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Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-1 303-14B-1 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma SECTION 303-14B Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma VEHICLE APPLICATION: 2011.50 Ranger CONTENTS PAGE DESCRIPTION AND OPERATION Electronic Engine Controls Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine Vehicles with 3.2L Duratorq-TDCi (Puma) diesel engine Electronic Engine Controls (System Operation and Component Description) System Diagram System Operation Component Description Mass air flow (MAF) sensor Camshaft position (CMP) sensor Crankshaft position (CKP) sensor Engine coolant temprature (ECT) sensor Engine oil pressure Manifold absolute pressure and temperature (MAPT) sensor 303-14B-2 303-14B-2 303-14B-3 303-14B-4 303-14B-4 303-14B-6 303-14B-6 303-14B-? 303-14B-? 303-14B-? 303-14B-? 303-14B-? 303-14B-? GENERAL PROCEDURES Crankshaft Position (CKP) Sensor Bracket Adjustment — Diesel 303-14B-8 REMOVAL AND INSTALLATION Crankshaft Position (CKP) Sensor — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma Crankshaft Position (CKP) Sensor — 3.2L Duratorq-TDCi (148kW/200PS) Puma Engine Coolant Temperature (ECT) Sensor Brake Pedal Position (BPP) Switch Powertrain Control Module (PCM) Camshaft Position (CMP) Sensor — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma Camshaft Position (CMP) Sensor — 3.2L Duratorq-TDCi (148kW/200PS) Puma (29 230 0) 303-14B-11 (29 230 0) (21 190 0) (33 502 0) (29 200 0) 303-14B-12 303-14B-13 303-14B-14 303-14B-15 (29 232 0) 303-14B-17 (29 232 0) 303-14B-18 Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-2 303-14B-2 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma DESCRIPTION AND OPERATION Electronic Engine Controls Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine Item Description Item Description Mass air flow (MAF) Engine coolant temprature (ECT) sensor Camshaft position (CMP) sensor Engine oil pressure sensor Crankshaft position (CKP) sensor Manifold absolute pressure and temperature (MAPT) sensor 2011.50 Ranger G1272720en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-3 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-3 DESCRIPTION AND OPERATION Vehicles with 3.2L Duratorq-TDCi (Puma) diesel engine Item Description Mass air flow (MAF) sensor Camshaft position (CMP) sensor Crankshaft position (CKP) sensor Engine coolant temprature (ECT) sensor Engine oil pressure sensor Manifold absolute pressure and temperature (MAPT) sensor 2011.50 Ranger G1272720en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-4 303-14B-4 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma DESCRIPTION AND OPERATION Electronic Engine Controls – System Operation and Component Description System Diagram Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine Item Description Item Description Mass air flow (MAF) Engine coolant temprature (ECT) sensor Camshaft position (CMP) sensor Engine oil pressure switch Crankshaft position (CKP) sensor Manifold absolute pressure and temperature (MAPT) sensor 2011.50 Ranger G1272724en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-5 303-14B-5 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma DESCRIPTION AND OPERATION Vehicles with 3.2L Duratorq-TDCi (Puma) diesel engine Item Description Item Description Mass air flow (MAF) sensor Engine coolant temprature (ECT) sensor Camshaft position (CMP) sensor Engine oil pressure switch Crankshaft position (CKP) sensor Manifold absolute pressure and temperature (MAPT) sensor 2011.50 Ranger G1272724en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-6 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-6 DESCRIPTION AND OPERATION System Operation Crankshaft position (CKP) sensor Component Description Mass air flow (MAF) sensor Uses a hot wire sensing element to measure the amount of air entering the engine Uses a second hot wire to measure intake air temperature Sends signals to the PCM The PCM will then calculate the required fuel injector pulse width in order to provide the desired air/fuel ratio Camshaft position (CMP) sensor The CKP sensor is an inductive sensor that allows the ECM to determine the angular position of the crankshaft and the engine speed The CKP sensor is installed in the rear left side of the block body, in line with the engine drive plate.The sensor is bolted with a clamp A three pin electrical connector provides the interface with the engine harness The head of the CKP sensor faces a reluctor ring pressed into the outer circumference of the engine drive plate The reluctor ring has a 60 minus tooth pattern There are 58 teeth at 6° intervals, with two teeth removed to provide a reference point with a centerline that is 21° BTDC (before