Engine - 2.3L: Overhaul Ford Ranger II

ASSEMBLY

1. Install the valves.
2. Lubricate the valve stems and guides with clean engine oil and, using the special tool, install the valve seals onto the cylinder head valve guides.
3. Place the valve spring in position over the valve and install the valve spring retainer.
4. Using the special tools, compress the valve spring and install the valve spring retainer keys.
5. Install the 16 valve tappets.
6. Install a new CHT sensor. Tighten to 12 Nm (9 lb-ft).
7. Install 4 new spark plugs. Tighten to 15 Nm (11 lb-ft).
8. Using a new gasket, install the EGR valve and the 2 bolts. Tighten to 20 Nm (15 lb-ft).
9. Using a new gasket, install the coolant outlet pipe and the 4 bolts. Tighten to 10 Nm (89 lb-in).
10. Install the engine lifting eyes and the bolts. Tighten to 45 Nm (33 lb-ft).

Special Tools Illustration Tool Name Tool Number Adapter for 205-126 (205-072-02) Aligner, Clutch Disc 308-006 (T71P-7137-H) Alignment Plate, Camshaft 303-465 (T94P-6256-CH) Engine Stand 014-0232 or equivalent Heavy-Duty Floor Crane 014-00071 or equivalent Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) Locking Tool, Flywheel 303-103 (T74P-8375-A Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Timing Peg, Crankshaft 303-507

