Engine - 2.3L: Removal & Installation Ford Ranger I

Removal

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1. Remove the fan and shroud. For additional information, refer to «ENGINE COOLING»(ref-204985) .
2. Remove the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
3. Remove the valve cover. For additional information, refer to «VALVE COVER»(ref-204978-S28078657362005111600000) .
4. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
5. Install the special tool in the slots on the rear of both camshafts.
6. Remove the plug bolt.
7. Install the special tools.
8. Install the special tools.
9. Remove the crankshaft pulley. Remove the crankshaft pulley bolt. Remove the special tools. Remove the crankshaft pulley.

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1. Install the crankshaft pulley and hand-tighten the bolt.
2. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover. Rotate the crankshaft pulley as necessary to align the bolt holes.
3. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in two stages. Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Rotate an additional 90 degrees (1/4 turn).
4. Remove the special tools.
5. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
6. Remove the special tool.
7. Remove the special tool.
8. Turn the engine two complete revolutions.
9. Turn the engine until the No. 1 piston is at TDC.
10. Install the special tool.
11. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley. If it is not possible to install the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, correct the engine timing.
12. Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
13. Remove the special tool.
14. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
15. Remove the special tool.
16. Install the plug bolt.
17. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-204978-S28078657362005111600000) .
18. Install the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
19. Install the fan and shroud. For additional information, refer to «ENGINE COOLING»(ref-204985) .

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1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204978-S25843911792005111600000) .
2. Using the special tool, remove the crankshaft front oil seal.

Installation

1. Using the special tool, install the crankshaft front oil seal.
2. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204978-S25843911792005111600000) .

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-204978-S41492509852005111600000) .
2. Remove the timing chain tensioner. Compress the timing chain tensioner and insert a paper clip into the hole. 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. If necessary, remove the bolts and the camshaft sprockets. Use the flats on the camshaft to prevent camshaft rotation.

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1. Remove the special tool.
2. 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. 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»(ref-204978-S41492509852005111600000) .

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1. Remove the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-204978-S11979933842005111600000) .
2. Using the special tools, apply compressed air to the cylinder. Using the special tools, compress the valve springs and remove the valve collets using some grease and a small screwdriver. Remove the valve spring retainers and the valve springs.

1. Using the special tools, install the valve springs. Insert the valve springs and the valve spring retainers. Compress the valve springs and install the valve collets. Disconnect and remove the air supply.
2. Install the valve tappets. For additional information, refer to «VALVE TAPPETS»(ref-204978-S11979933842005111600000) .

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1. Remove the camshafts. For additional information, refer to «CAMSHAFTS»(ref-204978-S20363138932005111600000) . Remove the valve tappets and place them in order to one side.
2. Unscrew the spark plug on cylinder No. 1 and connect the compressed air supply.
3. Using the special tools, apply compressed air to the cylinder. Using the special tools, compress the valve springs and remove the valve collets using some grease and a small screwdriver. Remove the valve spring retainers and the valve springs.
4. Using the special tools, remove the valve stem seals.

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1. Install the valve stem seal installation sleeve.
2. Using the special tool, install the valve stem oil seals.
3. Using the special tools, install the valve springs. Insert the valve springs and the valve spring retainers. Compress the valve springs and install the valve collets using some grease and a small screwdriver.
4. Disconnect the compressed air supply and screw in the spark plug.
5. Repeat the appropriate steps for all the other cylinders.
6. Coat the valve tappets with clean engine oil and insert them.
7. Tighten the spark plugs. For additional information, refer to «REMOVAL, OVERHAUL & INSTALLATION»(ref-142378) .
8. Install the camshafts. For additional information, refer to «CAMSHAFTS»(ref-204978-S20363138932005111600000) .

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Note. Valve tappets are select fit and the valve clearance must be checked before removing the tappets. For additional information, refer to VALVE CLEARANCE CHECK . If the valve clearance has already been checked, proceed with removal.

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1. Remove the timing chain. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-204978-S27119050622005111600000) .
2. Remove the special tool.
3. Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released. Remove the camshaft bearing caps. Remove the camshafts.

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1. Install the valve tappets.
2. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until the cam is fully seated. Stage 2: Tighten the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
3. Install the special tool.
4. Install the timing chain. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-204978-S27119050622005111600000) .
5. Confirm each valve's clearance at base circle with the lobe pointed away from the tappet.
6. Install the valve cover. For additional information, refer to «VALVE COVER»(ref-204978-S28078657362005111600000) .

