hose.
  • 86. 10. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Disconnect the RH spark plug wires from coil. Remove spark plug wire routing clip pushpin and position the wires aside. 11. Remove wiring harness bracket retainer, then position wiring harness aside. 12. Remove accelerator cable routing clip pushpin and wiring harness pushpin. 13. Remove the bolts.
  • 87. 14. Remove the bolt and position the coil and bracket aside. 15. Disconnect the vacuum hoses. 16. Remove the nut. 17. Disconnect the powertrain control module (PCM) electrical connector.
  • 88. 18. Disconnect the ground wires and position the wiring harness aside. 19. Detach the electrical connector retainer. 20. Remove the intake manifold bolts and lift up the intake manifold.
  • 89. 21. Remove the heated PCV hose retainers and remove the heated PCV fitting. 22. Remove the intake manifold. 23. To install, reverse the removal procedure.
  • 90. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 04/01/2003 Valve Cover — RH Removal and Installation All vehicles 1. Drain the cooling system. For additional information, refer to Section 303-03 . 2. Remove the air cleaner outlet pipe. • Disconnect the tube. • Detach the mass airflow (MAF) sensor wiring pushpin. • Loosen the clamps and remove the pipe. 3. Release hose clamps and remove hose. 4. Remove hose.
  • 91. 5. Disconnect the vacuum hose. 6. Loosen hose clamps and disconnect hoses. 7. Release hose clamps and disconnect hoses. 8. Release hose clamp and disconnect hose.
  • 92. 9. Release hose clamp and disconnect hose. Position hose aside. Vehicles with automatic transmission 10. Remove the nut and position the transmission fluid level indicator and tube assembly aside. All vehicles 11. Remove the bolts. 12. Detach the wiring harness retainer. • Remove the heater tube and bracket assembly. 13. Disconnect MAF sensor connector and wiring pushpin. Position wiring aside.
  • 93. 14. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Position the spark plug wires aside. 1. Disconnect the spark plug wires. 2. Disconnect the spark plug wire retainer and position the wires aside. 15. Disconnect fuel injector electrical connectors. Position wiring aside. 16. Remove the bolts and the valve cover.
  • 94. 17. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean and inspect the sealing surfaces. Install a new gasket if necessary. 18. To install, reverse the removal procedure.
  • 95. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Valve Cover — LH Special Tool(s) Disconnect Tool, Spring Lock Coupling (5/8") 412-038 (T83P-19623-C) Removal and Installation 1. Disconnect the battery negative cable. For additional information, refer to Section 414-01 . 2. Detach the accelerator and speed control cables. 1. Detach the accelerator and speed control cables from the throttle body. 2. Detach the accelerator and speed control cables from the bracket, and position the cables aside. 3. Detach the spark plug wire retainer. 4. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. Disconnect the spark plug wires.
  • 96. 5. Remove the bolts. 6. Remove the bolt. 7. Disconnect the coil electrical connector. 8. Disconnect the radio interference capacitor electrical connector and position the coil aside.
  • 97. 9. Loosen the bolt and disconnect the electrical connector. 10. Disconnect the following: 1. Exhaust gas recirculation (EGR) valve vacuum hose. 2. EGR valve vacuum regulator solenoid vacuum hoses. 3. EGR valve vacuum regulator solenoid electrical connector. 4. Camshaft position sensor electrical connector. 5. Differential pressure feedback electrical connector. 11. Disconnect fuel injector electrical connectors. Position wiring aside. 12. Detach the spark plug wire retainer.
  • 98. 13. Disconnect the fuel vapor hose and the vacuum hose. 14. Remove the bolt and position the electrical connector and bracket aside. 15. Remove the screws and the EGR valve vacuum regulator solenoid. 16. Remove the differential pressure feedback with the hoses from the exhaust manifold-to-EGR valve tube.
  • 99. 17. Relieve the fuel system pressure. For additional information, refer to Section 310-00 . 18. Detach the clip. 19. Using the special tool, disconnect the fuel supply line. 20. Remove the bolt and position the lower fuel line bracket aside. 21. Remove the bolt and position the fuel supply line aside.
  • 100. 22. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube. 23. Disconnect the hose. 24. Unscrew the fitting. 25. Remove the bolts and the valve cover.
  • 101. 26. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean and inspect the sealing surfaces. Install a new gasket if necessary. 27. To install, reverse removal procedure.
