Ford Ranger Technical Service Training

Ford Ranger Technical Service Training
Ford Ranger PDF Manuals

Ford Service Manual With the 2000 model year a new commercial vehicle, the Ford "RANGER" is introduced. This new pick-up truck is added to Ford’s four-wheel drive vehicle line, but is also available as a two-wheel drive version. The object of the Ford "RANGER" course is to present the vehicle and familiarize you with the vehicle components and systems. To this end, the training literature has been split into the following publications based on the main areas:

  • New Product Introduction TN7002080H (00/295) "FORD RANGER", CG 7807/S
  • New Product Introduction TN7002083H (00/295) "FORD RANGER – Powertrain", CG 7817/S

Ford Workshop Manual This New Product Introduction is designed to give an overview of the entire powertrain of the Ford "RANGER". The WL/WL-T engines are dealt with in detail. There are descriptions of the design and operation of the mechanical components and the engine management system. In addition, notes are provided on diagnosis and testing. Descriptions are also given of the R15M-D and R15MX-D manual transmissions as well as the transfer case. Further, the drive shafts, differentials and the freewheel mechanism are dealt with. Additionally, important instructions for use are to be found in the appropriate section. Detailed information about the vehicle’s chassis and electrical and electronic systems as well as the heating, ventilation and air conditioning system is provided in the corresponding Student Information publication.

Ford WL engine At a glance
Ford Engine

  1. 2.5L naturally aspirated diesel (57 kW or 78 PS at 4,100 rpm/168 Nm at 2,500 rpm)
  2. Cast iron cylinder block
  3. Aluminium alloy cylinder head with swirl chamber
  4. 3 valves per cylinder (1 exhaust valve and 2 intake valves)

Ford Engine management

  1. Mechanical fuel injection by distributor type fuel injection pump
  2. PCM controlled glow plug operation, idle speed, fuel injection timing and A/C cut-off

Ford Oil filter
The oil filter consists of two filter elements. The full-flow element is used for cleaning the oil which is forced into the lubrication system. The bypass element is used to clean the oil which is fed back into the oil pan.

Ford Air intake system (continued)

  • The turbocharger used in the Ford Ranger is a mixed flow type turbocharger. That means that the exhaust gas flows diagonally into the turbine.
  • This makes the flow of the exhaust gas smoother, reducing its resistance. In this way the charging efficiency is improved in comparison to a conventional radial turbocharger.
  • The mixed flow turbocharger also has a turbine of reduced size and weight for improved charging response.
  • With these features the mixed flow turbocharger improves engine response to the accelerator operation while providing adequate torque at low and middle engine speeds.

Boost compensator (WL-T engines only)

  1. The boost compensator adjusts the fuel injection amount according to the charging pressure, independently of the governor.
  2. Charging pressure from the intake manifold is fed into the pressurizing chamber of the boost compensator. When the pressure exceeds the set load of the spring, the diaphragm is pressed down and the adjusting rod moves down.
  3. As the adjusting rod moves down, a lever, which is in contact with the tapered section of the rod, moves in the direction shown in the illustration below.
  4. According to this movement, the tension lever moves to cause a sliding motion of the control sleeve to increase fuel flow.

Fuel injection timing control
The fuel injection timing control determines the optimal fuel injection timing according to the engine driving condition. The PCM judges the engine driving condition based on the signals from the input sensors shown in the figure below, and calculates the control signals of the fuel injection timing to drive the timer control valve (TCV).