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Ford Ranger WLPDF PDF Free
Ford Ranger WLPDF PDF Free
FORD RANGER
New Product Introduction TN7002083H
Powertrain
Student Information
CG 7817/S en 04/1999
Preface
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:
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.
Please remember that our training literature has been prepared solely for FORD TRAINING PURPOSES.
Repair and adjustment operations MUST always be carried out according to the instructions and
specifications in the workshop literature.
Please make extensive use of the training courses offered by Ford Technical Training Centers to gain
extensive knowledge in both theory and practice.
Service Training 1
Contents
Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Literature overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine/transmission combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine power output and torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WL engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
At a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
WL-T engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
At a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Balance shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2 Service Training
Contents
Page
Engine management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Power flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2H (2WD-high) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4H (4WD-high) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
N (neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4L (4WD-low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Shift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Rear differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Service Training 3
Notes
4 Service Training
Literature overview
Service Training 5
Engine/transmission combinations
1 2
4 3
7807/29/VF
6 Service Training
Engine/transmission combinations
90 kW
1
80
70
2
60
50
40
30
Nm 300
3
20
200
4
10
100
1500 2000 2500 3000 3500 4000 4500
7807/30/VF
1 Power output – 2.5L WL-T turbocharged diesel 3 Torque – 2.5L WL-T turbocharged diesel
2 Power output – 2.5L WL diesel 4 Torque – 2.5L WL diesel
Technical data
Service Training 7
At a glance WL engine
7807/31/VF
8 Service Training
WL engine At a glance
Engine
Engine management
D PCM controlled glow plug operation, idle speed, fuel injection timing and A/C cut-off
Emission control
D Diagnosis and testing through the data link connector (DLC) in the engine compartment
Service Training 9
Design WL engine
General
Cylinder head cover
A
A—A
3 2
7807/32/VF
D The cylinder head cover is made of aluminium D To reduce noise and vibration, the cylinder head
alloy. cover features full-floating mounting to the
cylinder head through a rubber gasket.
Cylinder head
7807/33/VF
10 Service Training
WL engine Design
3
7807/34/VF
1 Intake port
2 Exhaust port
3 Combustion chamber insert
4 Fuel injection nozzle assembly port
A–A
7807/35/VF
Service Training 11
Design WL engine
Cylinder block
7807/36/VF
7807/37/VF
Section A – A
1 Cross-drilled holes
12 Service Training
WL engine Design
Crankshaft pulley
2
7807/38/VF
Drive belts
7807/39/VF
1 Water pump
2 Drive belts (V-belts)
3 Generator
4 A/C compressor
5 Tensioner pulley
6 Crankshaft pulley
Service Training 13
Design WL engine
Pistons
1
D Offset pistons are used to reduce piston slapping 2
noise.
4
5
7807/40/VF
1 Offset
2 Piston pin
3 Front mark
4 Cylinder bore center
5 Piston pin center
7807/41/VF
1 Steel strut
14 Service Training
WL engine Design
Piston rings
D Top and second rings are inner bevel rings. D The oil ring is a bevel oil control ring with an
expander.
4
7807/42/VF
1 Top ring
2 Second ring
3 Oil ring
4 Expander
Service Training 15
Design WL engine
Valve mechanism
Structural view
3 4
7807/43/VF
1 Timing belt
2 Camshaft pulley
3 Camshaft
4 Rocker arm
5 Tensioner
16 Service Training
WL engine Design
Drive train
8
1
2
3 8
7 4
7807/44/VF
D The gears are helical. The fuel injection pump gear D When the engine is running, the friction gears
and timing gear are combined with a friction gear. rotate a little bit faster than the main gears and
cause friction that counteracts the play between the
D The friction gears are equipped for noise reduction. teeth of the main gears.
They have one tooth less than the appropriate gear
they are fitted to. NOTE: The gears are marked for production and
service. Refer to the current service
D The friction gears are fitted to their main gears by literature.
using spring washers in between.
