A failing EGR cooler is burning holes clean through Ranger intake manifolds

By Clinton Brett, Diesel Help Australia.

When a Ford Ranger PX1, PX2 or Mazda BT-50 UP, UR 3.2L comes in running low on power, sounding noisy and throwing a P00BD code, the intake manifold is often where the real damage is hiding. Diesel Help Australia’s Clinton Brett walks through a case where a failing EGR cooler let exhaust gas run hot enough to burn straight through the manifold wall, and why the quick filler fix attempted before the cause was found is one to steer customers away from.

Models: Ford Ranger PX1, PX2 and Mazda BT-50 UP, UR 3.2L, 2011 to 2015.

Symptoms: Low power, noisy, P00BD, mass airflow meter 1 circuit range or performance, airflow too high.

Failure or issue: EGR cooler and EGR valve failure. Intake manifold melted as a result.

Diagnosis and early detection: After speaking with a colleague, we agreed it was highly likely the EGR system is getting too hot. When the exhaust gas enters the intake manifold, it appears as if it is bouncing off the inner wall towards the outer wall and blasting the holes.

Advise to check the EGR operation and remove the EGR cooler for inspection. It may also be caused by a failed EGR cooler. Carefully remove the intake and without disturbing anything on the inside, try accessing with a good bore scope to observe any melting around the holes.

The EGR cooler showed evidence of leaking and failure, which resulted in overheating of the exhaust gases and melting of the intake manifold. In this case the manifold had recently been replaced before the cause was known, and the customer had attempted to seal it up with some filler, which is not recommended as it may become dislodged and enter the engine.

Solution: Remove and replace the intake manifold, EGR valve and EGR cooler with genuine parts only.

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