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Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-1 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-1 SECTION 309-00B Exhaust System — 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 Exhaust System (Component Location) 309-00B-2 REMOVAL AND INSTALLATION Catalytic Converter Diesel Particulate Filter (DPF) Exhaust Flexible Pipe Rear Muffler 309-00B-5 309-00B-8 309-00B-10 309-00B-12 Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-2 309-00B-2 Duratorq-TDCi (148kW/200PS) - Puma DESCRIPTION AND OPERATION Exhaust System – Component Location NOTE: Exhaust flexible pipes are very fragile and must not be subjected to any load They must be secured against twisting and bending during any work on the exhaust system Vehicles with diesel particulate filter & catalytic convertor Item Description Item Description DPF Heat shield Exhaust manifold DPF Temprature sensor Exhaust hanger insulator Pressure differential sensor Exhaust flexible pipe Fuel vapourizer Catalytic converter 10 Pressure differential sensor lines 11 Temprature sensor 2011.50 Ranger G1273971en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-3 309-00B-3 Duratorq-TDCi (148kW/200PS) - Puma DESCRIPTION AND OPERATION Vehicles with catalytic convertor Item Description Item Description Exhaust link pipe Exhaust manifold Exhaust flexible pipe Catalytic converter Exhaust hanger insulator Vehicles without diesel particulate filter & catalytic convertor Item Description Item Description Exhaust link pipe Exhaust manifold Exhaust hanger insulator Exhaust flexible pipe 2011.50 Ranger G1273971en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-4 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-4 DESCRIPTION AND OPERATION Item Description Rear muffler Exhaust hanger insulator 2011.50 Ranger G1273971en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-5 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-5 REMOVAL AND INSTALLATION Catalytic Converter Removal WARNING: When the engine and exhaust system are hot, they can cause severe burns or injury Turn off the engine and wait until they are cool before removing the exhaust system Vehicles with 2.2L diesel engine Torque: 47 Nm Torque: 23 Nm NOTE: Removal steps in this procedure may contain installation details Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) Vehicles with diesel particulate filter (DPF) NOTE: Vehicles with 2.2L diesel engine only Vehicles with 3.2L diesel engine Torque: 47 Nm Torque: 23 Nm NOTE: Vehicles with 3.2L diesel engine only 2011.50 Ranger G1273972en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-6 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-6 REMOVAL AND INSTALLATION Vehicles with diesel particulate filter (DPF) Torque: 48 Nm Torque: 47 Nm Torque: 47 Nm Vehicles without diesel particulate filter (DPF) 10 Torque: 47 Nm Torque: 47 Nm Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) 2011.50 Ranger G1273972en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-7 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-7 REMOVAL AND INSTALLATION All vehicles 11 Torque: 25 Nm CAUTION: Over bending the exhaust flexible pipe may cause damage resulting in failure 12 Torque: 48 Nm Vehicles without diesel particulate filter (DPF) 14 CAUTION: Make sure that the exhaust flexible pipe is not forcibly bent Torque: 25 Nm Vehicles with diesel particulate filter (DPF) 13 CAUTION: Make sure that the exhaust flexible pipe is not forcibly bent Installation To install, reverse the removal procedure 2011.50 Ranger G1273972en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-8 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-8 REMOVAL AND INSTALLATION Diesel Particulate Filter (DPF) Removal WARNING: When the engine and exhaust system are hot, they can cause severe burns or injury Turn off the engine and wait until they are cool before removing the exhaust system NOTE: Removal steps in this procedure may contain installation details Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) CAUTION: Over bending the exhaust flexible pipe may cause damage resulting in failure Torque: 40 Nm 2011.50 Ranger G1273973en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-9 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-9 REMOVAL AND INSTALLATION Torque: 40 Nm Torque: 40 Nm Torque: 40 Nm Torque: 40 Nm NOTE: Discard the gaskets at both the ends Torque: 47 Nm Torque: 47 Nm Installation To install, reverse the removal procedure 2011.50 Ranger G1273973en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-10 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-10 REMOVAL AND INSTALLATION Exhaust Flexible Pipe Removal WARNING: When the engine and exhaust system are hot, they can cause severe burns or injury Turn off the engine and wait until they are cool before removing the exhaust system Vehicles with 3.2L diesel engine Torque: 24 Nm NOTE: Removal steps in this procedure may contain installation details Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Vehicles with 2.2L diesel engine Torque: 24 Nm Torque: 24 Nm 2011.50 Ranger G1273974en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-11 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-11 REMOVAL AND INSTALLATION All vehicles Torque: 48 Nm Torque: 48 Nm Torque: 48 Nm CAUTION: Make sure that the exhaust flexible pipe is not forcibly bent Torque: 25 Nm CAUTION: Over bending the exhaust flexible pipe may cause damage resulting in failure Installation To install, reverse the removal procedure 2011.50 Ranger G1273974en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-12 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-12 REMOVAL AND INSTALLATION Rear Muffler Removal WARNING: When the engine and exhaust system are hot, they can cause severe burns or injury Turn off the engine and wait until they are cool before removing the exhaust system NOTE: Removal steps in this procedure may contain installation details Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Torque: 48 Nm 2011.50 Ranger G1273975en Exhaust System — 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L 309-00B-13 Duratorq-TDCi (148kW/200PS) - Puma 309-00B-13 REMOVAL AND INSTALLATION Installation To install, reverse the removal procedure 2011.50 Ranger G1273975en