Fuel Injection System - 2.3l Diesel Ford Ranger

COMPONENT TESTING

Note. Specific component testing information not available. Refer to tests performed under TESTING .

DESCRIPTION

The 2.3L Turbo Diesel Fuel Injection system consists primarily of the fuel tank, an electric fuel pump, fuel filter and fuel conditioner (water separator), injection pump, injectors, glow plug system and various fuel lines.

Fuel from the tank is pumped through an in-line, frame-mounted fuel filter by the electric pump. From the pump, fuel is carried to the conditioner which is mounted on the left-rear of the engine. The conditioner separates water from the fuel and provides additional filtering of contaminants before fuel enters the injection pump. A sensor in the conditioner activates a warning light in the dash when it has collected more than 50cc of water, indicating to the driver that the fuel conditioner should be drained.

Fuel in the injection pump is pressurized and distributed to the 4 injectors via metal fuel tubes. A fuel return system carries excess fuel from the injectors and the pump back to the fuel tank. A fuel cut-off solenoid, mounted on the injection pump, prevents fuel flow to the injectors when the ignition is turned off, stopping the 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.

FUEL INJECTION PUMP

A vane-type pump is utilized in this system. Fuel supplied to the pump is pressurized and fed into the pump body, where it is held in a high pressure chamber at the upper part of the pump plunger. Fuel injection is controlled by a sliding sleeve, operated by the throttle linkage, which governs the amount of fuel supplied to the injectors. Injection pressure varies with engine speed.

Surplus fuel in the injection pump is returned to the fuel tank through the overflow line after circulating through the pump to provide cooling and lubrication.

2.3L Turbo Diesel Fuel Injection Pump. Scheme 1

INJECTORS

The fuel injector nozzles inject fuel directly into the swirl combustion chamber. When high pressure fuel reaches 1707 psi (120 kg/cm 2 ) or more, it overcomes the injector needle pressure spring, lifts the needle valve off its seat and sprays into the combustion chamber.

When fuel pressure drops below injector nozzle opening pressure, the needle valve closes, preventing fuel from entering the combustion chamber. The fuel lubricates the injector nozzle between the needle valve and seat, then returns to the fuel tank through the return line.

GLOW PLUG SYSTEM

The glow plug system is designed to provide easy starting when the engine is cold. Under varying engine starting conditions, different levels of voltage are fed to the glow plugs (through the 2 relays and dropping resistor), heating the plugs sufficiently to ignite the fuel charge.

When the engine reaches normal operating temperature, the glow plugs are no longer necessary and all power to them is cut. If the ignition is left in the "RUN" position with the engine off for more than about 3 seconds, the first relay opens, cutting power to the plugs to prevent damage from overheating.

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°F (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.

Test Preparation

1. Always use CLEAN calibration fluid in injector test stand. Open test stand valve slightly and operate handle to bleed air from stand and pipe. Pump handle until clear, bubble-free fluid flows from pipe. Close valve.
2. Attach injector to stand and tighten securely. Bleed air from injector by opening stand valve and quickly operating tester handle through several strokes, until clear fluid is emitted from injector. Close valve.

Opening Pressure Test

Slowly lower tester handle and note pressure shown on gauge as injector nozzle opens. Repeat several times to obtain accurate reading. Injection starting pressure should be 1705-1850 psi (120-130 kg/cm 2 ). If starting pressure is not as indicated, replace injector.

Leakage Test

1. Wipe injector tips dry ( DO NOT use fingers). Using injector tester, maintain pressure at 1420-1565 psi (100-110 kg/cm 2 ). No fuel leakage should occur. A slight wetting of injector tip after 5 seconds is OK, but if droplets form or fall from injector, it must be replaced.
2. Operate tester using quick strokes while observing flow from injector return ports. A slight leak-off of 1 or 2 drops per stroke is normal. If fuel squirts from return port, injector must be replaced.

Spray Pattern Test

Operate injector tester with smooth, even strokes and observe fuel spray pattern. Fuel should be uniformly atomized in an even, straight pattern. An uneven spray, fuel droplets or a solid stream of fuel indicates a faulty nozzle. (Scheme 2) Clean nozzle and repeat test. If injector still fails test it should be replaced.

Injector Spray Patterns Injector must not drip when needle valve is closed. Scheme 2

Cleaning Injectors

1. If injectors pass tests, they should be cleaned and installed. Injectors may be cleaned by soaking in cold cleaning solution for 1 hour, or with a sonic cleaner and cleaning fluid (follow manufacturer's directions).
2. Remove injectors from cleaning solution and remove any remaining carbon from end of injector with brass wire brush. Wash off outside of injector, dry with compressed air. Make sure protective caps are clean. Install caps on injectors until injectors are ready to install.