  • 102. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 05/27/2003 Crankshaft Pulley Special Tool(s) Crankshaft Vibration Damper Remover 303-101 (T74P-6316-A) Installer, Crankshaft Vibration Damper Replacer 303-102 (T74P-6316-B) Strap Wrench 303-D055 (D85L-6000-A) or equivalent Material Item Specification Motorcraft Silicone Gasket Remover ZC-30 — Motorcraft Metal Surface Prep ZC-31 — Silicone Gasket and Sealant F7AZ-19554-EA WSE-M4G323A4 Removal 1. Remove the fan shroud. For additional information, refer to Section 303-03 . 2. Remove the accessory drive belt. For additional information, refer to Section 30305 . 3. CAUTION: This bolt is a torque-to-yield design and cannot be reused. Using the special tool, remove the crankshaft pulley bolt.
  • 103. 4. Using the special tool, remove the crankshaft pulley. Installation 1. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. 2. Using the special tool, install the crankshaft pulley. 3. Using the special tool, install a new crankshaft pulley bolt. • Tighten the bolt in two stages: • Stage 1: Tighten the bolt to 50 Nm (37 lb-ft). • Stage 2: Tighten the bolt an additional 90 degrees.
  • 104. 4. Install the accessory drive belt. For additional information, refer to Section 30305 . 5. Install the fan shroud. For additional information, refer to Section 303-03 .
  • 105. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Crankshaft Front Oil Seal Special Tool(s) Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) Aligner, Front Cover 303-093 (T74P-6019-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Material Item Specification Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C205A Removal 1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section. 2. Using the special tool, remove the crankshaft front oil seal. Installation 1. NOTE: Lubricate the seal lip with clean engine oil. Using the special tools, install the crankshaft front oil seal.
  • 106. 2. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
  • 107. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 04/15/2003 Engine Front Cover Material Item Specification Silicone Gasket and Sealant F7AZ-19554-EA or equivalent WSS-M4G323A4 Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C153G Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 . 2. Remove the crankshaft front oil seal. For additional information, refer to Crankshaft Front Oil Seal . 3. Drain the cooling system. For additional information, refer to Section 303-03 . 4. On A/C equipped vehicles, remove the A/C line bracket bolt and position the A/C line aside. 5. Remove the lower cylinder block cradle-to-engine front cover bolts. 6. Lower the vehicle. 7. Remove the bolt and the wiring harness routing clip.
  • 108. 8. Remove the accessory bracket bolts and position the bracket aside. 9. Remove the drivebelt tensioner. 10. Disconnect the generator wiring and position the wiring aside. 11. Remove the generator mounting bracket.
  • 109. 12. Disconnect the crankshaft position (CKP) sensor electrical connector. 13. Remove the wiring anchors and position the wiring aside. 14. Remove the wiring harness retainer and position the wiring aside. 15. Move the lower bypass hose clamp off of the coolant pump outlet.
  • 110. 16. Release the hose clamp and remove the lower heater water hose. 17. Release the hose clamp and remove the lower radiator hose. 18. NOTE: The water pump is removed for clarity. Remove the bolts and the engine front cover. • Discard the gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause gouges which make leak paths. Clean and inspect the sealing surfaces. Install a new gasket.
  • 111. 2. Apply silicone gasket and sealant to the oil pan and the engine block mating surfaces. 3. Apply silicone gasket and sealant to the front cover in two places. 4. Install the engine front cover. 5. Connect the coolant bypass hose clamp. 6. Install the lower radiator hose and clamp.
  • 112. 7. Install the lower heater water hose and clamp. 8. Position the wiring harness and install the bolt. 9. Secure the wiring anchors. 10. Connect the CKP sensor electrical connector.
  • 113. 11. Install the generator mounting bracket. 12. Connect the generator wiring. 13. Install the drivebelt tensioner. 14. Install the accessory bracket bolts.
  • 114. 15. Install the routing clip and bolt. 16. Raise and support the vehicle. For additional information, refer to Section 10002 . 17. Install the cylinder block cradle-to-engine front cover bolts. 18. On A/C equipped vehicles, install the A/C line bracket and bolt. 19. NOTE: Install the drain plug when finished draining. Drain the engine oil.
