Tune-Up - Diesel Ford Cab & Chassis Ranger

ENGINE IDENTIFICATION

Engine is identified by eighth character of Vehicle Identification Number (VIN). The VIN is stamped on a metal tab, attached to upper left side of instrument panel and is visible through windshield.

The VIN can also be found on Safety Standard Certification Label attached to left door lock edge.

VIN ENGINE CODES

TUNE-UP NOTES

Note. When performing tune-up procedures described in this article, the following notes and precautions must be followed

Due to late changes and corrections, always refer to engine compartment Emission Control Tune-Up Decal before attempting tune-up procedures. In the event manual specifications and decal specifications are different, always use decal specifications.

Ensure that all diesel injection lines and fittings are thoroughly cleaned before removing. Cap all lines, nozzles and fittings when removed. Dirt in system may damage injection pump or engine.

Some models are equipped with water separator units. Check periodically for presence of water and drain off if needed or when "Water-in-Fuel" indicator light glows (if equipped).

TESTING

1. Prior to checking compression, be sure batteries are fully charged. Do not add oil to cylinders. Adding oil may cause hydrostatic lock and extensive engine damage.
2. Start and warm engine to normal operating temperature. Turn ignition off. Remove air cleaner and/or intake opening cover. Disconnect injection pump solenoid leads.
3. Remove all glow plugs and insert compression gauge in No. 1 cylinder glow plug hole. With ignition off, crank engine through at least 6 compression strokes. Note number of strokes required to obtain highest reading.
4. Repeat check on each cylinder, cranking engine same number of compression strokes.

COMPRESSION SPECIFICATIONS

VALVE CLEARANCE

VALVE CLEARANCE SPECIFICATIONS (HOT)

GLOW PLUGS

Each cylinder has a glow plug screwed into the cylinder head. Tip of the glow plug projects into the combustion chamber to preheat cylinder and to aid in cold engine starting.

On 2.3L engine, the glow plug system provides for quicker starting with a cold engine. The system consists of 4 glow plugs, a control module, 2 relays, a dropping resistor, a coolant temperature sensor (CTS) and wiring harness.

When the engine is cranked, the control module cycles on preglow relay No. 1 for 1-6 seconds. After the engine starts, alternator output signals the module to stop relay No. 1 and an afterglow function takes over.

If coolant temperature is below 86° (30°C), afterglow relay No. 2 remains closed. This applies 6-6.7 volts to the glow plugs through the dropping resistor. When coolant temperature is above 86°F (30°C), the control module opens No. 2 relay, cutting off all current to glow plugs.

On 6.9L engines, full system voltage is supplied to glow plugs when ignition is turned on. Depending on coolant temperature, glow plug voltage is cycled between 12 and 4 volts or is maintained at a reduced voltage of 4-5 volts for a short period of time after engine start.

Glow plugs are 6-volt heaters, which are activated when ignition switch is turned on. Glow plugs are controlled by a control switch, based upon coolant temperature. Control switch allows glow plug operation only when coolant temperature is below 165°F (91°C).

GLOW PLUG TYPE

2.3L Diesel Firing Order. Scheme 12

6.9L Diesel Firing Order. Scheme 13

2.3L Engine Injection Timing Marks. Scheme 14

Scheme 15

Scheme 16

1. Remove upper timing belt cover. Turn crankshaft in normal direction of rotation to bring No. 1 on to TDC on compression stroke. Verify piston position by checking timing marks. (Scheme 14)
2. If coolant temperature is above 122°F (50°C) go to step 3). If temperature is below 122°F (50°C), by-pass cold start mechanism by rotating fast idle lever and inserting a spacer or wrench at least.27" (7 mm) thick between cold start advance lever and cold start device. (Scheme 15) (Scheme 15): By-Passing injection Pump Cold Start Device By-pass cold start device if coolant temperature is below 122 degrees F (50 degrees C).
3. Loosen injection pump-to-front cover and injection pump-to-mounting bracket nuts. Using back-up wrench, loosen fuel injection line nuts at pump. Remove plug bolt from timing port at center of pump hydraulic head.
4. Install Timing Adapter (014-00303) in timing port and mount dial indicator in adapter. (Scheme 16) Preload dial indicator to at least.10" (.25 mm). Rotate crankshaft about 30° counterclockwise and zero indicator dial. (Scheme 16): Timing Adaptor and Dial Indicator Installed
5. Rotate crankshaft clockwise to 5° ATDC. Dial indicator should read.0383-.0405" (.97-1.03 mm). Rotate injection pump body as needed to obtain correct reading. Rotate pump clockwise to decrease value, counterclockwise to increase value.
6. Tighten injection pump mounting nuts and repeat steps 4) and 5) to ensure timing is correct. Tighten fuel injection line nuts. Install timing port lug bolt with new copper gasket. Remove spacer and screwdriver (if used). Install timing belt cover, start engine and check for leaks.

