2003 Mazda B2300 Service & Repair Manual

2008 GENERAL INFORMATION Fuel System - General Information - Ranger SPECIFICATIONS MATERIAL SPECIFICATIONS GENERAL SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION & OPERATION FUEL SYSTEM The fuel system consists of the following:  Fuel rail  Fuel injectors  Fuel tank  Fuel pump  Fuel filter  Fuel supply and return tubes The vehicle is equipped with sequential multi-port fuel injection (SFI). Item Specification Fill Capacity 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 - Item Specification Fuel Pressure Engine running 414-448 kPa (60-65 psi) Key ON, engine OFF 414-448 kPa (60-65 psi) Fuel Tank Capacity Midship - long wheel base 77L (20.3 gal) Midship - standard 64L (17 gal) Midship - SuperCab 74L (19.5 gal) Description Nm lb-in Fuel tank filler pipe hose-to-fuel tank clamp 3 27 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger

Fuel delivery is accomplished through a mechanical returnless fuel system (MRFS).  The fuel pump supplies the fuel injectors with pressurized fuel through the fuel rail.  Fuel pressure is controlled by the fuel pressure regulator which is mounted to the fuel pump support rods within the fuel tank.  The fuel tubes route the fuel from the fuel pump to the fuel rail.  The fuel filter cleans the fuel delivered from the fuel pump to the fuel rail. DIAGNOSTIC TESTS FUEL SYSTEM Special Tools Principles of Operation The fuel tank filler pipe assembly is used to refuel the vehicle. The fuel tank inlet check valve prevents spitback of fuel during and after refueling. The fuel tank stores the fuel. The fuel tank contains a Fuel Pump (FP) module. The FP module consists of a fuel level sender and a FP. The fuel level sender sends a signal to the fuel gauge informing the driver of how much fuel is in the fuel tank. The FP provides fuel to the fuel tubes which supply the fuel rail. During refueling, the fuel tank vents to the atmosphere through the vent and filler pipes, on vehicles without On-Board Refueling Vapor Recovery (ORVR) systems. In vehicles equipped with ORVR the fuel tank and filler pipe are designed so that when the vehicle is being refueled, fuel vapors in the fuel tank travel to the Evaporative Emission (EVAP) canister, which absorbs the fuel vapors and vents the pressure from the fuel tank during refueling. Inspection & Verification Illustration Tool Name Tool Number Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool NOTE: The following procedure diagnoses a slow to fill concern only. For all other concerns, refer to the Introduction - Gasoline Engines article. WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger

1. Verify the customer concern by refueling the vehicle and observe the fuel fill rate. 2. Inspect to determine if any of the following mechanical concerns apply. VISUAL INSPECTION CHART WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTE: Do not use incandescent lights when inspecting the fuel system. Use only fluorescent or LED lighting. Mechanical  Bent, kinked or damaged fuel tank filler pipe  Bent, kinked or damaged fuel tank filler pipe vent tube (if equipped)  Incorrect routing of the fuel tank filler pipe  Incorrect routing of the fuel tank filler pipe vent tube (if equipped)  Incorrect position of fuel tank filler pipe clamps  Incorrect position of fuel tank filler pipe vent tube clamps (if equipped)  Fuel tank mounted vapor tubes bent or damaged  Evaporative Emission (EVAP) system tubes or hoses bent or damaged  Accident damage to the fuel tank  Accident damage to the vehicle effecting the fuel tank filler pipe-to-body connection  Unauthorized modifications and/or alterations to the vehicle  EVAP system fresh air hose plugged (dirt, spider webbing) 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC). 5. If the scan tool does not communicate with the VCM:  check the VCM connection to the vehicle.  check the scan tool connection to the VCM.  refer to MODULE COMMUNICATIONS NETWORK article, No Power To The Scan Tool, to diagnose no power to the scan tool. 6. If the scan tool does not communicate with the vehicle:  verify the ignition key is in the ON position.  verify the scan tool operation with a known good vehicle.  refer to MODULE COMMUNICATIONS NETWORK article to diagnose no response from the PCM. 7. Carry out the network test.  If the scan tool responds with no communication for one or more modules, refer to MODULE COMMUNICATIONS NETWORK article.  If the network test passes, retrieve and record continuous memory DTCs. 8. Clear the continuous DTCs and carry out the self-test diagnostics for the EVAP system using the scan tool. 9. If the DTCs retrieved are related to the concern, go to EVAPORATIVE EMISSION SYSTEM DTC CHART . For PCM-related DTCs, refer to the POWERTRAIN DTC CHARTS AND DESCRIPTIONS - GASOLINE ENGINES article. For all other DTCs, refer to MULTIFUNCTION ELECTRONIC MODULES article. 10. If no DTCs related to the concern are retrieved, go to Symptom Chart . DTC Chart EVAPORATIVE EMISSION SYSTEM DTC CHART NOTE: Make sure to use the latest scan tool software release. NOTE: The Vehicle Communication Module (VCM) LED prove out confirms power and ground from the DLC are provided to the VCM. DTC Description Action P0446 Evaporative Emission System Vent Control Circuit Go to Pinpoint Test A . P0451 Evaporative Emission System Pressure Sensor/Switch Range/Performance Go to Pinpoint Test A . P0452 Evaporative Emission System Pressure Sensor/Switch Low Go to Pinpoint Test A . Evaporative Emission System Pressure Sensor/Switch 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger

Symptom Chart Symptom Chart Pinpoint Test Pinpoint Test A: Slow to Fill Normal Operation Under normal operation, fuel should flow at a steady rate through the fuel tank filler pipe into the fuel tank. As fuel enters the fuel tank air is vented through the filler pipe or the On-Board Refueling Vapor Recovery (ORVR) system. This pinpoint test is intended to diagnose the following:  Fuel tank filler pipe vent tube, if equipped  Fuel tank filler pipe  Evaporative Emission (EVAP) system  Fuel tank inlet check valve (part of the fuel tank)  Fuel level vent valve, if equipped (part of the Fuel Pump (FP) module) P0453 High Go to Pinpoint Test A . P0454 Evaporative Emission System Pressure Sensor/Switch Intermittent Go to Pinpoint Test A . P1443 Evaporative Emission System Control Valve (Low/No Flow) Go to Pinpoint Test A . P1450 Unable to Bleed up Fuel Tank Vacuum Go to Pinpoint Test A . P1451 Evaporative Emission System Vent Control Circuit Go to Pinpoint Test A . P260F Emission System Monitoring Processor Performance Go to Pinpoint Test A . Condition Possible Sources Action  Slow to fill  Fuel tank filler pipe  Fuel tank filler pipe vent tube, if equipped  Evaporative Emission (EVAP) system  Fuel tank inlet check valve (part of the fuel tank)  Fuel level vent valve, if equipped (part of the Fuel Pump (FP) module)  Go to Pinpoint Test A .  All other fuel system concerns  Fuel system components  REFER to the Introduction - Gasoline Engines article. 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger

PINPOINT TEST A: SLOW TO FILL A1 CARRY OUT INSPECTION AND VERIFICATION  Carry out inspection and verification.  Was the cause of the concern found? YES : REPAIR or INSTALL new components to correct the concern. NO : Go to A2. A2 CHECK THE SYSTEM FOR ANY EVAP DTCs  Connect the scan tool.  Check the system for any of the following EVAP DTCs: P0446, P0451, P0452, P0453, P0454, P1443, P1450, P1451 and P260F.  Are any of these DTCs present? YES : REFER to Introduction - Gasoline Engines article to diagnosis the EVAP system. NO : Go to A3. A3 MONITOR THE FTP WHILE FILLING THE FUEL TANK  Monitor the FTP reference value while filling the fuel tank. Refer to the Reference Valves in the Introduction - Gasoline Engines article.  Is FTP within specification? YES : Go to A5. NO : Go to A4. A4 MONITOR THE FTP WHILE FILLING THE FUEL TANK WITH THE EVAP SYSTEM DISCONNECTED  Disconnect the fuel tank-to-EVAP canister quick connect coupling at the EVAP canister.  Monitor the FTP reference value while filling the fuel tank. Refer to Introduction - Gasoline Engines article.  Is FTP within specification? YES : INSPECT the EVAP system for blockage or restrictions. REPAIR the blockage or restriction. If the blockage or restriction cannot be repaired, INSTALL new EVAP system components. NO : Go to A5. A5 CHECK THE FUEL TANK FILLER PIPE ASSEMBLY FOR BLOCKAGE OR RESTRICTION  Remove the fuel tank filler pipe assembly. Refer to FUEL TANK & LINES article.  Inspect the fuel tank filler pipe and fuel tank filler pipe vent tube (if equipped) for a blockage or restriction.  Is the fuel tank filler pipe or fuel tank filler pipe vent tube (if equipped) blocked or restricted? YES : If possible, REPAIR the blockage or restriction. If the blockage or restriction cannot be repaired, INSTALL a new fuel tank filler pipe or fuel tank filler pipe vent tube. NO : Go to A6. 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger

A6 CHECK THE FUEL TANK INLET CHECK VALVE  Inspect the fuel tank inlet check valve for restriction or sticking.  Is the fuel tank inlet check valve restricted or sticking? YES : If possible, REPAIR the restrictions. If the restriction cannot be repaired, INSTALL a new fuel tank. REFER to FUEL TANK & LINES article. NO : Go to A7. A7 CHECK TO MAKE SURE THAT THE FUEL LEVEL VENT VALVE IS FUNCTIONING CORRECTLY  Remove the FP module. Refer to FUEL TANK & LINES article.  Inspect the fuel level vent valve for foreign material at the bottom drain hole.  Invert the FP Watch for a movement and a click noise.  Was a movement/click noise witnessed? YES : Fuel level vent valve is OK. RETEST the system for normal operation. NO : INSTALL a new FP module. REFER to FUEL TANK & LINES article. GENERAL PROCEDURES FUEL SYSTEM PRESSURE RELEASE Special Tools NOTE: The fuel level vent valve, if equipped, is part of the FP module. Illustration Tool Name Tool Number Fuel Pressure Test Kit 310-D009 (D95L-7211A) WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger

1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES article. 2. Remove the cap from the fuel pressure relief valve located on the fuel rail. Fig. 1: Identifying Fuel Pressure Relief Valve Cap Courtesy of FORD MOTOR CO. 3. Install the special tool onto the fuel pressure relief valve. Fig. 2: Identifying Fuel Pressure Relief Valve WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTE: 2.3L shown in illustration, 3.0L and 4.0L similar. NOTE: 2.3L shown in illustration, 3.0L and 4.0L similar. 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger

Courtesy of FORD MOTOR CO. 4. Open the drain valve on the special tool and relieve the fuel system pressure. Fig. 3: Identifying Drain Valve Courtesy of FORD MOTOR CO. 5. Upon completion of the fuel system repairs, cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. FUEL SYSTEM PRESSURE TEST Special Tools NOTE: 2.3L shown in illustration, 3.0L and 4.0L similar. NOTE: Open the drain valve slowly to relieve the system pressure. This may drain fuel from the system. Place fuel in a suitable container. NOTE: It may take more than one key cycle to pressurize the fuel system. Illustration Tool Name Tool Number Fuel Pressure Test Kit 310-D009 (D95L-7211A) WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger

1. Remove the cap from the fuel pressure relief valve located on the fuel rail. Fig. 4: Identifying Fuel Pressure Relief Valve Cap Courtesy of FORD MOTOR CO. 2. Install the special tool onto the fuel pressure relief valve. spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTE: 2.3L shown in illustration, 3.0L and 4.0L similar. NOTE: 2.3L shown in illustration, 3.0L and 4.0L similar. 2008 Ford Ranger 2008 GENERAL INFORMATION Fuel System - General Information - Ranger

2003 Mazda B2300 Service & Repair Manual

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