2.0l 4-cyl - VIN [c] & 2.3l 4-cyl - VIN [a] Ford Cab & Chassis Ranger

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Engine is identified by the 8th character of the Vehicle Identification Number (VIN). The VIN is stamped on a metal tag, attached to the upper left side of the instrument panel and is visible through the windshield. The VIN can also be found on the Safety Compliance Certification Label located on the door outside edge of the left door.

ENGINE IDENTIFICATION CODES

HYDRAULIC VALVE LIFTER ADJUSTMENT

Valve lifters are set at zero lash. No adjustment is necessary.

ADJUSTING TIMING

1. Remove engine front cover. Loosen timing belt tensioner adjustment screw. Retract tensioner and tighten adjusting screw to hold tensioner in retracted position. Remove crankshaft pulley and timing belt guide. Remove timing belt and inspect for wear or damage.
2. Replace belt if damaged or excessively worn. Align crankshaft gear and camshaft gear as described under Checking Timing procedure. Remove distributor cap and set rotor so that it points to No. 1 firing position by turning auxiliary shaft.
3. Install timing belt over crankshaft gear, auxiliary gear and camshaft gear, in that order. Loosen tensioner adjustment bolt to allow tensioner to move against timing belt. Remove spark plugs.
4. Rotate crankshaft 2 complete turns in normal rotation to remove slack from timing belt. Tighten tensioner pivot and adjustment bolts. Ensure that timing marks are still properly aligned.
5. Install crankshaft pulley and timing belt guide. Install engine front cover and spark plugs. Start engine and check ignition timing. Adjust ignition timing if necessary.

ENGINE REMOVAL

See ENGINE REMOVAL article in this section.

Removal (2.0L)

1. Drain cooling system. Remove air cleaner. Disconnect accelerator cable. Disconnect and label all vacuum hoses. Remove hot water hose from manifold cover nipple fitting. Remove engine oil dipstick. Disconnect heat tube at EGR valve.
2. Disconnect fuel line at carburetor fuel filter. Remove engine oil dipstick tube retaining bolt from intake manifold. Disconnect and remove PCV valve from intake manifold and engine block.
3. Remove distributor cap and wires as an assembly. Remove plastic spark plug wire connector from valve cover. Remove intake manifold retaining bolts and remove intake manifold from vehicle.

Removal (2.3L)

1. Drain cooling system. Disconnect negative battery terminal. Remove fuel cap to relieve fuel tank pressure. Remove pressure from fuel system at the fuel pressure relief valve using EFI Pressure Gauge (T80L-9974-A). Pressure relief valve is located on fuel line in upper right hand corner of engine compartment. NOTE: To access pressure relief valve, valve cap must be removed.
2. Disconnect electrical connectors at throttle position sensor, knock sensor, air charge temperature sensor and engine coolant temperature sensor. Disconnect and label vacuum hoses at vacuum tree. Remove throttle linkage shield.
3. Disconnect throttle linkage, cruise control and kickdown cable. Disconnect throttle cable from bracket and position aside. Disconnect air intake hose, air by-pass hose and crankcase vent hose. Disconnect PCV system. Disconnect coolant by-pass hose. Disconnect EGR tube from EGR valve at flange nut.
4. Disconnect fuel supply and return hoses at push-connect fittings. Remove engine oil dipstick bracket retaining bolt. Remove 4 upper intake manifold retaining nuts. Remove upper intake manifold and throttle body assembly.
5. Disconnect electrical connectors from injectors and set aside. Remove 2 fuel supply manifold retaining bolts. Carefully remove fuel supply manifold and injectors. Remove 4 bottom retaining bolts from lower manifold. Remove 4 upper retaining bolts from lower manifold. Remove lower manifold.

Installation (2.0L & 2.3L)

Clean all intake manifold gasket mating surfaces. Reinstall intake manifold on engine with new intake manifold gasket. Tighten all bolts in proper tightening sequence. (Scheme 1)and (Scheme 2). To complete installation, reverse removal procedure.

2.0L Engines Intake Manifold Bolt Tightening Sequence. Scheme 1

2.3L Engines Intake Manifold Bolt Tightening Sequence. Scheme 2

Removal

1. Remove air cleaner and duct assembly. Remove EGR line at exhaust manifold and loosen at EGR tube. Remove check valve at exhaust manifold. Remove hose from rear of by-pass valve.
2. Remove screw retaining heater hoses to valve cover. Remove 8 exhaust manifold-to-cylinder head attaching bolts. Remove exhaust pipe-to-exhaust manifold attaching bolts. Remove exhaust manifold.

