2001-2008 Ford Ranger Service & Repair Manual

2008 ENGINE 2.3L - Ranger SPECIFICATIONS MATERIAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Specification Fill Capacity High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A WSS-M1C267-A1 - Motorcraft Metal Surface Prep ZC-31 - - Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) WSS-M97B51-A1 - Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent WSS-M2C930-A 3.8L (4 qt) with filter change Multi-Purpose Grease XG-4 and/or XL-5 ESB-M1C93-B - Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A - Silicone Gasket and Sealant TA-30 WSE-M4G323-A4 - Silicone Gasket Remover ZC-30 - - Thread Sealant with PTFE TA-24 WSK-M2G350-A2 - Item Specification Displacement 2.3L No. of cylinders 4 Bore/stroke 87.5/94.0 Firing order 1-3-4-2 Oil pressure (hot @ 2,000 RPM) 29-39 psi 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger

200-268 kPa Engine weight (without accessory drive components) 133 Kg (293 lb) Cylinder Block Cylinder bore diameter 87.5-87.53 mm (3.444-3.445 in) Out of round 0.008 mm (0.0003 in) Main bearing bore diameter 57.020-57.038 mm (2.244-2.245 in) Head face flatness 0.1 mm/general 0.05 mm/200 x 200 (0.0003 in/general) (0.0019 in/7.87 x 7.87) Piston Diameter (1) 87.5-87.51 mm (3.444-3.445 in) Diameter (2) 87.51-87.52 mm (3.4452-3.4456 in) Diameter (3) 87.52-87.53 mm (3.444-3.446 in) Piston to bore clearance 0.025-0.045 mm (0.0009-0.0017 in) Ring groove width - top 1.203-1.205 mm (0.0473-0.0474 in) Ring groove width - 2nd 1.17-1.19 mm (0.0.460-0.0468 in) Ring groove width - oil 2.501-2.503 mm (0.0984-0.0985 in) Piston skirt coating thickness 0.008-0.020 mm (0.0003-0.0007 in) Piston Pin Diameter 20.995-21.0 mm (0.8266-0.8268 in) Length 59.6-60.4 mm (2.346-2.377 in) Piston to pin clearance 0.008-0.016 mm (0.0003-0.0006 in) Pin to rod clearance Press fit Cylinder Head Exhaust valve lift (in @ zero lash) 7.4 mm (0.2913 in) Intake valve lift (in @ zero lash) 7.9 mm (0.3110 in) Valve guide diameter 5.509-5.539 mm 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger

(0.216-0.218 in) Valve seat width - intake/exhaust 0.99-1.84 mm (0.038-0.072 in) Valve seat angle 45 degrees Valve seat runout 0.075 mm (0.0029 in) Valve lash adjustor bore diameter 31.00-31.03 mm (1.220-1.221 in) Cam bore diameter 25.015-25.040 mm (0.984-0.985 in) Valve Valve head diameter - intake 34.85-35.15 mm (1.372-1.383 in) Valve head diameter - exhaust 29.85-30.15 mm (1.175-1.187 in) Valve stem diameter - intake 5.470-5.485 mm (0.2153-0.2159 in) Valve stem diameter - exhaust 5.465-5.480 mm (0.2151-0.2157 in) Valve stem to guide clearance - intake 0.0027 mm (0.0009 in) Valve stem to guide clearance - exhaust 0.0029 mm (0.0011 in) Valve face runout 0.05 mm (0.001 in) Valve face angle 45 degrees Valve Spring - Compression Pressure Intake and exhaust (installed) 38.667 lb Intake (valve open) 8.9 mm (0.35 in) of lift 97.032 lb Exhaust (valve open) 7.4 mm of lift 93.338 lb Free length 44.92 mm (1.768 in) Assembled height 37.9 mm (1.492 in) Crankshaft Main bearing journal diameter 51.980-52.000 mm (2.046-2.047 in) Production repair 51.730-51.750 mm (2.036-2.037 in) Main bearing clearance 0.019-0.035 mm (0.0007-0.0013 in) Connecting rod journal diameter 49.980-50.000 mm (1.967-1.968 in) Production repair 49.730-49.750 mm (1.957-1.958 in) End play 0.22-0.43 mm (0.008-0.016 in) Rings 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger

Width - top 1.17-1.185 mm (0.0460-0.0466 in) Width - 2nd 1.197-1.199 mm (0.0471-0.0472 in) Width - oil 2.38-2.45 mm (0.093-0.096 in) Ring gap (in bore) - top 0.16-0.31 mm (0.006-0.012 in) Ring gap (in bore) - 2nd 0.33-0.48 mm (0.012-0.018 in) Ring gap (in bore) - oil 0.2-0.7 mm (0.007-0.027 in) Valve Tappet Diameter 30.97-30.98 mm (1.2192-1.2196 in) Tappet to valve clearance - intake 0.22- 0.28 mm (0.008-0.011 in) Tappet to valve clearance - exhaust 0.27-0.33 mm (0.010-0.013 in) Tappet to bore clearance 0.02-0.06 mm (0.0007-0.0023 in) Camshaft Lobe lift - intake 8.24999 mm (0.324 in) Lobe lift - exhaust 7.80007 mm (0.307 in) Runout (1) a 0.03 mm (0.001 in) Thrust clearance 0.09-0.24 mm (0.003-0.009 in) Journal diameter 24.96-24.98 mm (0.982-0.983 in) Journal to bore clearance 0.035-0.080 mm (0.001-0.003 in) Connecting Rod Bearing clearance 0.027-0.052 mm (0.001-0.002 in) Bearing thickness 1.496-1.520 mm (0.058-0.059 in) Crank bore diameter 53.025-53.045 mm (2.087-2.088 in) Pin bore diameter 20.965-20.985 mm (0.825-0.826 in) Length (center to center) 154.8 mm (6.094 in) Side clearance 1.95-3.05 mm (0.076-0.120 in) Axial clearance 0.14-0.36 mm (0.005-0.014 in) 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger

a No. 3 Journal - Supported by No. 1 and No. 5 Journals. TORQUE SPECIFICATIONS All dimensions are in mm unless noted. Description Nm lb-ft lb-in Accessory drive belt tensioner bolt 50 37 - A/C compressor bolts 25 18 - A/C manifold tube bolt 20 15 - Battery cable nuts 12 9 - Camshaft bearing caps a - - - Camshaft position (CMP) sensor bolts 7 - 62 Camshaft sprocket bolt 72 53 - Clutch pressure plate bolts 32 24 - Coolant outlet (front) connector bolts 25 18 - Coolant outlet pipe bolts 10 - 89 Coolant pump bolts 10 - 89 Coolant pump pulley bolts 20 15 - Coolant thermostat bolts 10 - 89 Coolant tube nuts 20 15 - Crankcase vent oil separator 10 - 89 Crankshaft oil seal retainer a - - - Crankshaft position (CKP) sensor 7 - 62 Crankshaft pulley bolt a - - - Cylinder block coolant drain plug 55 41 - Cylinder head bolts a - - - Cylinder head temperature (CHT) sensor 12 9 - Engine front cover bolts a - - - Engine ground cable-to-cylinder head stud bolt 10 - 89 Engine lifting eye bolts 45 33 - Engine support insulator-to-crossmember nuts 103 76 - Engine support insulator-to-engine bracket nuts 102 75 - Engine-to-transmission bolts 48 35 - Engine wire harness connector bracket bolt 10 - 89 EGR tube bracket bolt 10 - 89 EGR outlet tube-to-cylinder head fitting 55 41 - EGR outlet tube-to-intake manifold flange bolts 18 13 - EGR valve bolts 20 15 - Exhaust manifold-to-cylinder head nuts 54 40 - Exhaust manifold-to-cylinder head studs 17 13 - 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger

a Refer to the appropriate procedures in this article. Exhaust manifold-to-exhaust downpipe flange nuts 40 30 - Flywheel or flexplate bolt a - - - Fuel rail bolts 25 18 - Generator battery cable nut 8 - 71 Generator/A/C compressor support bracket bolts a - - - Ground strap bolt 10 - 89 Ignition coil bolts 6 - 53 Intake manifold bolts 18 13 - Knock sensor (KS) bolt 20 15 - Motor mount bolts 49 36 - Oil drain plug 28 21 - Oil filter adapter bolts 25 18 - Oil level indicator tube bolt 10 - 89 Oil pan bolts a - - - Oil pressure sensor 15 11 - Oil pump assembly bolts a - - - Oil pump chain tensioner bolts 10 - 89 Oil pump pickup tube and screen bolts 10 - 89 Oil pump sprocket bolt 25 18 - PCM harness ground cable stud bolt 10 - 89 PCM harness retainer nut 4 - 35 Power steering pressure (PSP) tube nut 20 15 - Power steering pump bolts 25 18 - Solenoid control wire and nut 6 - 53 Spark plugs 15 11 - Starter motor bolts 25 18 - Timing chain guide bolts 10 - 89 Timing chain tensioner bolts 10 - 89 Timing peg plug 20 15 - Torque converter-to-flywheel nuts 35 26 - Tranmission-to-cylinder block bolts 48 35 - Transmission-to-oil pan bolts 48 35 - Transmission bracket-to-transmission bolts 90 66 - Transmission dust shield bolts 10 - 89 Transmission lines bracket bolt 28 21 - Valve cover bolts a - - - Wiring harness bracket-to-transmission nut 10 - 89 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger

DESCRIPTION AND OPERATION ENGINE The 2.3L (140 CID) 4-cylinder engine has the following features:  Dual overhead camshaft  Four valves per cylinder  Sequential multiport fuel injection (SFI)  Aluminum cylinder head  Aluminum cylinder block  Electronic ignition system with 2 coil packs The 2.3L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a distributorless ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the ladder assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transmission to provide greater strength. The camshafts are mounted in the cylinder heads and act against valve tappets to open and close the valves. The camshafts are driven off the front of the cylinder head by one timing chain. The chain is driven by a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston with a cast iron connecting rod. The oil pump is driven by the crankshaft via a dedicated chain that is driven by the same sprocket that drives the timing chain. Identification - Always refer to these labels when installation of new parts is necessary or when checking engine calibrations. The engine parts often differ within a CID family. Verification of the identification codes will make sure that the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete listing of the codes and their application Code Information - The engine code information label, located on the side of the valve cover and the front side of the valve cover, contains the:  engine build date.  engine plant code.  engine code. Exhaust Emission Control System - Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the Introduction - Gasoline Engines article. Induction System - The sequential multiport fuel injection (SFI) provides the fuel/air mixture needed for combustion in the cylinders. The 4 solenoid-operated fuel injectors:  are mounted in the cylinder head.  meter fuel to the air intake stream in accordance with engine demand.  are positioned so their tips direct fuel just ahead of the engine intake valves. 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger

PCV System - All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake manifold. Lubrication System - The engine lubrication system operates as follows:  Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.  Oil is pumped through the oil filter on the left front side of the cylinder block.  Oil enters the main gallery where it is distributed to the crankshaft main journals and to the cylinder head.  From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and piston ring assembly. Fig. 1: Engine Cylinder Identification Courtesy of FORD MOTOR CO. DIAGNOSTIC TESTS ENGINE For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION article. For driveability concerns, refer to the Introduction - Gasoline Engines article. GENERAL PROCEDURES VALVE CLEARANCE CHECK 1. Remove the valve cover. For additional information, refer to Valve Cover . CAUTION: Turn the engine clockwise only and use the crankshaft bolt only or the engine may be damaged. NOTE: Measure each valve's clearance at base circle with the lobe pointed away from the tappet, before removing the camshafts. Failure to measure all clearances prior to removing the camshafts will necessitate repeated 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger

2. Use a feeler gauge to measure each valve's clearance and record its location. Fig. 2: Measuring Each Valve's Clearance Using A Feeler Gauge Courtesy of FORD MOTOR CO. 3. Select the closest tappet size available and mark the installation location. 4. If any tappets do not measure within specifications, install new tappets in those locations. For additional information, refer to Valve Tappets . IN-VEHICLE SERVICING INTAKE MANIFOLD Material removal and installation and wasted labor time. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: The nominal desired mid-range clearance is:  Intake: 0.25 mm (0.0095 in)  Exhaust: 0.30 mm (0.0115 in) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. NOTE: The acceptable clearances after being fully installed are:  Intake: 0.22-0.28 mm (0.008-0.011 in)  Exhaust: 0.27-0.33 mm (0.010-0.013 in) Item Specification 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger

Fig. 3: Intake Manifold - Cables and LH Connections Courtesy of FORD MOTOR CO. Fig. 4: Intake Manifold - RH Connections Courtesy of FORD MOTOR CO. Motorcraft Metal Surface Prep ZC-31 - Silicone Gasket Remover ZC-30 - Item Part Number Description 1 9A825 Speed control cable 2 N802768 Speed control cable position retainer clip 3 9A758 Accelerator control cable 4 W500222 EGR tube bolts (2 required) 5 9J280 Fuel supply tube 6 - Knock sensor (KS) electrical connector (part of 14A290) 7 9Y476 Evaporative emissions (EVAP) vent tube quick connect coupling Item Part Number Description 8 - Manifold absolute pressure (MAP) sensor electrical connector (part of 2008 Ford Ranger 2008 ENGINE 2.3L - Ranger

2001-2008 Ford Ranger Service & Repair Manual

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