Service Training 17
Design WL engine
Valve actuation
7807/45/VF
1 Camshaft
2 Adjustment bolt
3 Nut
4 Rocker arm
5 Valve stem
6 Valve clearance measuring point
18 Service Training
WL engine Design
Lubrication system
Structural view
7
3
7807/46/VF
Service Training 19
Design WL engine
Oil pump
D The oil pump used in the Ford Ranger diesel D The oil pressure relief valve is integrated in the oil
engines is a gear type. pump housing.
7807/47/VF
1 Drive gear
2 Oil pressure relief valve
3 Driven gear
4 Driving gear
20 Service Training
WL engine Design
Oil cooler
7807/48/VF
1 Oil cooler
2 Oil cooler bypass valve
3 Oil pressure control valve
4 Oil filter
Oil filter
1 2
7807/49/VF
1 Full-flow element
2 Bypass element
Service Training 21
Design WL engine
Lubrication system
D For each cylinder an oil spray tube is mounted in D The oil spray tubes continously spray oil under the
the lower part of the cylinder block. pistons to cool the piston crown.
7807/50/VF
22 Service Training
WL engine Design
3
7807/51/VF
2
1
7807/52/VF
1 Oil pressure
2 Oil channel
3 Oil hole to spray tube
4 Check ball spring
5 Check ball
Service Training 23
Design WL engine
Cooling system
D The water pump is integrated in the cylinder block. D The cooling fan is connected to the water pump
pulley by a thermomodulated coupling and driven
by a V-belt.
2
1
5
6
7807/53/VF
24 Service Training
WL engine Design
6
2
7
7807/54/VF
Service Training 25
Design WL engine
D Intake air from the fresh air duct is filtered by the D A resonator is fitted for optimal noise control.
air cleaner and passed through the intake manifold
to the combustion chambers.
2
1
4
7807/55/VF
26 Service Training
WL engine Design
Exhaust system
2
3
7807/56/VF
1 Exhaust manifold
2 Front pipe
3 Oxidation catalytic converter (OC)
4 Muffler
5 Tailpipe
Service Training 27
At a glance WL-T engine
7807/57/VF
28 Service Training
WL-T engine At a glance
Engine
D Intercooler
D 2 balance shafts
Engine management
D PCM controlled glow plug operation, idle speed, fuel injection timing, EGR operation and A/C cut-off
Emission control
D Diagnosis and testing through the data link connector (DLC) in the engine compartment
Service Training 29
Design WL-T engine
Balance shafts
7807/58/VF
7807/59/VF
30 Service Training
WL-T engine Design
7807/60/VF
A Front of engine
Operation
D In-line four-cylinder engines are normally D This is known as secondary vertical vibration and
constructed to have the pistons of the No. 1 and can be quite severe at high engine speeds.
No. 4 cylinders moving in the opposite direction of
those of the inner No. 2 and No. 3 cylinders. D The balance shafts offset this secondary vertical
vibration by creating vibration of the same
D Therefore the force generated by pistons No. 1 and magnitude (as indicated by the dotted line in the
No. 4 offsets the force generated by pistons No. 2 illustration on the next page) in the opposite
and No. 3. direction.
Service Training 31
Design WL-T engine
2 3
1
5
4
7807/61/VF
32 Service Training
WL-T engine Design
Pistons
3
7807/62/VF
1 Cooling channel
2 Engine oil
3 Oil spray tube
Service Training 33
Design WL-T engine
Valve mechanism
Structural view
7807/63/VF
1 Camshaft
2 Rocker arm
3 Balance shaft
4 Camshaft pulley
5 Tensioner
6 Timing belt
34 Service Training
WL-T engine Design
Drive train
11
12
2
3
9 4
10
7
8
5
7807/64/VF
D The gears are helical. The fuel injection pump gear, NOTE: The gears are marked for production and
balance shaft gears and timing gear are combined service. Refer to the current service
with a friction gear. literature.