Note. Models with C-6 transmissions and late production models with manual transmissions are equipped with a pump-mounted fast idle bracket and solenoid. Bracket and solenoid must be removed on these models to provide access for pump wrench and rotating tool during timing procedure.

Scheme 17

1. Using injector pump wrench (T83T 9000 B), loosen (but keep snug) 3 nuts attaching fuel injection pump to pump mounting adapter.
2. Install injection pump rotating tool (T83T 9000 C) on front of pump. Rotate pump to align injection pump mounting flange timing mark with pump mounting adapter timing mark. (Scheme 17) (Scheme 17): 6.9L Static Timing Mark Alignment Keep mounting nuts snug during static timing check.
3. Remove tools and tighten mounting nuts to specifications. Visually recheck timing to ensure that marks are still aligned after tightening nuts.

Scheme 18

1. Start and warm engine to normal operating temperature. Coolant temperature MUST be above 192°F (89°C) to perform dynamic timing procedure. Stop engine and install magnetic pick-up probe of dynamic timing meter (78 0100) into timing pointer probe hole. (Scheme 18) (Scheme 18): 6.9L Magnetic Pick-Up Probe & Luminosity Probe Installation
2. Remove No. 1 cylinder glow plug. Install luminosity probe in place of glow plug, and tighten to 12 ft. lbs. (16 N.m). (Scheme 18) Connect photocell over luminosity probe and connect to dynamic timing meter. Connect dynamic timing meter to battery and set to 20° offset.
3. Raise vehicle and support rear axle. Place transmission in Neutral and start engine. Using throttle control tool (14-0302), set engine speed at 1400 RPM with no accessory load. Observe injection timing on meter. Timing should be 2-4° ATDC. Add 1° for altitudes over 3000 feet.
4. If timing is not within specifications, stop engine and loosen pump retaining nuts (keep nuts snug).
5. As viewed from front of engine, rotate top of pump to right to retard timing or to left to advance timing with pump rotating tool. Moving timing mark.030" (.75 mm) is equal to 2° of timing. Retighten nuts. CAUTION: Engine should not be restarted with pump retaining nuts loose. Torquing action could cause pump to break off from mounting flange.
6. Recheck timing using meter. If still not to specifications, repeat steps 4) and 5). When timing is correct, tighten retaining nuts to specification. Remove timing meter and other test equipment. Reinstall glow plug using anti-seize compound on threads.

LINKAGE ADJUSTMENT

With engine off, check that throttle lever contacts injection pump stop at full accelerator depression. Adjust stop screw on throttle lever if necessary.

2.3L

1. With transmission in Neutral and all lights and accessories off, bring engine to normal operating temperature. Connect tachometer to engine. Ensure idle speed adjusting screw is against its stop.
2. Run engine at 2000-3000 rpm for about 5 seconds, then let it idle for 2 minutes. Check idle speed. Adjust idle speed to specification as indicated on Emission Tune-Up. Decal in engine compartment. Use idle speed adjustment screw on side of pump for adjustment.

2.3L Idle Speed Adjusting Screw. Scheme 19

6.9L

1. Apply reflective tape to rear flange rim of the crankshaft pulley. Start and rune engine to normal operating temperature. Connect a photoelectric tachometer (99 0001) to engine and check idle speed. Measure idle speed with transmission in Neutral (man. trans.) or "D" (auto. trans.).
2. Turn idle speed adjusting screw to adjust speed. (Scheme 20) Shift transmission out of gear, and momentarily accelerate engine. Shift back into specified gear and recheck idle speed. Readjust if necessary.

6.9L Idle Adjusting Locations. Scheme 20

6.9L SLOW IDLE SPEED (RPM)

COLD (FAST) IDLE SPEED

Note. Fast idle speed on 2.3L engine is not adjustable.

1. Apply reflective tape to rear flange rim of crankshaft pulley. Attach photoelectric tachometer to engine. Disconnect wiring harness from fast idle solenoid. Apply battery voltage to solenoid to activate it. Momentarily accelerate engine to set solenoid plunger.
2. Check fast idle speed. Adjust fast idle speed by turning solenoid plunger in or out. (Scheme 20) Momentarily accelerate engine and recheck fast idle speed. Readjust if necessary.
3. Stop engine. Remove battery voltage from solenoid and reconnect wiring harness to solenoid. Remove tachometer.

FAST IDLE SPEED (RPM)

All Models

Since diesel engines do not produce manifold vacuum, all models are equipped with a belt-driven vacuum pump. The pump produces vacuum for operation of power brake and speed control systems.

A brake/low-vacuum warning light on the instrument panel glows if system vacuum is not adequate to operate brake booster or other vacuum systems.

The warning light remains on after engine start-up until vacuum builds up in system. The vacuum pump is required to operate accessories.

Scheme 21

Scheme 22

1. The vacuum regulator valve (VRV) provides vacuum signals to control transmission shift points. Vacuum setting of valve should be checked periodically, using the following procedure. Engine must not be running during this procedure.
2. Disconnect 2-port vacuum connector from VRV, located on left side of pump. (Scheme 21) Remove throttle cable from pump throttle lever, located on right side of pump. (Scheme 21): Location of Vacuum Regulator Valve on 6.9L Fuel Injection Pump
3. Remove and reposition throttle return spring. Place one end of spring over throttle lever ball stud and other end over throttle cable support bracket. Insert gauging block (T83T 7B200 AH) between pump boss and wide open throttle stop screw. (Scheme 22) (Scheme 22): Repositioning Throttle Return Spring on 6.9L Insert gauging block between pump boss
4. Attach a vacuum pump to upper port (labeled "VAC") of VRV. Attach vacuum gauge to lower port (labeled "TRANS") of regulator valve.
5. Apply and maintain 20 in. Hg to VRV. Vacuum gauge attached to regulator valve should indicate 6.4-7.4 in. Hg. If vacuum reading is not to specification, adjust regulator valve.
6. To adjust valve, loosen 2 VRV valve-to-injection pump mounting screws and rotate valve until vacuum gauge reads 6.4-7.4 in. Hg. Tighten screws. If valve cannot be adjusted to obtain vacuum reading, replace regulator valve.
7. Release vacuum and remove gauging block. Reconnect throttle return spring in original position and make sure fuel injection pump lever returns and stays at idle position.
8. Apply and maintain 20 in. Hg to VRV again. Vacuum gauge MUST indicate 13 in. Hg. If vacuum reading is less than 13 in. Hg, replace VRV and adjust new valve using above procedure.
9. Remove vacuum pump and gauge. Reconnect all disconnected components in their original positions.

1. Remove banjo fitting from injection pump fuel return line. Install adapter connector (10356). Install connect pressure tester (19-0002) onto adapter connector.
2. Place transmission in Neutral and run engine at 800 RPM. Pressure should be 27-40 psi (1.9-2.8 kg/cm 2 ). Operate engine at 4400 RPM with no accessory load. Pressure should be 91-104 psi (6.4-7.3 kg/cm 2 ). If not to specification, replace fuel injection pump.

1. Remove screw from transfer pump pressure port cover, and install transfer pump pressure connector (T83T-9000-A). Connector should go through cover and into pressure port. Install adapter (5650) onto connector and connect pressure tester (19-0002).
2. Connect photoelectric tachometer to engine. Place transmission in Neutral and run engine at 3300 RPM with no accessory load. Pressure should be 95-110 psi (6.8-7.7 kg/cm). If not to specification, replace fuel injection pump.

WATER SEPARATOR

Water should be drained from the water separator whenever the warning lamp comes on or every 5000 miles. More frequent drain intervals may be required depending on fuel quality and vehicle usage.

Draining

1. Shut engine off. Place an empty container under the water separator. On E-Series, the water separator is located inside the driver's side frame rail in line with the front wheel. On F-series and Ranger, the separator is located in the engine compartment.
2. Raise the plastic cover on the drain handle (if equipped). Turn ignition switch to the "ON" position (Ranger only). Grasp the handle or ring and pull out until liquid flows.
3. Release the drain handle or ring and ensure the liquid has stopped flowing. Start engine and ensure the "WATER-IN-FUEL" indicator lamp has gone out.

FUEL INJECTION

DIESEL FUEL INJECTORS

BELT ADJUSTMENT

Using a strand tension gauge, measure belt tension midway between pulleys. Used belts are any operated for more than 10 minutes.

BELT ADJUSTMENT (TENSION IN LBS. (KG) USING STRAND TENSION GAUGE)

BATTERY

BATTERY SPECIFICATIONS

STARTER

The 2.3L engine uses a Mitsubishi starter. The Model engine uses a Delco-Remy starter.

STARTER SPECIFICATIONS

GLOW PLUG RESISTANCE @68 °F (20 °C)

ALTERNATORS

All models use Motorcraft external regulator alternators.

ALTERNATOR SPECIFICATIONS

ALTERNATOR REGULATOR

All models use Motorcraft Solid State Electronic Regulator, calibrated and present by manufacturer. No adjustment is required or possible.

SERVICE INTERVALS

REPLACEMENT INTERVALS

CAPACITIES

TRANSMISSION & DIFFERENTIAL CAPACITIES

COOLING SYSTEM CAPACITIES

SYSTEM REFRIGERANT CAPACITY

ENGINE OIL & FUEL CAPACITIES