2001-2010 Mazda B2300 B4000 Trucks Service & Repair Manual
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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
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