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Note. Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference.

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1. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages. Stage 1: Tighten the camshaft bearing bolt caps one turn at a time until tight. Stage 2: Tighten the bolts to 7 Nm (62 lb-in). Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
2. Install the camshaft drive gears and hand-tighten the bolts.
3. Install the timing chain and sprockets. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-204978-S27119050622005111600000) .

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
2. Raise the vehicle on a hoist.
3. Remove the exhaust flange nuts.
4. Lower the vehicle.
5. Remove the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
6. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .
7. Disconnect the upper radiator hose and the engine reservoir hose.
8. Remove the A/C compressor. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139348) .
9. Disconnect the heater water hose.
10. Remove the oil indicator and the upper bolt for the tube assembly.
11. Remove the lower bolt and remove the oil indicator tube assembly.
12. Remove the bolts and the front radiator tube.
13. Raise the vehicle.
14. Remove the pushpins and position the right inner fender splash shield out of the way.
15. Disconnect the alternator electrical connectors.
16. Remove the lower Front End Accessory Drive (FEAD) mounting bolts.
17. Lower the vehicle.
18. Remove the upper mounting bolt and the FEAD assembly.
19. Remove the two nuts and position the coolant tube out of the way.
20. Remove the nuts and the exhaust manifold.
21. Remove the exhaust manifold gasket.

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1. Install the exhaust manifold gasket.
2. Install the exhaust manifold and the nuts.
3. Position the coolant tube and install the nuts.
4. Position the FEAD bracket and install the bolts in the sequence shown in two stages. Stage 1: Install the bolts finger tight. Stage 2: Tighten the bolts to 47 Nm (35 lb-ft).
5. Connect the alternator electrical connectors.
6. Position the right inner splash shield and install the pushpins.
7. Lower the vehicle.
8. Install the upper radiator tube and install the bolts.
9. Install the oil indicator tube assembly and the lower bolt.
10. Install the oil indicator tube upper bolt and the oil indicator.
11. Connect the heater water hose.
12. Install the A/C compressor. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139348) .
13. Connect the upper radiator hose and the engine reservoir hose.
14. Fill the cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .
15. Install the serpentine drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
16. Raise the vehicle.
17. Install the exhaust flange nuts.
18. Lower the vehicle.
19. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .

1. Clean and inspect all mating surfaces.
2. Apply a 2.5-mm (0.1-in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the oil pan in the sequence shown.
3. Install the engine oil level indicator tube and the bolt. Install the engine oil level indicator.
4. Install the engine into the vehicle. For additional information, refer to «ENGINE»(ref-204978-S40389499632005111600000) .

Note. Engine balancing is not required. Balance weights should not be installed on the new flywheel.

Note. Special bolts are used for installation. Do not use standard bolts.

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1. Inspect the pilot bearing. Install a new pilot bearing as necessary.
2. Install the flywheel.
3. Install the special tool.
4. Tighten the bolts in the sequence shown in three stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
5. Install the clutch. For additional information, refer to «CLUTCHES»(ref-153163) .
6. Install the transmission. For additional information, refer to «MANUAL TRANSMISSION»(ref-204987) .

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1. Remove the transmission. For additional information, refer to «REMOVAL & INSTALLATION - A/T»(ref-156143) .
2. Install the special tool and remove the flexplate bolts.

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1. Install the flexplate.
2. Install the special tool.
3. Tighten the nuts in the sequence shown in three stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).
4. Install the transmission. For additional information, refer to «REMOVAL & INSTALLATION - A/T»(ref-156143) .

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1. Remove the flywheel (6375) or flexplate. For additional information, refer to «FLYWHEEL»(ref-204978-S20729630532005111600000) .
2. Remove the bolts and the crankshaft rear oil seal.

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1. Install the crankshaft rear oil seal on the Crankshaft Rear Main Oil Seal Installer.
2. Install the Crankshaft Rear Main Oil Seal Installer and the crankshaft rear oil seal on the crankshaft. Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
3. Remove the Crankshaft Rear Main Oil Seal Installer.
4. Install the flywheel or flexplate. For additional information, refer to «FLYWHEEL»(ref-204978-S20729630532005111600000) .