  • 115. 20. Lower the vehicle. 21. Install crankshaft front oil seal. For additional information, refer to Crankshaft Front Oil Seal in this section. 22. Fill the engine with clean engine oil. 23. Connect the battery ground cable. For additional information, refer to Section 414-01 . 24. Fill the engine with coolant. For additional information, refer to Section 303-03 .
  • 116. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Timing Drive Components — Camshaft Timing Special Tool(s) Tensioner, Timing Chain 303-571 (T97T-6K254-A) Extension, Torque Wrench 303-575 (T97T-6256-F) Socket, Camshaft Sprocket Nut 303-565 (T97T-6256-G) Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) Adapter for 303-564 303-578 (T97T-6256-A) Holding Tool, Camshaft 303-577 (T97T-6256-C) Timing Tool, Crankshaft TDC 303-573 (T97T-6303-A)
  • 117. Adapter for 303-577 303-576 (T97T-6256-D) 1. Remove the valve covers. For additional information, refer to Valve Cover — RH Valve Cover — LH and in this section. 2. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 3. Remove the fuel supply manifold. For additional information, refer to Section 30304C . 4. Remove the accessory drive belt. For additional information, refer to Section 30305 . 5. Remove the thermostat housing. For additional information, refer to Section 30303 . 6. Remove the roller followers. For additional information, refer to Roller Followers in this section. 7. NOTE: You must retime the LH and RH camshafts when either camshaft is disturbed. Turn the crankshaft clockwise to position the number one cylinder at TDC. 8. NOTE: The special tool must be installed on the damper and should contact the engine block, this positions the engine at top dead center (TDC). Install the special tool. 9. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt. Using the special tool, loosen the RH camshaft sprocket bolt. 10. NOTE: The camshaft timing slots are off-center. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools and install the special tools on the front of the RH cylinder head.
  • 118. 11. Raise and support the vehicle. For additional information, refer to Section 10002 . 12. Remove the RH wheel and tire. For additional information, refer to Section 20404 . 13. Remove the RH lower splash shield. 14. Remove the RH camshaft tensioner. 15. Lower the vehicle. 16. NOTE: Leave the top two special tool clamp bolts loose. Install the special tools on the rear of the RH cylinder head. 17. Install the special tool.
  • 119. 18. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt. Tighten the bolts. 1. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). 2. Tighten the camshaft bolt. 19. Remove the special tool. 20. Install the RH camshaft tensioner. 21. Raise the vehicle. 22. Install the RH lower splash shield.
  • 120. 23. Install the RH wheel and tire. For additional information, refer to Section 204-04 . 24. Lower the vehicle. 25. Remove the special tools from the RH cylinder head. 26. Remove the LH camshaft tensioner. 27. Install the special tools on the front of the LH cylinder head and tighten the top two clamp bolts to 10 Nm (89 lb-in). 28. Loosen the LH camshaft sprocket bolt. 29. Loosen the top two clamp bolts on the special tool to allow the camshaft sprocket to rotate freely. 30. NOTE: The camshaft timing slots are off-center.
  • 121. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the rear of the LH cylinder head. 31. Install the special tool. 32. Tighten the bolts. 1. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). 2. Tighten the camshaft bolt. 33. Remove the special tool. 34. Install the LH camshaft tensioner.
  • 122. 35. Remove all of the special tools. 36. Install the roller followers. For additional information, refer to Roller Followers in this section. 37. Install the thermostat housing. For additional information, refer to Section 30303 . 38. Install the accessory drive belt. For additional information, refer to Section 30305 . 39. Install the fuel supply manifold. For additional information, refer to Section 30304C . 40. Install the lower intake manifold. For additional information, refer to Intake Manifold in this section. 41. Install the valve covers. For additional information, refer to Valve Cover — LH and Valve Cover — RH in this section.
  • 123. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Timing Drive Components — Hydraulic Chain Tensioner, RH Removal and Installation 1. Remove the wheel and tire. For additional information, refer to Section 204-04 . 2. Remove the lower splash shield. 3. Remove the RH camshaft tensioner. 4. To install, reverse the removal procedure.
  • 124. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Timing Drive Components — Hydraulic Chain Tensioner, LH Removal and Installation 1. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 2. Remove the thermostat housing. For additional information, refer to Section 30303 . 3. Remove the LH camshaft tensioner. 4. To install, reverse the removal procedure.
