Ford Ranger: PX/PX2 P5AT 3.2 TDCi Injector Cup Cracking – Coolant Contamination

The 3.2L five-cylinder TDCi injector cups (pressed-in sleeves in the cylinder head) develop cracks at the base, allowing coolant to enter the combustion chamber. This causes white smoke, progressive coolant consumption and if unchecked can lead to hydro-lock and catastrophic engine failure. Subject to an Australian safety recall (FCAI/ACCC records). Repair requires cylinder head removal and cup replacement plus full coolant and oil flush. Among the most serious documented faults on PX Rangers.

• White steam-like smoke from exhaust especially at startup
• Coolant level dropping with no visible external leak
• Milky or frothy contamination on oil dipstick
• Sweet smell from exhaust
• Rough running or cylinder misfire

1. 1

   Check oil dipstick for milky or frothy contamination.

2. 2

   Inspect coolant reservoir for oil sheen.

3. 3

   Check exhaust for persistent white smoke especially on cold start.

4. 4

   Confirm recall completion status with Ford dealer using the VIN.

Parts involved: Fuel injector.

$2,500 to $6,000 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.

• “Has the injector cup recall been completed on this vehicle?”
• “Any history of white smoke or unexplained coolant loss?”
• “Has the oil ever appeared milky or frothy?”
• “When was the coolant last changed?”

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.