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Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-1 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-1 SECTION 303-08A Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma VEHICLE APPLICATION: 2011.50 Ranger CONTENTS PAGE DESCRIPTION AND OPERATION Engine Emission Control 303-08A-2 Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine 303-08A-2 Vehicles with 3.2L Duratorq-TDCi (Puma) diesel engine 303-08A-3 REMOVAL AND INSTALLATION Exhaust Gas Recirculation (EGR) Valve — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (23 312 0) Exhaust Gas Recirculation (EGR) Valve — 3.2L Duratorq-TDCi (148kW/200PS) - Puma (23 312 0) Cooled Exhaust Gas Recirculation (EGR) Valve — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma Exhaust Gas Recirculation (EGR) Cooler — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (23 299 0) Exhaust Gas Recirculation (EGR) Cooler — 3.2L Duratorq-TDCi (148kW/200PS) - Puma (23 299 0) Exhaust Gas Recirculation (EGR) Valve Outlet Tube — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma (23 301 0) Exhaust Gas Recirculation (EGR) Valve Outlet Tube — 3.2L Duratorq-TDCi (148kW/200PS) - Puma (23 301 0) 303-08A-4 303-08A-6 303-08A-8 303-08A-9 303-08A-11 303-08A-13 303-08A-14 Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-2 303-08A-2 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma DESCRIPTION AND OPERATION Engine Emission Control Vehicles with 2.2L Duratorq-TDCi (Puma) diesel engine Item Description Item Description Intake air temperature (IAT) sensor EGR cooler Exhaust gas recirculation (EGR) valve outlet tube Exhaust manifold Heat shield EGR valve 2011.50 Ranger G1272530en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-3 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-3 DESCRIPTION AND OPERATION Vehicles with 3.2L Duratorq-TDCi (Puma) diesel engine Item Description Intake air temperature (IAT) sensor Exhaust gas recirculation (EGR) valve outlet tube EGR valve EGR cooler Exhaust manifold Heat shield 2011.50 Ranger G1272530en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-4 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-4 REMOVAL AND INSTALLATION Exhaust Gas Recirculation (EGR) Valve — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma(23 312 0) General Equipment Hose Clamp Remover/Installer Removal General Equipment: Hose Clamp Remover/Installer NOTE: Removal steps in this procedure may contain installation details Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) Torque: 10 Nm Torque: 24 Nm Installation NOTE: Install all the bolts finger tight before final tightening 2011.50 Ranger G1272522en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-5 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-5 REMOVAL AND INSTALLATION NOTE: Make sure that new gaskets are installed To install, reverse the removal procedure 2011.50 Ranger G1272522en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-6 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-6 REMOVAL AND INSTALLATION Exhaust Gas Recirculation (EGR) Valve — 3.2L Duratorq-TDCi (148kW/200PS) - Puma(23 312 0) General Equipment Hose Clamp Remover/Installer Removal General Equipment: Hose Clamp Remover/Installer NOTE: Removal steps in this procedure may contain installation details Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) Torque: 10 Nm Torque: 24 Nm Installation NOTE: Install all the bolts finger tight before final tightening NOTE: Make sure that new gaskets are installed 2011.50 Ranger G1272523en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-7 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-7 REMOVAL AND INSTALLATION To install, reverse the removal procedure 2011.50 Ranger G1272523en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-8 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-8 REMOVAL AND INSTALLATION Cooled Exhaust Gas Recirculation (EGR) Valve — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma General Equipment Hose Clamp(s) Hose Clamp Remover/Installer Removal NOTE: Removal steps in this procedure may contain installation details Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Installation NOTE: Install all the bolts finger tight before final tightening To install, reverse the removal procedure General Equipment: Hose Clamp Remover/Installer General Equipment: Hose Clamp(s) Torque: • 1: 10 Nm • 2: 24 Nm 2011.50 Ranger Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 3.2L Duratorq-TDCi (148kW/200PS) - Puma, General Procedures) G1089520en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-9 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-9 REMOVAL AND INSTALLATION Exhaust Gas Recirculation (EGR) Cooler — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma(23 299 0) General Equipment Hose Clamp Remover/Installer Removal NOTE: Removal steps in this procedure may contain installation details Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures) Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) Refer to: Exhaust Gas Recirculation (EGR) Valve - 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma (303-08 Engine Emission Control - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma, Removal and Installation) Torque: 22 Nm Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) 2011.50 Ranger General Equipment: Hose Clamp Remover/Installer Torque: 23 Nm G1272531en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-10 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-10 REMOVAL AND INSTALLATION Installation NOTE: Make sure that new gaskets are installed To install, reverse the removal procedure 2011.50 Ranger G1272531en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-11 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-11 REMOVAL AND INSTALLATION Exhaust Gas Recirculation (EGR) Cooler — 3.2L Duratorq-TDCi (148kW/200PS) - Puma(23 299 0) General Equipment Hose Clamp Remover/Installer Removal NOTE: Removal steps in this procedure may contain installation details Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures) Refer to: Exhaust Gas Recirculation (EGR) Valve - 3.2L Duratorq-TDCi (148kW/200PS) - Puma (303-08 Engine Emission Control 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma, Removal and Installation) Torque: 22 Nm Refer to: Cooling System Draining, Filling and Bleeding - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma (303-03 Engine Cooling - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma, General Procedures) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation) 2011.50 Ranger General Equipment: Hose Clamp Remover/Installer Torque: 23 Nm G1272532en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-12 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-12 REMOVAL AND INSTALLATION Installation NOTE: Make sure that new gaskets are installed To install, reverse the removal procedure 2011.50 Ranger G1272532en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-13 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-13 REMOVAL AND INSTALLATION Exhaust Gas Recirculation (EGR) Valve Outlet Tube — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma(23 301 0) Torque: 10 Nm Removal NOTE: Removal steps in this procedure may contain installation details NOTE: The O-ring is to be reused unless damaged Torque: 10 Nm Installation NOTE: Install all the bolts finger tight before final tightening To install, reverse the removal procedure NOTE: Make sure that new gaskets are installed 2011.50 Ranger G1272533en Engine Emission Control — 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - 303-08A-14 Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A-14 REMOVAL AND INSTALLATION Exhaust Gas Recirculation (EGR) Valve Outlet Tube — 3.2L Duratorq-TDCi (148kW/200PS) - Puma(23 301 0) Installation Removal NOTE: Removal steps in this procedure may contain installation details NOTE: Install all the bolts finger tight before final tightening To install, reverse the removal procedure NOTE: The O-ring is to be reused unless damaged Torque: 10 Nm NOTE: Make sure that new gaskets are installed Torque: 10 Nm 2011.50 Ranger G1272534en