  • 125. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Timing Drive Components — Camshaft Drive Cassette, LH Removal 1. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 2. Remove valve covers. For additional information, refer to Valve Cover — RH and Valve Cover — LH in this section. 3. Remove the fuel supply manifold. For additional information, refer to Section 30304C . 4. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section. 5. Remove the thermostat housing. For additional information, refer to Section 30303 . 6. Remove all of the roller followers. For additional information, refer to Roller Followers in this section. 7. NOTE: You must retime the LH and RH camshafts when either camshaft is disturbed. Turn the crankshaft clockwise to position number one cylinder at TDC. 8. Remove the LH camshaft chain tensioner. 9. Remove the LH camshaft sprocket bolt. • Install the special tools to hold the camshaft sprocket. • Loosen but do not remove the bolt.
  • 126. 10. Remove the tool and bolt. 11. Hold the crankshaft from turning and loosen the jackshaft sprocket bolt.
  • 127. 12. Remove the primary chain tensioner. 13. Remove the primary chain and sprocket.
  • 128. 14. Remove the camshaft drive cassette. 1. Remove the chain guide bolts. 2. Remove the sprockets. 3. Lift the chain and guide up and out of the cylinder head. 15. Clean all surfaces. Clean all debris from engine.
  • 129. Installation 1. Install the chain guide through the cylinder head. 2. Install the chain.
  • 130. 3. Install the new chain guide bolts. 4. NOTE: The camshaft chain sprockets must be orientated correctly. Install the lower chain sprocket and the camshaft sprocket.
  • 131. 5. Install, but do not tighten the camshaft sprocket bolt. 6. Install the primary chain and gear.
  • 132. 7. Install the primary drive chain tensioner. 8. Hold the crankshaft from turning and tighten the jackshaft sprocket bolt in two stages. • Stage 1: Tighten bolts to 45 Nm (33 lb-ft). • Stage 2: Tighten bolts an additional 90 degrees. 9. Install the engine front cover. For additional information, refer to Engine Front Cover in this section. 10. Time the engine. For additional information, refer to Timing Drive Components — Camshaft Timing in this section.
  • 133. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Valve — Valve Spring Special Tool(s) Valve Spring Compressor 303-581 (T97T-6565-A) Spacer, Valve Spring Compressor 303-382 (T91P-6565-AH) Removal 1. Remove the camshaft roller followers. For additional information, refer to Roller Followers in this section. 2. Position the piston at top dead center (TDC). 3. Remove the spark plug and apply compressed air in the cylinder to hold both valves in position. 4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. Using the special tool to compress the valve spring, remove the valve spring retainer keys, the valve spring and the retainer. 5. Inspect the components. For additional information, refer to Section 303-00 .
  • 134. Installation 1. Position the valve spring and the valve spring retainer. 2. Install the special tool between the valve spring coil to prevent valve stem seal damage. 3. Using the special tool to compress the valve spring, install the valve spring retainer keys. 4. Install the camshaft roller followers. For additional information, refer to Roller Followers in this section. 5. Install the spark plug. 6. Repeat all steps for each cylinder being serviced.
  • 135. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Valve — Valve Seals Special Tool(s) Installer, Valve Stem Oil Seal 303-370 (T90T-6571-A) Material Item Specification Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C205A Removal 1. Remove the valve springs. For additional information, refer to Valve — Valve Spring in this section. 2. Remove the valve stem seals. Installation 1. NOTE: Lubricate parts with clean engine oil prior to installing. Using the special tool, install the valve stem seals. 2. Install the valve springs. For additional information, refer to Valve — Valve Spring in this section.
  • 136. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Hydraulic Lash Adjusters Material Item Specification Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C205A Removal and Installation 1. Remove the camshaft roller followers. For additional information, refer to Roller Followers in this section. 2. Remove the hydraulic lash adjusters. 3. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure.
  • 137. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Roller Followers Special Tool(s) Compressor, Valve Spring 303-581 (T97T-6565-A) Material Item Specification Super Premium SAE SW-30 Motor Oil WSS-M2C153XO-5W30-QSP or G equivalent Removal 1. Remove the valve covers. For additional information, refer to Valve Cover — LH or Valve Cover — RH in this section. 2. Remove the fuel supply manifold. For additional information, refer to Section 30304C . 3. NOTE: Mark each camshaft roller follower to ensure its original position during reassembly. Using the special tool, remove the camshaft roller followers. 4. NOTE: Lubricate the parts with clean engine oil prior to installing. To install, reverse the removal procedure.