Service Training 35
Design WL-T engine
Cooling system
9
3
7
2
8
7807/65/VF
36 Service Training
WL-T engine Design
General
D Intake air from the fresh air duct is filtered by the D A turbocharger is fitted to the WL-T engine to
air cleaner and forced by the turbocharger through improve mid-range engine torque.
the intercooler and then through the intake
manifold into the combustion chambers.
5 4
3
7807/66/VF
1 Intake manifold
2 Turbocharger
3 Fresh air duct
4 Air cleaner
5 Intercooler
Service Training 37
Design WL-T engine
Turbocharger
D The turbocharger used in the Ford Ranger is a D The mixed flow turbocharger also has a turbine of
mixed flow type turbocharger. That means that the reduced size and weight for improved charging
exhaust gas flows diagonally into the turbine. response.
D This makes the flow of the exhaust gas smoother, D With these features the mixed flow turbocharger
reducing its resistance. In this way the charging improves engine response to the accelerator
efficiency is improved in comparison to a operation while providing adequate torque at low
conventional radial turbocharger. and middle engine speeds.
A B
7807/67/VF
38 Service Training
WL-T engine Design
Exhaust system
1
6
7
3
2 5
7807/68/VF
1 Exhaust manifold
2 Turbocharger
3 Joint pipe
4 Front pipe
5 Oxidation catalytic converter (OC)
6 Muffler
7 Tailpipe
Service Training 39
Glow plug system Engine management
General
D The glow plug system heats the glow plugs, which D The glow plug system consists of 4 glow plugs, a
are installed in the swirl combustion chamber, and glow plug relay and a glow plug indicator.
raises the temperature in the swirl combustion
chamber. This improves ignitability at engine start. D The glow plug relay and the glow plug indicator
are controlled by the PCM.
2
1
7807/69/VF
40 Service Training
Engine management Glow plug system
Glow plugs
Service Training 41
Fuel system Engine management
3
2
7807/71/VF
42 Service Training
Engine management Fuel system
D Fuel injection pumps used for the WL-T engine are D Vehicles with WL-T engines and vehicles with air
equipped with a boost compensator which controls conditioning system have a fast idle control device
the fuel injection amount according to the charging (FICD) to maintain smooth and stable idle speed.
pressure.
2 4
1
5
7807/72/VF
Service Training 43
Fuel system Engine management
D The boost compensator adjusts the fuel injection D As the adjusting rod moves down, a lever, which is
amount according to the charging pressure, in contact with the tapered section of the rod,
independently of the governor. moves in the direction shown in the illustration
below.
D Charging pressure from the intake manifold is fed
into the pressurizing chamber of the boost D According to this movement, the tension lever
compensator. When the pressure exceeds the set moves to cause a sliding motion of the control
load of the spring, the diaphragm is pressed down sleeve to increase fuel flow.
and the adjusting rod moves down.
5
2
4
7807/74/VF
44 Service Training
Engine management Fuel system
D The fuel shutoff valve opens and closes the fuel D When the ignition switch is OFF (engine stopped),
passage to the plunger intake port in accordance power supply to the fuel shutoff valve is cut and
with the ignition switch condition (ON/OFF). the fuel passage is closed.
A 1 B
7807/75/VF
Service Training 45
Fuel system Engine management
D On vehicles with PATS, the fuel shutoff valve is D The diesel smart module is controlled by the PCM.
operated by means of the diesel smart module. The diesel smart module compares a code word
coming from the PCM with that registered in the
D An electronic signal from the PCM makes the diesel smart module.
diesel smart module switching the fuel shutoff
valve on and off. D If the received code word is valid, the diesel smart
module activates the fuel shutoff valve and the fuel
D For reasons of safety the diesel smart module is passage is open.
covered by a protection frame.
1
2
3
4
8 7
6 5
7807/76/VF
46 Service Training
Engine management Fuel system
Fuel filter
1
D The cartridge type fuel filter has an integral
2
sedimentor.