Installation

Install exhaust manifold and tighten manifold-to-cylinder head attaching bolts to specification in proper sequence. (Scheme 3) Reverse removal procedure to install remaining components.

Exhaust Manifold Bolt Tightening Sequence. Scheme 3

1. Drain cooling system. Remove air cleaner assembly. Remove heater hose retaining screw from valve cover. Disconnect spark plug wires from spark plugs. Remove distributor cap and wires as an assembly. Remove sparks plugs and oil dipstick.
2. Disconnect and label all vacuum hoses. Remove valve cover retaining bolts and remove valve cover. Remove intake manifold as previously described. Remove alternator belt. Remove bolts attaching alternator bracket to cylinder head. Remove upper radiator hose.
3. Remove timing belt cover retaining bolts. Remove power steering pump bracket, if equipped. Loosen timing belt idler pulley retaining bolts. Position idler pulley in unloaded position and tighten retaining bolts. Remove timing belt from cam pulley and auxiliary pulley.
4. Remove heat stove from exhaust manifold. Remove 8 exhaust manifold-to-cylinder head attaching bolts. Remove timing belt idler pulley. Remove timing belt idler pulley spring from cylinder head. Disconnect oil pressure sending unit wire. Remove head bolts and cylinder head.

Clean all gasket mating surfaces. Position new cylinder head gasket on block. Reinstall cylinder head and tighten head bolts in proper sequence. (Scheme 4) Reverse removal procedure to install remaining components.

Cylinder Head Bolt Tightening Sequence. Scheme 4

1. Loosen thermactor pump bolts and remove drive belt. Remove fan blade and water pump pulley attaching bolts. Remove fan and pulley. Loosen alternator retaining bolts and remove drive belt. Drain cooling system and remove upper radiator hose.
2. Remove crankshaft pulley bolt and pulley. Remove thermostat housing and gasket. Remove bolts attaching power steering pump to engine and position pump aside. Remove front cover attaching bolts and remove front cover.

Reverse removal procedure to install engine front cover and all other remaining components.

Align timing pointer with TDC mark on crankshaft pulley. Remove engine front cover. Release tension from timing belt by loosening timing belt tensioner bolts. Remove timing belt from gears.

Reverse removal procedures and align timing belt and gears as described in VALVE TIMING in this article.

Checking Timing

1. Remove access plug from engine front cover. Set crankshaft at top dead center. Align timing mark (TDC) on crankshaft pulley with "TC" mark on engine front cover. CAUTION: Always turn engine in direction of normal rotation. Backward rotation may cause timing belt to jump time.
2. Look through access hole in engine front cover to ensure timing mark on camshaft gear is lined up with pointer on inner timing belt cover. (Scheme 5)
3. Remove distributor cap and check that rotor is pointing at No. 1 spark plug wire terminal in distributor cap. Reinstall distributor cap and access plug.

Timing Belt Alignment Mark Locations. Scheme 5

1. Drain cooling system. Remove air cleaner assembly. Disconnect spark plug wires from spark plugs and valve cover and position aside. Disconnect and label all vacuum hoses. Remove valve cover bolts and valve cover.
2. Remove alternator retaining bolts and remove drive belt. Remove bolts that attach alternator bracket to cylinder head and position alternator aside. Remove upper radiator hose. Remove fan shroud retaining bolts and remove fan shroud. Remove timing belt cover.
3. Remove power steering belt, if equipped. Release tension from timing belt and remove timing belt. Using Valve Spring Compressor (T74P-6565-A), depress valve springs and remove rocker arms. Using Gear Puller (T74P-6256), remove camshaft gear from camshaft.
4. Using Seal Remover (T74P-6700-A), remove camshaft seal. Remove rear camshaft retainer. Raise vehicle on hoist. Remove right and left engine mount bolts and nuts. Place a transmission jack under engine and raise engine as high as possible.
5. Place wood blocks between engine mounts and chassis brackets. Remove transmission jack. Lower vehicle from hoist. Remove camshaft, using care not to damage camshaft journals or lobes.

1. Ensure that threaded plug is installed in rear of camshaft. Coat camshaft lobes with polyethylene grease. Lubricate camshaft journals with heavy oil before installation. Carefully slide camshaft through bearings. Install camshaft rear retainer.
2. Using Seal Installer (T74P-6150-A), install camshaft seal. Install camshaft gear. Use Gear Holder (T74P-6256-B) to hold camshaft gear while tightening bolt. Reverse removal procedures to complete camshaft installation.