  • 138. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Camshaft — LH Material Item Specification Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C205A Removal 1. Remove the camshaft roller followers. For additional information, refer to Roller Followers in this section. 2. Remove the LH camshaft chain tensioner. For additional information, refer to Timing Drive Components — Hydraulic Chain Tensioner, LH in this section. 3. Remove the bolt and the camshaft sprocket. 4. NOTE: Mark the position of the camshaft bearing caps so they can be installed in their original position. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube. 5. Remove the camshaft.
  • 139. Installation 1. NOTE: Lubricate the parts with clean engine oil before installing. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in the original position. Position the camshaft bearing caps, the oil supply tube, and the bolts. 3. NOTE: After installing the bolts, check the camshaft for free rotation. Tighten the camshaft bearing cap bolts in two stages in the sequence shown. 1. Stage 1: Tighten the bolts to 6 Nm (53 lb-in). 2. Stage 2: Tighten the bolts to 16 Nm (12 lb-ft). 4. Retime both camshafts. For additional information, refer to Timing Drive Components — Camshaft Timing in this section.
  • 140. 5. Install the camshaft roller followers. For additional information, refer to Roller Followers in this section.
  • 141. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 06/26/2000 Camshaft — RH Special Tool(s) Extension, Torque Wrench 303–575 (T97T-6256-F) Material Item Specification Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent WSS-M2C205A Removal 1. Remove the camshaft roller followers. For additional information, refer to Roller Followers in this section. 2. Remove the RH camshaft chain tensioner. For additional information, refer to Timing Drive Components — Hydraulic Chain Tensioner, RH in this section. 3. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt. Using the special tool, remove the bolt and the camshaft sprocket. 4. NOTE: Mark the position of the camshaft bearing caps so they can be installed in their original position. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube.
  • 142. 5. Remove the camshaft. Installation 1. NOTE: Lubricate the parts with clean engine oil before installing. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in their original position. Position the camshaft bearing caps, the oil supply tube, and the bolts. 3. NOTE: After installing the bolts, check the camshaft for free rotation. Tighten the camshaft bearing cap bolts in two stages in the sequence shown. 1. Stage 1: Tighten the bolts to 6 Nm (53 lb-in). 2. Stage 2: Tighten the bolts to 16 Nm (12 lb-ft).
  • 143. 4. Retime both camshafts. For additional information, refer to Timing Drive Components — Camshaft Timing in this section. 5. Install the camshaft roller followers. For additional information, refer to Roller Followers in this section.
  • 144. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 12/18/2003 Exhaust Manifold LH Removal and Installation 1. With the vehicle in neutral, position it on a hoist. For additional information, refer to Section 100-02 . 2. Remove the exhaust pipe-to-exhaust manifold nuts. 3. Remove the exhaust gas recirculation (EGR) tube. • Disconnect the differential pressure feedback EGR system from the EGR tube. • Disconnect the EGR tube from the EGR valve and the exhaust manifold. 4. Remove the retainers and the LH exhaust manifold. 5. NOTE: Use new exhaust manifold gaskets and retaining nuts. To install, reverse the removal procedure.
  • 145. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 12/18/2003 Exhaust Manifold — RH Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100-02 . 2. Remove the nuts. 3. Lower the vehicle. 4. Remove the RH exhaust manifold. 5. NOTE: Use new exhaust manifold gaskets and nuts. To install, reverse the removal procedure.
  • 146. SECTION 303-01C: Engine — 4.0L SOHC IN-VEHICLE REPAIR 2001 Ranger Workshop Manual Procedure revision date: 12/18/2003 Cylinder Head — LH Removal CAUTION: If the fuel supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold. 1. Remove the intake manifold. For additional information, refer to Intake Manifold in this section. 2. Remove the roller followers. For additional information, refer to Roller Followers in this section. 3. Remove the fan shroud. For additional information, refer to Section 303-03 . 4. Remove the accessory drive belt. For additional information, refer to Section 30305 . 5. Disconnect the generator wiring. 6. Remove drivebelt tensioner. For additional information, refer to Section 303-05 . 7. Remove the generator mounting bracket. 8. Remove the bolt and the wiring harness routing clip.
  • 147. 9. Remove the bolts and position the accessory bracket aside. 10. Disconnect the crankshaft position (CKP) sensor electrical connector. 11. Remove the electrical harness retainer. 12. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.