top dead center) on cylinder of bank A If the CKP sensor fails, the ECM: Uses signals from the CMP sensors to determine the angular position of the crankshaft and the engine speed Adopts a limp home mode where engine speed is limited to a maximum of 3000 rev/min With a failed CKP sensor, engine starts will require a long crank time while the ECM determines the angular position of the crankshaft Engine coolant temprature (ECT) sensor Provides camshaft position information which is used by the PCM for fuel synchronization The ECT sensors are NTC (negative temperature coefficient) thermostats that allow the ECM to monitor the engine coolant temperature ECT 2011.50 Ranger G1272724en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-7 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-7 DESCRIPTION AND OPERATION sensor is secured with a twist-lock and latch mechanism, and is sealed with an O-ring A two pin electrical connector provides the interface between the sensor and the engine harness ECT The input from this sensor is used in calibration tables and by other systems If there is an ECT fault, the ECM adopts an estimated coolant temperature On the second consecutive trip with an ECT fault, the ECM illuminates the MIL (malfunction indicator lamp) ECT is installed in the lower hose connector which attaches to the bottom of the thermostat The input from this sensor is used for OBD (on-board diagnostic) diagnostics and, in conjunction with the input from ECT , to confirm that the thermostat is functional Engine oil pressure In the MAPT sensor housing are located a piezo-pressure sensor element (MAP (manifold absolute pressure) sensor) and the electronic circuits for signal amplification and temperature compensation The IAT sensor element is an NTC (negative temperature coefficient) resistor A special coating process renders the MAP and IAT sensor elements resistant to damp and humidity in the intake pipe The MAPT sensor receives a reference voltage of Volts from the PCM The output signal from the MAP sensor element is an analogue voltage signal which changes proportionately to the absolute pressure in the intake manifold A high absolute pressure in the intake manifold (throttle valve wide open) means a high voltage, and a low absolute pressure in the intake manifold (throttle valve closed) means a low voltage With ignition on and wide-open throttle the MAP sensor measures the BARO (barometric pressure) The resulting value is stored in the Keep Alive Memory and serves as a reference pressure for the prevailing manifold absolute pressure at the various load states The EOP switch detects the oil pressure When a defined engine oil pressure is reached, the EOP switch opens This information is transmitted via the CAN bus to the instrument cluster where the EOP warning lamp is switched on or off accordingly Manifold absolute pressure and temperature (MAPT) sensor 2011.50 Ranger G1272724en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-8 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-8 GENERAL PROCEDURES Crankshaft Position (CKP) Sensor Bracket Adjustment — Diesel Special Tool(s) 303-1562 Timing Tool 303-1587 Timing Tool, Crankshaft 303-698 Timing Tool, Crankshaft 2011.50 Ranger G1502527en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-9 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-9 GENERAL PROCEDURES Adjustment Refer to: Timing Cover (303-01 Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation) Refer to: Crankshaft Position (CKP) Sensor 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma (303-14 Electronic Engine Controls 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma, Removal and Installation) Refer to: Crankshaft Position (CKP) Sensor 3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-14 Electronic Engine Controls - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation) NOTE: Make sure that the special tool is located in the flywheel timing slot Special Tool(s): 303-698 Tighten bolts before removing tool Remove the Special Tool(s): 303-698 Torque: 25 Nm Special Tool(s): 303-1587 Vehicles with automatic transmission Loosen the bolts Vehicles with manual transmission Loosen the bolts NOTE: Make sure that the special tool is located in the flexplate timing slot 2011.50 Ranger G1502527en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-10 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-10 GENERAL PROCEDURES Special Tool(s): 303-1562 Tighten bolts before removing tool Remove the Special Tool(s): 303-1562 Torque: 25 Nm 2011.50 Ranger G1502527en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-11 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-11 REMOVAL AND INSTALLATION Crankshaft Position (CKP) Sensor — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma(29 230 0) Rotate the crankshaft until a flywheel tooth is visible through the CKP sensor housing Removal NOTE: Removal steps in this procedure may contain installation details Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Torque: Nm CAUTION: The tip of the sensor must rest on a flywheel tooth NOTE: Make sure that a new component is installed To install, reverse the removal procedure Installation CAUTION: Only rotate the crankshaft clockwise 2011.50 Ranger G1272725en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-12 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-12 REMOVAL AND INSTALLATION Crankshaft Position (CKP) Sensor — 3.2L Duratorq-TDCi (148kW/200PS) - Puma(29 230 0) Installation Removal CAUTION: Only rotate the crankshaft clockwise Rotate the crankshaft until a flywheel tooth is visible through the CKP sensor housing CAUTION: The tip of the sensor must rest on a flywheel tooth NOTE: Removal steps in this procedure may contain installation details Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Torque: 25 Nm NOTE: Make sure that a new component is installed To install, reverse the removal procedure Torque: Nm 2011.50 Ranger G1272726en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-13 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-13 REMOVAL AND INSTALLATION Engine Coolant Temperature (ECT) Sensor(21 190 0) Removal NOTE: Removal steps in this procedure may contain installation details Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures) Torque: 24 Nm Installation To install, reverse the removal procedure 2011.50 Ranger G1272736en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-14 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-14 REMOVAL AND INSTALLATION Brake Pedal Position (BPP) Switch(33 502 0) Removal NOTE: Removal steps in this procedure may contain installation details NOTE: Only if equipped with driver lower air bag module Refer to: Driver Lower Air Bag Module (501-20 Supplemental Restraint System, Removal and Installation) Installation To install, reverse the removal procedure 2011.50 Ranger G1272738en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-15 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-15 REMOVAL AND INSTALLATION Powertrain Control Module (PCM)(29 200 0) General Equipment Ford Diagnostic Equipment Vehicles with PCM security shield Removal Torque: 15 Nm CAUTION: If a new PCM is to be installed, upload the PCM configuration information using the Programmable Modules Installation Routine, prior to commencing the removal of the PCM NOTE: Removal steps in this procedure may contain installation details All vehicles Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures) Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation) All vehicles Torque: 11 Nm Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation) 2011.50 Ranger G1272749en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-16 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-16 REMOVAL AND INSTALLATION Torque: 10 Nm Torque: 11 Nm Carry out the Pilot Correction Learn procedure using the following menu options: ToolBox/Powertrain/Service Functions General Equipment: Ford Diagnostic Equipment Change the engine oil and the oil filter Carry out the oil reset procedure Installation To install, reverse the removal procedure Carry out the Injector Correction Factors procedure using the following menu options: ToolBox/Powertrain/Service Functions General Equipment: Ford Diagnostic Equipment Carry out the Oil Quality History function using the following menu options: ToolBox/Powertrain/Service Functions General Equipment: Ford Diagnostic Equipment Carry out the Stored Speed Limit function using the following menu options: ToolBox/Powertrain/Service Functions General Equipment: Ford Diagnostic Equipment Carry out the Pump Learn procedure using the following menu options: ToolBox/Powertrain/Service Functions General Equipment: Ford Diagnostic Equipment 2011.50 Ranger G1272749en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-17 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-17 REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma(29 232 0) Installation Removal To install, reverse the removal procedure NOTE: Removal steps in this procedure may contain installation details 2011.50 Ranger G1344013en Electronic Engine Controls — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-14B-18 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B-18 REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor — 3.2L Duratorq-TDCi (148kW/200PS) - Puma(29 232 0) Installation Removal To install, reverse the removal procedure NOTE: Removal steps in this procedure may contain installation details 2011.50 Ranger G1344015en