CAMSHAFT END THRUST

1. Remove engine front cover. Push camshaft toward rear of engine. Install a dial indicator so that indicator plunger is on camshaft gear attaching bolt.
2. Zero dial indicator. Using a large screwdriver between camshaft gear and cylinder head, pull camshaft forward and release it. Read dial indicator.
3. If dial indicator reading is greater than .009" (.29 mm), replace thrust plate at rear of cylinder head. Remove dial indicator from engine. Reinstall engine front cover.

CAM LOBE LIFT

1. Remove air cleaner. Remove valve cover. Using a vernier caliper, measure both distance "A" and "B" of each cam lobe. (Scheme 6) Measurement "A" minus measurement "B" is cam lobe lift.
2. Check lift of each lobe in consecutive order and note all readings. If readings are not within specifications, replace camshaft and all rocker arms.

Measuring Cam Lobe Lift. Scheme 6

Removal & Installation

When camshaft bearing replacement is necessary, do so using Camshaft Bearing Remover/Installer (T71P-6250-A). (Scheme 7)

Removing & Installing Camshaft Bearings. Scheme 7

1. Remove engine front cover. Release tension from timing belt. Remove fuel pump. Remove distributor assembly. Using Gear Puller (T74P-6256-B), remove gear from front of auxiliary shaft. Remove 2 bolts from auxiliary shaft retaining plate. Remove retaining plate.
2. Carefully slide auxiliary shaft from engine. Do not allow distributor drive gear or fuel pump lobe to contact bearing surfaces.

To install, reverse removal procedure.

VALVE ARRANGEMENT

E-I-E-I-E-I-E-I (Front-to-rear).

VALVE STEM OIL SEALS

Valve stem oil seals are used on all valves. If seals are removed for any reason, new seals must be used on reassembly. For removal and installation procedures, see VALVE SPRINGS in this article.

1. Remove air cleaner. Remove screw retaining heater hose to valve cover. Disconnect vacuum hoses as necessary. Disconnect spark plug wires from spark plugs and position aside. Remove valve cover from engine.
2. Using Valve Spring Compressor (T74P-6565-A), compress valve spring and remove rocker arm. Remove spark plug and place Air Line Adapter (6513-ABA) into spark plug hole. Apply 140 psi (9.8 kg/cm 2 ) to cylinder.
3. Again compress valve spring and remove retainer locks and spring retainer. Release pressure from valve spring and remove spring. Remove and discard valve stem oil seal.

1. Install new valve stem oil seal using Seal Installer (T73P-6571-A). Install and compress valve spring. With valve spring compressed, install spring retainer and retainer locks.
2. Apply polyethylene grease to all contact surfaces of rocker arm. Compress valve spring and install rocker arm.
3. Remove air pressure and air line adapter from spark plug hole and reinstall spark plug. Install all remaining components in reverse order of removal.

VALVE SPRING INSTALLED HEIGHT

1. Valve spring installed height should be measured with rocker arms removed. Measurement should be made from cylinder head spring pad to top of valve spring retainer.
2. If height is not within specifications, install .030" (.76 mm) spacers between cylinder head spring pad and valve spring. Do not install more spacers than are necessary to obtain specified height.

VALVE SPRING INSTALLED HEIGHT SPECIFICATIONS

VALVE GUIDE SERVICING

Always use reamers in proper sequence (smallest first). Reface valve seat after valve guide has been reamed. After reaming, use a scraper to break sharp corner at top inside diameter of valve guide bore. Valves with oversized stems are available with stems that are .003" (.08 mm), .015" (.38 mm) and .030" (.76 mm) oversize.

HYDRAULIC VALVE LIFTER

Service lifters only as complete assemblies. Disassemble lifters and thoroughly clean. DO NOT interchange parts between lifters. Reassemble lifters and test with hydraulic lifter test fluid and lifter leak-down tester. Leak-down rate on hydraulic lifters is 2-8 seconds at 1/8" (3.2 mm) travel.

Exploded View of Hydraulic Lifter Assembly. Scheme 8

OIL PAN

See OIL PAN REMOVAL article in this section.

Remove cylinder head. Remove oil pan retaining bolts and remove oil pan. Remove oil pump pick-up tube. Remove connecting rod cap and bearing. Push piston up through cylinder bore. Remove piston from cylinder bore.