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1. Remove the front springs. For additional information, REFER to «FRONT - 2WD»(ref-166188) .
2. Remove the push pins and position the right inner fender splash shield out of the way.
3. Lower the vehicle.
4. Remove the clutch fan. For additional information, refer to «ENGINE COOLING»(ref-204985) .
5. Remove the RH and LH engine support insulator nuts.
6. Install the Lifting Eyes.
7. Raise the engine with the 3-Bar Engine Support Kit.
8. Raise and support the vehicle.
9. Remove the nuts and the engine support insulators.

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1. Install the engine support insulators and the nuts.
2. Lower the vehicle.
3. Lower the engine and remove the 3-Bar Engine Support Kit.
4. Remove the Lifting Eyes.
5. Install the LH and RH engine support insulator nuts.
6. Install the clutch fan. For additional information, refer to «ENGINE COOLING»(ref-204985) .
7. Raise the vehicle.
8. Position the right inner fender splash shield and install the push pins.
9. Install the front springs. For additional information, REFER to «FRONT - 2WD»(ref-166188) for 4x2 vehicles, or «FRONT - 4WD TORSION BAR»(ref-166121) for 4x4 vehicles.

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1. Relieve the fuel pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-142378-S37506531652002073100000) .
2. Disconnect the battery ground cable (14301). For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
3. Recover the A/C system. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139348) .
4. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .
5. Drain the engine oil.
6. Remove the hood (16612).
7. Remove the accelerator control snow shield (9E766).
8. Remove the air cleaner tube (9B659).
9. Remove the upper radiator hose (8260).
10. Remove the lower radiator hose (8286).
11. Remove the fan and shroud. For additional information, refer to «ENGINE COOLING»(ref-204985) .
12. Disconnect the Powertrain Control Module (PCM) electrical connector (12A650). Remove the retaining nut on the harness clamp. Position the harness on the engine.
13. Remove the ground stud for the PCM.
14. Remove the heater hose assembly. Disconnect the heater water hoses at the bulkhead. Disconnect the vacuum hose. Disconnect the heater water hoses at the engine and remove the assembly.
15. Disconnect the vacuum hose to the vacuum reservoir.
16. Disconnect the engine-to-degas bottle bypass hose.
17. Disconnect the degas bottle-to-engine supply hose.
18. Disconnect the A/C compressor clutch electrical connector.
19. Disconnect the Mass Airflow Sensor (MAF) electrical connector.
20. Disconnect the A/C compressor manifold. Plug the lines and the compressor ports.
21. Position the accelerator and speed control cables aside. Disconnect the accelerator cable and speed control cable (if so equipped) from the throttle linkage. Disconnect the accelerator cable and speed control cable (if so equipped) from the mounting bracket and position out of the way.
22. Disconnect and position aside the following: the Power Steering Pressure (PSP) switch electrical connector the high pressure power steering hose
23. Remove the fuel line clip, and use the special tool to disconnect the fuel supply hose.
24. Disconnect the following: 42-pin electrical connector VMV vacuum regulator solenoid supply hose evaporative purge hose
25. Disconnect the brake booster vacuum hose and the engine ground strap.
26. Disconnect the positive battery cable (14300). Disconnect the negative battery cable (14301). Disconnect the solenoid control wire at the starter.
27. Remove the starter wiring harness clamp bolt and position the wiring harness out of the way.
28. Raise the vehicle on a hoist.
29. Position the RH splash shield out of the way.
30. Disconnect the alternator electrical connections.
31. Disconnect the block heater electrical connector, if so equipped.
32. Disconnect the front Heated Oxygen Sensor (HO2S) electrical connector at the bell housing.
33. Remove the bolt retaining the transmission cooling tubes to the engine. Remove the bracket.
34. Remove the transmission dust shield.
35. Remove the exhaust manifold-to-front pipe nuts.
36. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector at the rear of the transmission.
37. Remove the engine wiring harness bolts and position the engine wiring harnesses out of the way.
38. Disconnect the oil pressure sensor electrical connector.
39. Remove the engine oil filter.
40. Disconnect the transmission wiring harness. Disconnect the vehicle speed sensor, transmission range sensor, backup light switch and the transmission electrical connectors. Disconnect the pushpins and position the harness forward to the engine.
41. Remove the oil filter adapter.
42. Remove the bolts and the starter.
43. Remove the starter dust shield.
44. Remove the four torque converter nuts.
45. Remove nine of the transmission-to-engine bolts.
46. Lower the vehicle.
47. Remove the transmission fluid indicator and tube assembly.
48. Install engine lifting bracket.
49. Support the transmission with a floor jack.
50. Support the engine with the Floor Crane using the Spreader Bar.
51. Remove the two side transmission-to-engine bolts.
52. Remove the four engine support insulator nuts.
53. Remove the engine from the vehicle.