Note. If engine coolant temperature is above 86°F (30°C), disconnect wire from coolant temperature sensor (CTS) for all tests. Unless otherwise noted, perform all tests with engine off.

1. Turn on ignition. Check voltage between glow plug buss bar and engine block. If voltage is at least 10 volts for 1-6 seconds after ignition is turned on, go to step 9. If not, go to step 2.
2. Check for battery voltage on battery side of glow plug relay No. 1. If voltage exists, go to step 3. If not, repair or replace circuit between battery and relay No. 1, then go back to step 1.
3. Connect voltmeter between pin No. 1 of control module and ground. Turn on ignition and read voltage. If voltage is at least 10 volts, go to step 4. If not, replace ignition switch or repair circuit to control module pin No. 1, then go back to step 1.
4. Turn off ignition. Check for continuity between No. 1 glow plug relay and buss bar. If continuity exists, go to step 5. If not, repair or replace circuit as needed, then go back to step 1.
5. With voltmeter connected between pin No. 2 of control module and ground, turn on ignition. If voltmeter reads at least 10 volts for 1-6 seconds after ignition is turned on, replace glow plug relay No. 1, then go back to step 1. If not, go to next step.
6. Disconnect CTS and control module connector. Check for continuity between pin No. 13 of control module and ground. If continuity is indicated, repair short to ground in pin No. 13 circuit. If no continuity exists, go to next step.
7. Reconnect control module connector (leave CTS disconnected). Connect voltmeter between pin No. 2 of control module and ground. Turn on ignition. Voltmeter should read at least 10 volts for 1-6 seconds after ignition is turned on. If not, replace control module and go back to step 1. If voltage is correct, go to next step.
8. Remove CTS. Place sensor in water at 68°F (20°C). Check resistance of sensor. If resistance is between 2800 and 3800 ohms, repair circuit between pin No. 13 of control module and CTS. If not, replace CTS. After repairing circuit or replacing CTS, go back to step 1.
9. Connect voltmeter between buss bar and ground. Turn ignition on. Voltage should be 5-8 volts for 6 seconds after glow plug relay No. 1 turns off. If voltage reading is correct, go to step 14. If not, go to next step.
10. Check for battery voltage at glow plug relay No. 2. If voltage exists, go to next step. If not, repair circuit between battery and relay No. 2, then go back to step 1.
11. Turn off ignition and check for continuity between buss bar and glow plug relay No. 2. If continuity exists, go to step 13. If not, go to next step.
12. Disconnect glow plug system dropping resistor from wiring harness. With ohmmeter multiply knob on "X1" setting, check continuity of resistor. If continuity exists, repair circuit as needed. If not, replace resistor and go back to step 1. CAUTION: Use care when handling resistor as it becomes very hot during glow plug system testing.
13. Connect voltmeter between pin No. 4 of control module and ground. Read voltage while cranking engine. If voltmeter indicates 10 volts or more for at least 7 seconds after cranking starts, replace glow plug relay No. 2 and repeat step 9. If it does not, replace the control module and go back to step 1.
14. Connect voltmeter as in step 13 and read voltage while cranking engine. If meter reads 9 volts or more, go to step 16. If not, go to next step.
15. Connect voltmeter between pin No. 3 of control module and ground. If voltmeter reads at least 9 volts while cranking engine, replace control module and go back to step 1. If not, replace ignition switch and/or repair wiring to pin No. 3 of module, then go back to step 1.
16. Disconnect glow plug buss bar. Remove glow plugs and inspect for breaks, cracks or other damage. If plugs are OK, go to next step. If not, check engine compression as possible cause of damage.
17. Measure resistance of each glow plug. Resistance should be no more than .23 ohms at 68°F (20°C). Replace plugs as needed. Install good and/or new plugs and buss bar, then go back to step 1. If all plugs check out OK, go to next step.
18. With control module and engine harness connectors disconnected, check for continuity between pin No. 7 and pin No. 9 of control module and pin No. 4 of engine harness connector (from harness side). If continuity exists in both circuits, leave engine harness disconnected and go to next step. If not, repair defective circuit and go back to step 1.
19. Check for continuity between pin No. 4 of engine harness connector (engine side) and ground. If continuity exists, reconnect engine harness and go to next step. If not, repair circuit and go back to step 1.
20. If engine will start, go to next step. If not, the glow plug system is OK. Problem is engine related.
21. Connect voltmeter connected between buss bar and ground and start engine. Voltmeter should indicate 5-8 volts for 6-30 seconds. If so, problem is located outside of glow plug system. If no voltage is read after engine starts, turn engine off and go to next step. If voltage is correct, but lasts for more than 30 seconds, turn engine off and go to step 24.
22. Connect voltmeter between pin No. 12 of control module and ground. Start engine. If voltage is about 14 volts, turn engine off and go to next step. If voltage is 12 volts or less, repair wiring between pin No. 12 and alternator, then go back to step 1.
23. Connect voltmeter between pin No. 4 of control module and ground. Start engine. If voltmeter reads 10 or more volts for 6-30 seconds, repeat steps 9 through 13 as they were incorrectly performed. If reading is not as indicated, replace control module and go back to step 1.
24. Connect voltmeter between buss bar and engine block. Reconnect CTS and start engine. Watch voltmeter while disconnecting CTS. If voltmeter reads 5-8 volts with sensor connected and no voltage with sensor disconnected, problem is located outside of glow plug system. If not, go back to step 21.

Glow Plug System Wiring Diagram. Scheme 3

Removal

1. Disconnect negative cables from both batteries. Remove radiator fan, shroud and all belts. Turn crankshaft in direction of normal engine rotation to bring No. 1 piston to TDC on compression stroke.
2. Remove timing belt covers. Loosen timing belt tensioner. Loosen and remove timing belt from injection pump sprocket. (Scheme 4)
3. Remove nut attaching sprocket to injection pump. Using puller, remove sprocket. Disconnect throttle cable and speed control cable, if equipped. Disconnect coolant hoses from injection pump wax element.
4. Disconnect hoses from boost compensator and A/C throttle kicker. Disconnect fuel return line at injection pump from injection return pipe.
5. Disconnect and plug chassis fuel return line from injection pump. Disconnect and cap fuel supply line from fuel conditioner. Disconnect and remove fuel lines at injection pump and injectors. Cap all lines and fittings. Remove injection pump-to-front cover nuts (2), injection pump bracket-to-engine bracket bolts (2) and engine bracket-to-engine block bolts (2). Remove pump.

Installing Timing Belt Ensure all timing marks are properly aligned. Scheme 4

Installation

1. Position injection pump on engine and install 2 injection pump-to-front cover nuts. Install mounting brackets and and tighten bolts.
2. Install pump sprocket. To ease timing belt installation, fabricate a tensioner spring tool. (Scheme 5) Using tensioner spring tool, release belt tension, then rotate tensioner toward water pump and tighten tensioner top bolt. Install belt in original direction of rotation. NOTE: Maintain tension on belt to prevent it from slipping on crankshaft, camshaft and injection pump sprockets. After belt is positioned, loosen tensioner top bolt to tension belt.
3. Ensure all timing marks are properly aligned. (Scheme 4) Adjust injection pump timing. Tighten 2 injection pump retaining nuts and 4 bolts.
4. Install and tighten injection lines on injection pump and injectors. Install all remaining fuel lines. Connect hoses to boost compensator and A/C throttle kicker.
5. Connect throttle cable and speed control cable, if equipped. Install timing covers. Install drive belts, radiator fan and shroud. Connect battery ground cables. Start engine and check for leaks.

Using Tensioner Spring Tool To Install Timing Belt. Scheme 5

Removal & Installation

Disconnect negative cable from both batteries. Remove buss bar retaining nuts, disconnect electrical connectors from No. 3 and 4 glow plugs and remove buss bar. Remove glow plugs with a 12 mm deep socket. Reverse removal procedure to install.

1. Disconnect battery negative cable from both batteries. Disconnect and remove injection lines from injectors and injection pump. Cap all lines and fittings.
2. Remove fuel return pipe and gaskets. Discard gaskets. Remove injectors using a 21 mm deep socket. Remove holder gasket and injector gasket with "O" Ring Remover (T71P-19703-C).

Clean outside of injectors with a brass brush and clean solvent. Dry thoroughly. Install new injector gasket and holder gasket. Install injectors. Reverse removal procedure to complete installation. Start engine and check for leaks.

INJECTION PUMP TIMING

1. Remove upper timing belt cover. Turn crankshaft in normal direction of rotation to bring No. 1 piston to TDC on compression stroke. Verify piston position by checking timing marks. (Scheme 4)
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 6)
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 7) Preload dial indicator to at least.10" (.25 mm). Rotate crankshaft about 30° counter-clockwise and zero indicator dial.
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 plug bolt with new copper gasket. Remove spacer and screwdriver (if used). Install timing belt cover, start engine and check for leaks.

By-Passing Injection Pump Cold Start Device By-pass cold start device if coolant temperature is below 122 degrees F (50 degrees C). Scheme 6

Timing Adapter & Dial Indicator Installed. Scheme 7

IDLE SPEED

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.

Adjusting Idle Speed. Scheme 8

FUEL CONDITIONER

Water should be drained from fuel conditioner every 5000 miles or when warning lamp glows. Warning lamp will glow when about half a quart of water has accumulated in sedimenter. To drain conditioner, put pan under conditioner, located under left rear side of engine. Pull conditioner ring until outflowing fuel is free of water. Release pull ring and ensure draining has stopped.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TESTING