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1. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
2. Remove the plug bolt.
3. Install the special tool.
4. Position the oil pump assembly and tighten the bolts in the sequence shown, in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft).
5. Position a new oil pump pickup tube gasket and the pickup tube, and tighten the 4 bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
6. Using the special tool, install the a new crankshaft rear seal and retainer plate assembly.
7. Tighten the crankshaft rear seal and retainer plate assembly bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
8. 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 bolts in the sequence shown. Tighten to 25 Nm (18 lb-ft).
9. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
10. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
11. Apply silicone gasket and sealant to the locations shown.
12. Install a new cylinder head gasket.
13. Install the cylinder head and the new bolts. Tighten the bolts in the sequence shown, in 5 stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (11 lb-ft). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Tighten an additional 90 degrees (1/4 turn). Stage 5: Tighten an additional 90 degrees (1/4 turn).
14. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten the camshaft bearing 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).
15. Install the washers and the oil pump chain and sprockets. The crankshaft sprocket flange must be facing away from the engine block.
16. Tighten the oil pump sprocket bolt. Tighten to 25 Nm (18 lb-ft).
17. Install the oil pump chain drive tensioner shoulder bolt. Tighten to 10 Nm (89 lb-in).
18. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt and tighten the tensioner bolt. Tighten to 10 Nm (89 lb-in).
19. Position the camshaft sprockets and loosely install the bolts. Do not tighten the sprocket bolts at this time.
20. Using the edge of a vise, compress the timing chain tensioner plunger.
21. Using a small pick, push back and hold the ratchet mechanism.
22. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
23. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
24. Install the timing chain.
25. Position the timing chain guides and install the 2 LH guide bolts. Tighten to 10 Nm (89 lb-in).
26. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to apply tension to the timing chain. Tighten to 10 Nm (89 lb-in).
27. Install the special tool in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.
28. Tighten the camshaft sprocket bolts. Tighten to 72 Nm (53 lb-ft).
29. Clean the engine front cover gasket surface with silicone gasket remover and metal surface prep.
30. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the front cover.
31. Apply silicone gasket and sealant to the locations shown.
32. Install the front cover. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten the 8-mm bolts to 10 Nm (89 lb-in). Stage 2: Tighten the 10-mm bolts to 25 Nm (18 lb-ft). Stage 3: Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
33. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
34. 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.
35. Install a new crankshaft pulley bolt. Using the special tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Rotate an additional 90 degrees.
36. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
37. Remove the special tool.
38. Remove the special tool.
39. Turn the crankshaft clockwise 1 and 3/4 turn.
40. Install the special tool.
41. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
42. 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 bolt, correct the engine timing.
43. Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
44. Remove the special tool.
45. Position a new crankshaft position (CKP) sensor and loosely install the 2 bolts.
46. Adjust the CKP with the alignment tool, the tool must engage a tooth of the vibration damper, and tighten the 2 mounting bolts. Tighten to 7 Nm (62 lb-in).
47. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
48. Remove the special tool.
49. Install the timing peg plug. Tighten to 20 Nm (15 lb-ft).
50. Clean the valve cover gasket sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
51. Apply silicone gasket and sealant to the locations shown.
52. Install the valve cover and the fasteners. Tighten to 10 Nm (89 lb-in).
53. Install the following: Camshaft position (CMP) sensor and the bolt. Tighten to 7 Nm (62 lb-in). Cylinder head temperature (CHT) sensor. Tighten to 12 Nm (9 lb-ft). Spark plugs. Tighten to 15 Nm (11 lb-ft).
54. Using a new O-ring seal, install the coolant pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
55. Install the coolant pump pulley and the 3 bolts. Tighten to 20 Nm (15 lb-ft).
56. Using new O-ring seals, install the fuel rail and fuel injectors as an assembly, the ground strap and the bolt. Tighten the 2 fuel rail bolts to 25 Nm (18 lb-ft). Tighten ground strap bolt to 10 Nm (89 lb-in).
57. Install the left motor mount and the 4 bolts. Tighten to 49 Nm (36 lb-ft).
58. Install the crankcase vent oil separator and the KS. Tighten the KS bolt to 20 Nm (15 lb-ft). Tighten the crankcase vent oil separator bolts to 10 Nm (89 lb-in).
59. Using a new gasket, install the thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
60. Install the ignition coil and the 4 bolts. Tighten to 6 Nm (53 lb-in).
61. Connect the spark plug wires to the spark plugs.
62. Position the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.
63. Connect the ignition coil and the CHT sensor electrical connectors. Position back the CHT sensor cover.
64. Connect the fuel injector electrical connectors and attach the wiring harness pin-type retainers.
65. Inspect and install new intake manifold gaskets, if necessary.
66. Install the intake manifold and the bolts. Tighten to 18 Nm (13 lb-ft).
67. Install the EGR tube. Install the EGR tube bracket to the intake manifold. Tighten to 10 Nm (89 lb-in). Connect the EGR tube to the cylinder head. Tighten to 55 Nm (41 lb-ft).
68. Connect the EGR tube to the intake manifold. Tighten to 18 Nm (13 lb-ft).
69. Attach the engine wiring harness pin-type retainers to the intake manifold.
70. Connect the CMP sensor electrical connector and the PCV hose.
71. Install the engine wiring harness connector bracket, the 3 bolts and connect the KS electrical connector. Tighten to 10 Nm (89 lb-in).
72. Connect the CKP sensor electrical connection and attach the wiring pin-type retainers.
73. Connect the following electrical connectors: Manifold absolute pressure (MAP) sensor Throttle position (TP) sensor Idle air control (IAC) valve
74. Install the power steering pump assembly and the 4 bolts. Tighten to 25 Nm (18 lb-ft).
75. Install the EGR valve. Using a new gasket, position the EGR valve and install the 2 bolts. Tighten to 20 Nm (15 lb-ft). Connect the coolant hose. Connect the electrical connector.
76. Install the rear coolant outlet pipe. Using a new gasket, install the rear coolant outlet pipe and the 4 bolts. Tighten to 10 Nm (89 lb-in). Connect the coolant hose.
77. If equipped, install the block heater.
78. Install 7 new exhaust manifold-to-cylinder head studs. Tighten to 17 Nm (13 lb-ft).
79. Position a new gasket and install the exhaust manifold and 7 new nuts. Tighten to 54 Nm (40 lb-ft).
80. Position the coolant tube assembly and install the 2 nuts. Tighten to 20 Nm (15 lb-ft).
81. Connect the coolant hose to the thermostat and the PCV fitting on the intake manifold.
82. Position the right motor mount and install the 4 bolts. Tighten to 49 Nm (36 lb-ft).
83. Position the generator and support bracket assembly and install the 5 bolts in the sequence shown, in 2 stages. Stage 1: Install finger tight. Stage 2: Tighten to 47 Nm (35 lb-ft).
84. Position the A/C compressor and install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
85. Position the front coolant outlet pipe and install the 2 bolts. Tighten to 10 Nm (89 lb-in).
86. Install the engine oil level indicator tube and the bolt. Tighten to 10 Nm (89 lb-in).
87. Install the accessory drive belt.
88. Using the Spreader Bar and the Floor Crane, remove the engine from the Engine Stand.
89. Position the flywheel or the flexplate and loosely install the bolts.
90. Using the special tool, tighten the bolts in the sequence shown, in 3 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).

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1. Lubricate the transmission input shaft pilot bearing with front axle grease.
2. Adjust the clutch pressure plate. Using a suitable press, press downward on the fingers until the adjusting ring moves freely. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
3. Using the special tool, position the clutch disc on the flywheel.
4. Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern sequence. Tighten to 32 Nm (24 lb-ft).

Special Tools Illustration Tool Name Tool Number Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

Material