2012 Ford Ranger 2.5L Diesel · DX61 DOH

The variable-displacement vane-type oil pump on 2.2 and 3.2 Duratorq TDCi engines can completely lose its prime if the engine oil is allowed to drain for longer than 10 minutes during a service. Because the pump is mounted above the sump oil level, it cannot self-prime once dry. Starting the engine without priming the pump leads to zero oil pressure, rapid main bearing destruction, and catastrophic engine seizure within seconds.

The 3.2-litre 5-cylinder Duratorq TDCi engine relies on a variable-nozzle turbocharger that is prone to premature failure. Carbon build-up in the variable vane mechanism causes the electronic actuator to stick or burn out, while oil feed pipe sludging starves the turbo bearings. If the turbo seals fail, engine oil is drawn directly into the intake tract, creating a dangerous diesel runaway risk or sudden loss of boost pressure.

Both early 2.2 and 3.2 Duratorq diesels and early 2.0 EcoBlue engines suffer from injector failure. In 2015, Ford recalled nearly 14,000 UK Rangers for faulty injector batches that caused engines to cut out without warning while driving. Failed injectors suffer from high leak-back rates or internal nozzle jamming, leading to cylinder bore wash, uneven fueling, violent knocking, and melted pistons.