Ford Ranger & Mazda BT50 3.2L 5 Cylinder Issues

PX and PX2 Duratorq 

ISSUE: BLOWN HEAD GASKET 

Ford Ranger 3.2 Litre head gasket repair

A common cylinder issue on Ford Ranger and Mazda BT50 3.2 Litre 5 Cylinder Diesel engine is a blown head gasket. Repair of the blown head gasket can be done by any reputable engine reconditioner or mechanic, by removing the head, dismantling all the damaged components and cleaning them. ETP Online supplies the replacement head, valves and gaskets required for the repair.

In order to properly repair the head, it is recommended to have the head pressure tested, a full surface grind done, wash and then reassemble the head with new valve steam seals. 

Further to the blown head gasket issue, Ford Ranger and Mazda BT50 engines have other common problems including:

Common Faults:

• Faulty EGR coolers
• Holes in pistons
• Turbo Failure
• Leaking Diesel injectors

ISSUE: FAULTY EGR COOLERS

The failure of an EGR Cooler can result in the exhaust filling up with water, which both creates a lack of water in the radiator which then leads to a blown head gasket. To verify whether an EGR cooler has failed or not, it needs to be pressured tested using a simulation of normal working conditions. 

To properly test an EGR Cooler, it's best to carry out two specific test. Firstly, pumping cold fluid, usually fluorescent coolant through the assembly as a pressure of around 18 PSI. This is higher than the normal operating pressure. It is then held there for 15 minutes. If the fluid can be seen escaping from anywhere.

The second test involves increasing the temperature of the coolant in the EGR to 90 degrees, whilst maintaining the same 18 PSI of pressure. Again, the EGR is viewed for any leaks. 

In some circumstances the EGR can leak under either cold or hot tests, regardless of which test is fails under we recommend replacing it. The reason for this test is to help determine the cause of other issues that you may have in the system. It may also help predict any issues that may occur later on. 

Lastly, the cost of replacing an EGR assembly is substantially less than that of a failed engine, so it's a much better pathway. 

The question then gets asked, if you're going to replace it anyway, why test it?

It's quite simple. When you're trying to find the cause of a loss of coolant or a loss of water somewhere in the system, the EGR is a common place to start. Testing it will tell you whether it is indeed the cause or something else is the problem. Water loss can come from any number of areas, down to something as simple as a leaking coolant hose, leaking radiator or something more severe. Testing the EGR will help identify that. 

ISSUE: HEAD GASKET FAILURE

In any vehicle, a head gasket failure can be caused be any number of factor. A failed EGR cooler, an issue in the radiator, a burst cooling hose, a failed thermostat or issues with the fueling system. 

Generally though, the vehicles that require head gasket replacements are caused by poor maintenance. The best way to avoid this on a Ford Ranger or Mazda BT50 is to have the cooling system checked at regular services.

Ranger and Mazda BT50 3.2 litre P5AT cylinder head

To have the head on a P5AT engine reconditioned generally includes, a cylinder head bend check, a hardness test, straightening if needed, complete dismantling, ultra sonic clean and pressure test. The valve guides and valves may also need to be replaced, during which a valve grind and surface grind may be required. The final wash and reassembly is then carried out. 

ISSUE: DIESEL INJECTORS

Diesel Injectors in a Ford Ranger & Mazda BT50 P5AT engine can create holes in pistons when they fail. If the injectors fail, they create something similar to a cutting torch effect on top of the piston which then blows a hole into it. As a result, it's recommended that you recondition or replace your injectors at 100,000km intervals. In addition, it's recommended to have your injector seats recut when the injectors are replaced, to ensure a perfect seal of the new injector seals. It's possible to have compression leak past the injector seals if the seat has not been recut or is damaged.

ISSUE: OIL CHANGE

Whilst doing an oil change, it's important to take care whilst doing an engine oil change for the Ford Ranger and Mazda BT50 engines. Engine failure can occure after a service if not done properly.

You must ensure the engine oil change does not take more than 10 minutes. Let the engine drain for less than 10 minutes, to avoid the engine oil pump draining back. If the engine oil pump drains back, it will then not re-prime, thus causing engine failure on restart. 

ISSUE: TURBO FAILURE

Can you feel that your vehicle is lacking power or boost? This may be because the turbo has failed. 

To repair the issue, it's necessary to properly sand back the intake system to ensure no marks or chips from the turbo. Then replace the turbo with a genuine Garrett turbo as used by Ford originally. Then, replace all the components of the oil system that may be effected, including the oil and filter, air filter system, and maybe the oil feed line. At the very least the oil feed line must be cleaned to ensure a good flow to the engine. 

Finally, once reconstructing the engine it's necessary to check all the intake parts are properly cleaned, with no leaks and no blockages. 

If you need replacements parts for any Ford Range or Mazda BT50 model, here at ETPOnline we have you covered.