3
5
7807/77/VF
Fuel heater
1 Switch
2 Atmospheric pressure
3 Diaphragm
4 Heater element
5 Filter outlet pressure
5 4
7807/78/VF
Service Training 47
Fuel system Engine management
D A heater element and a vacuum switch for fuel D As a result, the heat is generated in the heater
pressure detection, to operate the heater element, element to dissolve the wax. When the wax is
are integrated in the filter cap. dissolved and the negative pressure drops below
–22.0 kPa (–165 mmHg, –6.50 inHg), the switch
D When driving while the engine is cold, the diesel for fuel pressure detection is turned off, stopping
fuel waxes to block the fuel filter and the fuel the electrical current to the heater element.
negative pressure after passing the filter is
increased.
2 3
9 10
1 4
5
7 6
8
12 11
7807/79/VF
48 Service Training
Engine management Fuel system
Injection nozzles
7807/80/VF
1 Injection nozzle
2 Fuel injection pump
3 Colored rings
Service Training 49
Fuel system Engine management
50 Service Training
Engine management Fuel system
D The TCV is located on the upper part of the fuel D This maintains normal condition of advanced
injection pump and controls the fuel injection injection. The orifice will constantly be opened and
timing by changing the pump internal pressure. the overflow fuel will be returned to the fuel tank
through the orifice and return pipe.
D The TCV is made up of a solenoid coil, a spring,
and a piston and an orifice. D Excitation current is sent to the solenoid coil
according to a signal from the PCM, and as a result
D The piston will be pushed downwards (in the the spring force decreases and the piston is pulled
direction of retarded injecting) by the spring force upwards. Then the fuel outlet hole and housing
and the fuel outlet hole and housing hole passage hole passages are shut and the pump internal fuel
will be opened. Therefore the pump internal fuel will only return through the orifice.
will be returned through the return pipe to the fuel
tank. D At this point, the pump internal pressure will
suddenly rise and the timer piston will be further
pushed to the direction of advanced injection.
A B
1 1
6
3 6
3 3
5 10 5
7
9 8
4 4
7807/82/VF
Service Training 51
Engine management
Overview
1 7
21 8
2
20
9
3
19 10
4
18 11
17
5
12
16
ÁÁ
ÁÁ
ÁÁ
15
ÁÁ
14
6
13
7807/83/VF
52 Service Training
Engine management
WL-T
4
5
3
12
4 10
WL 11
5 WL-T
8 13 6 7
7 WL
6
15
16
17
10
14
7807/84/VF
Service Training 53
Engine management
WL engine
1 2
3
4 5
6
16 7
8 9
17
19
10
18
20 15
13
14
11
12
21
7807/85/VF
54 Service Training
Engine management
WL-T engine
1 3 4
2
27
18
12
26 21 19 15 13
14 5
20
25
11 9
17 16
24 22
10 8 6
23
7807/86/VF
Service Training 55
Engine management
Overview of operation
Control Item
D i
Device Fuel
Idle speed Glow plug A/C cut-off injection
control control control timing EGR control
control
NE sensor F F F
ECT sensor F F F F F
A/C switch F F
Starter motor
(engine start F
signal)
Ignition
switch (power F
Input supply to the
PCM)
Glow plugs
(glow plug
voltage F
signal)
Idle switch F F
Control lever
position F F F
sensor
FICD F
solenoid valve
No. 1
FICD F
solenoid valve
No. 2
Glow plug F
Output relay
Glow plug F
indicator
A/C relay F
Timer control F
valve (TCV)
EGR solenoid F
valve
56 Service Training
Engine management
Service Training 57
Sensors and input signals Engine management
1
2
Y
Y
4
7807/88/VF
D The engine speed (NE) sensor detects the rotation D Because the fuel injection pump gear has 96 teeth,
speed of the fuel injection pump gear, which is the NE sensor sends 96 pulses per 2 crankshaft
used by the PCM as an engine speed signal. revolutions to the PCM.
58 Service Training
Engine management Sensors and input signals
A/C signal
Ignition switch
Service Training 59
Sensors and input signals Engine management
2 3 4
B
7807/92/VF
60 Service Training
Engine management Sensors and input signals
Idle switch
2
1
7807/94/VF
1 Push rod
2 Idle switch
Service Training 61
Notes
62 Service Training
Engine management PCM controlled systems
3
4
C
1 E 5
2
6
P
8
7
9 G
7807/95/VF
D By activating fast idle control device (FICD) No. 1 D The PCM actuates the solenoids as shown below.
and No. 2, the fuel injection amount and idle speed For detailed information on the FICD design and
stability are controlled. operation refer to the section “Fuel system – fast
idle control device (FICD)”.
D The actuation of FICD solenoid No. 1 and/or No. 2
depends on the engine load and temperature.
Service Training 63
PCM controlled systems Engine management
D The glow plug system is controlled by the PCM. D For detailed information on the glow plug system
The PCM actuates the glow plug relay according to components refer to the section “Glow plug
the input signals of the ECT sensor, NE sensor, system”.
ignition switch and starter motor.
3 4
1 F M
10 E
O
5
9 D
8 J
7807/96/VF
64 Service Training
Engine management PCM controlled systems
D The glow plug relay will be activated in any of the D When, after the pre-glow phase, the ignition switch
following conditions: is kept in the ON position (not cranking/starting the
– during the pre-glow phase engine) with the engine cold, the PCM still
– while the engine is cranking activates the glow plug relay for approximately
– during the temperature-hold phase when the 15 seconds (temperature-hold phase).
engine coolant temperature is below 60oC
(140oF) D This keeps the engine’s combustion chamber
– during the long-afterglow phase when the temperature ready for starting.
engine coolant temperature is below 60oC
(140oF)
Long-afterglow phase
D The operational timing schedule of the glow plug
D The long-afterglow feature activates the glow plugs
system is designed according to the conditions of
for approximately 10 minutes after engine start
the engine coolant temperature.
when the engine is cold.
Service Training 65
PCM controlled systems Engine management
D For improving the reliability of the engine, the D The A/C relay is activated again when the engine
PCM stops the power supply to the A/C relay when coolant temperature decreases.
the engine coolant exceeds a certain temperature.
2 3
4
1 E
5
7 G
7807/97/VF
66 Service Training
Engine management PCM controlled systems
D The fuel injection timing control determines the D The PCM determines the optimal injection timing
optimal fuel injection timing according to the based on each input signal, and then determines the
engine driving condition. The PCM judges the opening angle of the TCV according to the
engine driving condition based on the signals from injection timing.
the input sensors shown in the figure below, and
calculates the control signals of the fuel injection D The TCV is driven by the injection timing signal
timing to drive the timer control valve (TCV). (ON/OFF signal) from the PCM. When the
injection timing signal is ON, the injection timing
D The PCM controls the fuel injection timing by is retarded under any of the following conditions:
driving the TCV installed to the fuel injection 1. While cranking
pump to change the fuel pressure on the timer 2. When the engine speed is low with the ECT
piston and move the timer piston position. below 70°C (158°F)
3. When the engine speed is high
1 F
2
J
6
5
H
3 Q
4 E
7807/98/VF
Service Training 67
PCM controlled systems Engine management
68 Service Training
Engine management PCM controlled systems
2
1 F
R
7 E
3
6 5 4
7807/100/VF
Service Training 69
Diagnostics Engine management
D The data link connector (DLC) has the “FEN” D The memory function memorizes the signal
(“from engine”) terminal for diagnostic trouble systems judged to be abnormal in the failure
code (DTC) output, and the “TEN” (“test engine”) detection function. The memory cannot be erased
terminal for setting the engine condition suitable when the ignition switch is turned off (LOCK
for the test mode. position) or after recovering from the failure.
D The DLC is located in the engine compartment. D To erase the failure information, disconnect the
battery ground cable.
D The diagnostic system has a failure detection
function that detects input/output signal
malfunctions.
Fail-safe function
70 Service Training
Engine management Diagnostics
DTC table
Service Training 71
Notes
72 Service Training
Power flow Clutch
D The clutch is a single plate, dry-friction disc with a D On RHD vehicles, the clutch pedal is mounted on
diaphragm-style spring clutch pressure plate. an integrated bracket with the brake pedal and
accelerator pedal.
D The clutch master cylinder transmits fluid pressure
to the clutch slave cylinder, which in turn moves D The clutch master cylinder has an integrated return
the clutch release fork and the clutch release restrictor valve to obtain smooth clutch
bearing. engagement.
D The clutch pedal has a turn-over type assist spring D The clutch slave cylinder contains a conical spring
to reduce the force required to operate the clutch to maintain the push rod end free play at zero for
pedal. maintenance-free operation.
10
8 7 3
6
5 4
7807/101/VF
Service Training 73
R15M-D and R15MX-D manual transmission Power flow
7807/102/VF
74 Service Training
Power flow R15M-D and R15MX-D manual transmission
General
Service Training 75
R15M-D and R15MX-D manual transmission Power flow
A 10
B
8
9
1 A 7
2
11
10
6
5 12
7807/103/VF
A Section A – A B Section B – B
1 Spring 7 Select lock spindle
2 Steel ball 8 Steel ball
3 Shift rod 9 Spring
4 5th/reverse shift rod 10 Control lever end
5 3rd/4th shift rod 11 Reverse stopper pin
6 1st/2nd shift rod 12 5th stopper pin
76 Service Training
Power flow R15M-D and R15MX-D manual transmission
B
A
A B
9
B
1
A
2
3
8
7
12
6
5
10
4
9
11
7807/104/VF
A Section A – A B Section B – B
1 Spring 7 Steel ball
2 Steel ball 8 Spring
3 Shift rod 9 Control lever end
4 5th/reverse shift rod 10 Reverse stopper pin
5 3rd/4th shift rod 11 Select lock spindle
6 1st/2nd shift rod 12 5th stopper pin
Service Training 77
R15M-D and R15MX-D manual transmission Power flow
1st gear
7807/105/VF
2nd gear
7807/106/VF
3rd gear
7807/107/VF
78 Service Training
Power flow R15M-D and R15MX-D manual transmission
4th gear
7807/108/VF
5th gear
7807/109/VF
Reverse gear
A
1
A
7807/110/VF
1 Section A – A
Service Training 79
R15M-D and R15MX-D manual transmission Power flow
D The double cone synchronizer mechanism is a D The double cone synchronizer mechanism includes
compact device capable of heavy duty meshing. a synchronizer ring, a double cone, and an inner
cone.
D The synchronizer mechanism reduces meshing time
and improves operation.
1 4
5
6
7807/111/VF
80 Service Training
Power flow R15M-D and R15MX-D manual transmission
7807/112/VF
1 Synchronizer ring
2 Hub sleeve
3 Synchronizer key
4 Inner cone
5 Double cone
1 Synchronizer ring
2 Hub sleeve
3 Synchronizer key
4 Inner cone
5 Double cone
6 Key channel gap
Service Training 81
R15M-D and R15MX-D manual transmission Power flow
ring.
1 Synchronizer ring 3
5
2 Hub sleeve
2
3 Synchronizer key 4
4 Inner cone
5 Double cone
6 Synchronizer teeth
7807/114/VF
1 Synchronizer ring
2 Hub sleeve
3 Synchronizer key 3
5
4 Inner cone
2
5 Double cone 4
6 Synchronizer teeth
7807/115/VF
82 Service Training
Power flow Transfer case
General
D The transfer case of the R15MX-D manual D The power is transmitted to the front differential by
transmission is a chain-drive part-time transfer in a maintenance free chain, requiring no tension
which the shift is engaged mechanically. The speed adjustment.
selection is controlled by a single-lever shift
mechanism that provides N, 2H, 4H and 4L. D The transfer is a non-synchro type transmission.
1 2
6
3 4 7
18 8
10 9
17
11
12
15
13
16
14
7807/116/VF
Service Training 83
Transfer case Power flow
2H (2WD-high)
2
H L 3
4 4WD 2WD
5
B
6
7
11
10
7807/117/VF
84 Service Training
Power flow Transfer case
2H (2WD-high)
Shift control
Power flow
Service Training 85
Transfer case Power flow
4H (4WD-high)
1
A
H L
2
4WD 2WD
3
4
B
5
12 7
9
11
10
7807/118/VF
86 Service Training
Power flow Transfer case
4H (4WD-high)
Shift control
Power flow
Service Training 87
Transfer case Power flow
N (neutral)
A 1
H L
4WD
2
6
3
7807/119/VF
88 Service Training
Power flow Transfer case
N (neutral)
Shift control
Power flow
Service Training 89
Transfer case Power flow
4L (4WD-low)
A
1
H L
2
4WD 2WD
3
4
B
5
13 7
12 11
9
10
7807/120/VF
90 Service Training
Power flow Transfer case
4L (4WD-low)
Shift control
Power flow
Service Training 91
Transfer case Power flow
Shift mechanism
Outline
4H
2 3
4
1
5
6 2
2H N 4L
7807/121/VF
92 Service Training
Power flow Transfer case
D The purpose of the interlock pin is to prevent the D There are detents in the H-L shift rod for selection
transfer case from going into a “2L” (2WD-low) of “4H”, “N”, and “4L” positions. On the
condition. 2WD-4WD shift rod there are detents for the “4H”
and “2H” positions.
D If it were possible to shift to “2L”, the torque (T)
from the transmission would become 2.21 T D The detent balls and springs are used to ensure that
inside the transfer. If this were to happen, severe the transfer stays in the selected gear.
damage to the transfer and rear differential would
result. D The detent ball and spring installed on the H-L
shift rod are larger than those on the 2WD-4WD
D The interlock pin prevents this from happening by shift rod. The reason for this is that it is very
allowing only one rod to move at a time. Thus the important that the transfer does not jump out of
H-L shift rod can be moved only when the gear while in 4WD. (Imagine, for example, the
2WD-4WD shift rod is in the 4WD position. transfer jumping into neutral when climbing a steep
grade.)
NOTE: With the transfer in “4L”, the torque
inside the transfer becomes 2.21 T just
as in the case of unwanted “2L”, but the
power is transmitted to the front and rear
powertrains. Thus, each powertrain only
receives 2.21 T/2=1.1 T, as it is
designed.
1 1
1 3
2
3
7807/122/VF
Service Training 93
Transfer case Power flow
6
1 2 3
4H
4H³2H
8
7
9
2H
7807/123/VF
94 Service Training
Power flow Transfer case
Service Training 95
Drive shafts Power flow
D The driveshaft of the 2WD version is a two-piece, D Both driveshafts of the 4WD version need
three-joint type with a center bearing support. lubrication during service.
1
1
2
2
2
7807/124/VF
96 Service Training
Power flow Drive shafts
D The halfshafts for the front wheels have D The inner joints provide length compensation of
maintenance-free constant velocity (CV) joints. the halfshaft during suspension movement.
1 2
7807/125/VF
Service Training 97
Rear differential Power flow
D There are two types of differentials available, a D With a standard differential, if a wheel starts
standard differential and a limited-slip differential. spinning due to poor traction such as mud or snow,
the driving force is exerted on that wheel by the
D The purpose of the limited-slip differential is to action of the differential.
provide driving force to both wheels by preventing
either wheel from spinning. D With the limited-slip differential, the differential
action is automatically limited and driving force is
exerted on both wheels.
A B
7807/126/VF
98 Service Training
Notes
Service Training 99
Remote freewheel (RFW) mechanism Power flow
D This in turn prevents the loss of fuel economy and D The RFW control module receives signals from the
excessive noise during 2WD operation. different switches. It accordingly activates one of
the two solenoids, causing a vacuum from the
D The RFW system consists of the following vacuum pump to be applied to the RFW actuator,
components: and switching the RFW unit to LOCK or FREE.
– RFW control module
– transfer neutral switch D The RFW control module operates the 4WD and
– 4WD indicator switch RFW indicator according to the system’s condition.
– RFW switch
– RFW main switch D To prevent reduced performance of the actuator as a
– RFW LOCK solenoid result of a decrease in vacuum pump performance,
– RFW FREE solenoid such as during low engine speed or at high altitude
– 4WD indicator operation, the actuation system includes a one-way
– RFW indicator check valve.
Principle of operation
Component Operation
sends ON/OFF signals to LOCK and FREE solenoids
RFW control module and indicators according to signals from various swit-
ches
transfer neutral switch detects selector lever N positon
4WD indicator switch detects selector lever 2H position
Input RFW switch detects RFW unit “LOCK”
RFW main switch cancels RFW unit “LOCK”
selector lever sets transfer case operation mode (2H, 4H, N, or 4L)
RFW solenoids switched ON/OFF by electrical signals from RFW
(LOCK and FREE) control module,
regulates RFW unit “LOCK” or “FREE”
RFW LOCK solenoid switched ON when locked
RFW FREE solenoid switched ON when free
Output 4WD indicator illuminates when 4H or 4L is selected
RFW indicator illuminates when RFW unit is locked
RFW unit transmits front driveshaft rotation to front wheels
RFW actuator locks or frees RFW unit
one-way check valve prevents loss of vacuum
D The RFW unit is automatically locked when the D If the RFW unit is locked, the transfer case can be
selector lever is moved from 2H to 4H while the changed from 2H to 4H or vice versa while the
vehicle is stopped. At this time, the 4WD indicator vehicle is running. At this time, the LOCK
and the RFW LOCK indicator illuminate to inform indicator remains illuminated to inform the driver
the driver that the vehicle is in four-wheel drive that the RFW unit remains locked.
mode and that the RFW unit is locked.
4H to 4L, or 4L to 4H selection
4H to 2H (free) selection
D The switching mechanism of the RFW unit is a D The rotation of the right front wheel is absorbed by
mechanical dog clutch on the left side of the front the front differential straight bevel gears, with the
differential. result that the ring gear, drive pinion gear, and front
driveshaft do not turn.
D The RFW unit actuator pulls the sleeve away from
the front differential output shaft, allowing the
front differential to rotate freely.
4 5
3
2
7 6
3 4
2
1 5
8 7
6
7807/129/VF
D The RFW actuator pushes the sleeve over the D The rotation of the front driveshaft is then
output shaft, and the front differential output shaft transferred, through the front differential, to the
and intermediate shaft are coupled together. front wheels, and four-wheel drive operation is
possible.
D If the sleeve and the output shaft are not aligned
when actuated, the RFW actuator applies pressure
to the sleeve until it can slide into place.
7 5
3
4
2
1
6
7
7807/130/VF
System overview
R.F.W.
LOCK
3 4
6
1 5
2
8
9 7
9 7
10
17
11
15 14
18
16
13
12
7807/132/VF
D When the selector lever is moved from 2H (2H-F D When the selector lever is moved from 4H to 4L
in control module) to 4H, the 4WD indicator (both 4H-L in the control module) or vice versa,
switch (in the transfer case switch) changes from there is a change to the neutral condition midway
ON to OFF. through the changeover, thereby momentarily
switching ON the transfer neutral switch (in the
D As a result, the RFW control module establishes a transfer case switch), and switching OFF the 4WD
condition known as 4H-L1, and the lock solenoid is indicator.
switched ON, causing the actuator to move towards
the lock side. At the same time, the 4WD indicator D During 4H or 4L operation, the lock solenoid is
is illuminated. ON (as a result of 4H-L condition), and the RFW
actuator is held in the lock position. If the RFW
D When the RFW unit is fully locked, the RFW main switch is pressed at this time, there is no
switch is switched ON, and condition 4H-L is effect upon the RFW actuator.
established in the control module. The RFW
LOCK indicator illuminates to show the driver that
the RFW unit is locked. Ignition switch turned from OFF to ON
Electronic control
Electric circuit
2 3 4 5 6
12 11 10 9
7807/131/VF
The abbreviations conform to standard SAE J1930 with the exception of those marked with an asterisk *.