Scheme 9

1. Install bearing halves in rod and rod cap. Ensure ring gaps are properly positioned on piston. (Scheme 9) Install ring compressor on piston and install piston into block. (Scheme 9): Correct Spacing of Piston Ring Gaps
2. Guide piston rods over rod journals. Install rod caps and tighten nuts. Reverse removal procedure to complete installation of remaining components.

FITTING PISTONS

Note. Make all measurements with piston and block at normal room temperature (70°F, 21°C).

1. Measure piston skirt 90° to piston pin axis. Measure cylinder bore 90° to crankshaft centerline, at top, middle, and bottom of bore. Use these measurements to determine piston-to-cylinder bore clearance.
2. Measure cylinder bore 90° to crankshaft centerline at top of bore (below ring travel) and at bottom of bore (above ring travel). These measurements determine cylinder taper. Taper (difference between the 2 measurements) must not exceed .010" (.25 mm).
3. Measure cylinder bore at center of piston travel, 90° to crankshaft centerline. Measure bore at center of piston travel in line with crankshaft centerline. Out-of-round is the difference between the 2 measurements, and must not exceed .005" (.13 mm).
4. If taper or out-of-round are beyond limits, or cylinder walls are deeply scored, hone or bore cylinders for installation of new pistons. After cylinders have been honed or bored, measure cylinder diameter. Compare cylinder diameter measurements with those in PISTON SIZE CHART to obtain correct size piston.

PISTON SIZE (2.0L) CHART

PISTON SIZE (2.3L) CHART

FITTING RINGS

1. Select proper ring set for size of cylinder bore. Position ring in cylinder bore. Push ring down into bore to area where normal ring wear is not encountered. Use a piston to position ring so that it is square with cylinder wall.
2. Measure gap between ends of ring using feeler gauge. If ring gap is less than or greater than specified, a smaller or larger ring will have to be used. Check side clearance of compression rings with feeler gauge, of specified thickness, inserted between ring and its lower land on piston.
3. Feeler gauge should slide freely around entire circumference of piston without binding. If feeler gauge binds because of high spots on lower land of piston, piston should be replaced.

Using an arbor press and Piston Pin Remover/Installer (T68P-6135-A), press piston pin from piston and connecting rod.

Apply a light coat of oil to all parts that are to be assembled. Position piston and connecting rod (Scheme 10) Using arbor press and piston pin remover/installer, press piston pin through piston and connecting rod until centered in connecting rod.

Piston Pin Replacement. Scheme 10

CONNECTING ROD BEARINGS

1. Fit rod bearings one at a time, while leaving all other bearings securely fastened. To determine bearing clearance, remove bearing cap. Place a strip of Plastigage on bearing surface across full width of bearing cap, about 1/4" off center away from oil holes.
2. Install bearing cap and tighten bolts to specifications. Do not allow crankshaft to turn. Remove cap and measure compressed width with scale furnished in Plastigage kit.
3. Standard size bearings may be used in combination with a .001" or .002" (.03 mm or .05 mm) undersize bearing. If .002" (.05 mm) undersize bearings are used on more than one journal, they must be installed on piston side of rod on crankshaft journal.
4. After bearings are installed, lightly oil crankshaft journal and bearing surfaces and install bearing cap.

MAIN BEARINGS

1. Fit main bearings one at a time, while leaving all other bearings securely fastened. To determine bearing clearance, remove bearing cap. Place a strip of Plastigage on bearing surface across full width of bearing cap, about 1/4" off center away from oil holes.
2. Install bearing cap and tighten bolts to specifications. Do not allow crankshaft to turn. Remove cap and measure compressed width with scale furnished in Plastigage kit. Standard size bearings may be used in combination with a .001" or .002" (.03 mm or .05 mm) undersize bearing.
3. If .002" (.05 mm) undersize bearings are used on more than one journal, they must be installed in cylinder block side of crankshaft journal. After bearings are installed, lightly oil crankshaft journal and bearing surfaces and install bearing cap.

CRANKSHAFT END PLAY

Note. Engine must be removed from vehicle to check crankshaft end play.

1. Force crankshaft toward rear of engine. Attach dial indicator to rear of engine so that indicator contact rests against crankshaft flange. Zero dial indicator. Push crankshaft forward and note dial indicator reading.
2. If end play exceeds specification, replace thrust bearing. If end play is less than specified, check for damaged or improperly aligned thrust bearing.

REAR MAIN BEARING OIL SEAL

Note. Engine or transmission must be removed from vehicle to replace rear main bearing oil seal.