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1. Remove the bolts, the clutch pressure plate and the clutch disc.
2. Install the special tool and remove the flywheel or flexplate.
3. Mount the engine on a suitable engine stand.
4. Remove the drive belt.
5. Remove the engine oil level indicator assembly. Remove the engine oil level indicator. Remove the bolts. Remove the engine oil level indicator tube.
6. Remove the water outlet tube. Remove the bolts. Remove the water outlet tube.
7. 7. Remove the A/C compressor.
8. Remove the accessory bracket.
9. Remove the right motor mount.
10. Disconnect the following: the coolant hose from the thermostat the coolant hose from the Exhaust Gas Recirculation (EGR) valve
11. Remove the coolant tube assembly.
12. Remove the exhaust manifold and gasket.
13. Remove the block heater, if so equipped.
14. Remove the water outlet. Disconnect the engine coolant temperature sender electrical connector. Remove the coolant hose. Remove the water outlet tube and the mounting gasket.
15. Remove the EGR valve. Disconnect the electrical connector. Remove the bolts. Remove the EGR valve.
16. Remove the power steering pump.
17. Disconnect the following electrical connectors: Idle Air Control (IAC) valve Throttle Position (TP) sensor Manifold Absolute Pressure (MAP) sensor
18. Disconnect the swirl control valve monitor electrical connector.
19. Disconnect the Crankshaft Position (CKP) sensor and the wiring harness pin-type retainers.
20. Disconnect the following electrical connectors: Knock Sensor (KS) electric thermostat swirl control vacuum solenoid
21. Disconnect the Camshaft Position (CMP) sensor electrical connector and disconnect the PCV hose from the intake manifold.
22. Disconnect the engine wiring harness pin-type retainers from the intake manifold.
23. Remove the engine wiring harness connector bracket. Position the engine wiring harness aside.
24. Disconnect the EGR tube from the intake manifold.
25. Remove the EGR tube. Remove the EGR tube bracket from the intake manifold. Disconnect the EGR tube from the cylinder head. Remove the EGR tube.
26. Detach the fuel supply line clip from the front of the intake manifold. Disconnect the vacuum hose from the intake manifold.
27. Remove the intake manifold assembly.
28. Disconnect the fuel injector electrical connectors and the wiring harness pin-type retainers.
29. Disconnect the ignition coil and the Cylinder Head Temperature (CHT) sensor electrical connectors.
30. Detach the engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness.
31. With a twisting motion, use the special tool to pull the spark plug wires off the spark plugs.
32. Remove the ignition coil.
33. Remove the bypass hose.
34. Remove the thermostat housing.
35. Remove the knock sensor and the engine vent cover.
36. Remove the left motor mount.
37. Remove the fuel injector supply manifold with the injectors and the ground strap.
38. Remove the water pump pulley.
39. Remove the water pump.
40. Remove the following: CMP sensor CHT sensor spark plugs
41. Remove the valve cover.
42. Remove the CKP sensor.
43. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No.1 piston at TDC.
44. Install the special tool in the slots on the rear of both camshafts.
45. Install the special tools.
46. Remove the crankshaft pulley. Remove the crankshaft pulley bolt. Remove the special tools. Remove the crankshaft pulley.
47. Remove the front cover.
48. Remove the timing chain tensioner. Compress the timing chain tensioner plunger and insert a paper clip into the location shown. Remove the bolts.
49. Remove the timing chain guides.
50. Remove the timing chain assembly.
51. Remove the camshaft drive sprockets.
52. Remove the oil pump chain tensioner and guide. Release the tension on the tensioner spring. Remove the tensioner and the shoulder bolt. Remove the guide.
53. Remove the oil pump chain and sprockets. Remove the bolt. Remove the chain and sprockets.
54. Remove the special tool.
55. Remove the camshaft bearing caps. Loosen the camshaft bearing cap bolts in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps.
56. Remove the camshafts.
57. Remove the bolts and the cylinder head.
58. Remove the cylinder head gasket.
59. Remove the cylinder head alignment dowels.
60. Remove the bolts and the oil pan.
61. Remove the rear main oil seal.
62. Remove the oil pump pickup tube and gasket.
63. Remove the oil pump assembly and gasket.

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