CriticalVery commonEngine

Ford Ranger: 3.2L TDCi HPFP Metal Contamination of Fuel System

3.2L TDCi HPFP Metal Contamination of Fuel System is a very common engine fault on the Ford Ranger on the 2011–2018 cars, and we rate it critical. Putting it right costs $4,500 to $15,000 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 45 documented faults on the Ford Ranger.

Vehicle: Ford Ranger
Engine: 3.2L
Years: 2011–2018
Fuel: diesel
System: Engine

This page covers the Ford Ranger as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Ford Ranger faults45 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the High-pressure fuel pump yet. We would rather show none than show a picture of a different part.

What goes wrong

The Bosch CP4.1 high-pressure fuel pump fitted to the 3.2L PUMA TDCi can experience premature internal wear, shedding fine metal particles throughout the entire high-pressure fuel circuit. Contaminated fuel reaches the injectors, fuel rail, and low-pressure lines. Ford issued service action SSM 45370 (AU) and TSB 13-10-6 covering pump replacement and complete fuel system cleansing. Full contamination events require replacement of the pump, all six injectors, fuel rail, return lines, and filter — documented repair bills exceeding NZD $12,000 have been recorded. Risk increases markedly when non-Ford-specification diesel or extended service intervals are used.

What you would notice

Hard starting or extended cranking before engine fires
Sudden loss of power under load
Rough running or misfiring at all engine speeds
White or grey smoke from exhaust
Engine stall during acceleration
High-pitched whine from fuel pump area

How to check it

Where to look. High-pressure fuel pump mounted on engine block and driven off the camshaft; high-pressure fuel rail above intake manifold; fuel injectors in cylinder head

Remove fuel filter housing and inspect for metallic swarf or discoloured fuel.
Check service records for any documented fuel pump replacement or Ford service action completion.
Request full fuel supply history.
Scan for active or historic fuel rail pressure codes P0087, P0193, P0001.

Parts involved: High-pressure fuel pump.

What it costs to put right

$4,500 to $15,000 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Has the high-pressure fuel pump ever been replaced?”
“Has Ford performed service action SSM 45370 or TSB 13-10-6 on this vehicle?”
“What fuel brand and grade has been used consistently?”
“Are there any stored fault codes relating to fuel rail pressure?”

Now check the Ford Ranger you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.

Ford Ranger buyer questions

Is 3.2l tdci hpfp metal contamination of fuel system serious on a Ford Ranger?

We rate it critical and very common on the Ford Ranger. The Bosch CP4.1 high-pressure fuel pump fitted to the 3.2L PUMA TDCi can experience premature internal wear, shedding fine metal particles throughout the entire high-pressure fuel circuit. Contaminated fuel reaches the injectors, fuel rail, and low-pressure lines. Ford issued service action SSM 45370 (AU) and TSB 13-10-6 covering pump replacement and complete fuel system cleansing. Full contamination events require replacement of the pump, all six injectors, fuel rail, return lines, and filter — documented repair bills exceeding NZD $12,000 have been recorded. Risk increases markedly when non-Ford-specification diesel or extended service intervals are used.

How much does it cost to fix on a Ford Ranger?

$4,500 to $15,000 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Ford Ranger years are affected?

Our research records this fault on the 2011–2018 Ford Ranger. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.

How do I check for it before I buy?

Remove fuel filter housing and inspect for metallic swarf or discoloured fuel. Check service records for any documented fuel pump replacement or Ford service action completion. Request full fuel supply history. Scan for active or historic fuel rail pressure codes P0087, P0193, P0001. Look here: High-pressure fuel pump mounted on engine block and driven off the camshaft; high-pressure fuel rail above intake manifold; fuel injectors in cylinder head