Install 2 sheet metal screws into seal. Pull on screws until seal is removed from engine.

1. Position seal on Seal Installer (T82L-6701-A). Seal must be installed with spring side facing toward engine. (Scheme 11) Place seal installer and seal assembly on engine.
2. Install 2 bolts through seal installer into crankshaft. Alternately tighten bolts until seal is completely installed. Remove seal installer.

Installing Rear Main Bearing Oil Seal. Scheme 11

1. Drain cooling system. Remove fan shroud attaching bolts and place shroud over fan. Remove bolts that attach fan to water pump. Remove fan and shroud from vehicle.
2. If equipped, loosen air conditioning compressor adjusting idler pulley and remove drive belt. Loosen power steering pump bolts and remove alternator and power steering pump belts.
3. Remove water pump pulley. Remove heater hose from water pump. Remove timing belt cover. Remove lower radiator hose from water pump. Remove water pump attaching bolts and remove water pump from engine.

To install, reverse removal procedure. Make sure that gasket surfaces are clean. Apply Sealer (D8AZ-19554-A) to water pump bolts prior to installation.

Note. For further information on cooling system capacities and other cooling system components, see ENGINE COOLING SYSTEMS article in this section.

ENGINE OILING SYSTEM

System is pressure fed from a rotor-type oil pump. Oil flows through oil filter before entering main oil gallery. (Scheme 12)

Engine Oiling System. Scheme 12

Crankcase Capacity

Crankcase capacity is 4 quarts (3.8L) for 2.0L engine and 5 quarts (4.7L) for 2.3L engines. Add 1 quart (.9L) when oil filter is replaced.

Oil Filter

Oil filter should be replaced every 12 months or 7500 miles, whichever occurs first.

Normal Oil Pressure

Normal oil pressure with engine at normal operating temperature and running at 2000 RPM should be 40-60 psi (2.8-4.2 kg/cm 2 ).

Oil Pressure Regulator Valve

Oil pressure regulator valve is located in oil pump body. Valve is nonadjustable.

Remove oil pan. Remove nut securing pick-up tube bracket to main bearing cap stud. Remove 2 bolts attaching oil pump to engine block. Remove oil pump assembly. Be careful not to drop oil pump drive shaft.

Disassembly

1. Remove 2 bolts attaching oil pick-up tube to oil pump. Remove pick-up tube and gasket. Remove pump cover attaching screw and remove cover. Remove inner rotor and shaft assembly. Remove outer rotor. Drill a small hole in pressure relief valve chamber cap. (Scheme 13)
2. Insert a small screw into cap and remove from pump housing. Remove pressure relief valve spring and plunger from pump housing.

Exploded View of Oil Pump Assembly. Scheme 13

Scheme 14

1. Clean all parts in solvent and dry thoroughly with compressed air. Ensure that all dirt or metal particles are removed from pressure relief valve chamber.
2. Check inside of pump housing, outer rotor and inner rotor for excessive wear or damage. Check mating surface of pump cover for wear. If pump cover mating surface is excessively worn, scored or grooved, replace pump assembly.
3. Measure rotor tip clearance. (Scheme 14) If rotor tip clearance exceeds specification, pump assembly must be replaced. (Scheme 14): Checking Inner Rotor Tip Clearance
4. With rotor assembly installed in pump housing, place a straightedge across pump housing. Using a feeler gauge, measure clearance between straightedge and both inner and outer rotors.
5. Maximum rotor end play should not exceed.005" (.13 mm). If clearance limit is exceeded, pump must be replaced.
6. Check oil pump drive shaft-to-housing clearance by measuring outside diameter of shaft and inside diameter of housing bearing. Clearance should be.0015-.0030" (.038-.076 mm). If not, replace pump assembly.
7. Check pressure relief valve-to-bore clearance. Check tension of pressure relief valve spring. Spring tension should be 15.2-17.2 lbs. (6.9-7.8 kg) when spring is extended to 1.2" (30.4 mm). If spring tension is not correct, replace pump assembly.

Reassembly

To reassemble, reverse disassembly procedure. Thoroughly oil all parts before assembly. Ensure that dimple on outer rotor is facing outward and on same side as identification mark on inner rotor. Install a new pressure relief valve cap.

Prime oil pump before installation. Reverse removal procedure to install all components.

OIL PUMP SPECIFICATIONS

OIL PUMP SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS (2.0L)

GENERAL SPECIFICATIONS (2.3L)

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION