Building the Ranger Engines

Ford’s Struandale Engine Plant in Nelson Mandela Bay has played an instrumental role in the success of the locally assembled Ford Ranger – both in South Africa and in the more than 100 markets it is exported to around the world.

All the engines used in the Silverton-built Ford Ranger are proudly manufactured at the Gqeberha facility, using the latest technologies and advanced quality management systems to ensure the highest level of performance, reliability and durability that Ranger is renowned for.

This video provides insight into the Struandale operations which currently produces three different diesel engine programmes, comprising the silky smooth and powerful 3.0L V6 Diesel, the refined and efficient 2.0L Single Turbo and 2.0L Bi-Turbo Diesel, as well as the renowned 2.2L and 3.2L Duratorq TDCi.

10 interesting facts on the Struandale Engine Plant:

1. This plant opened in 1964, making it the first dedicated engine assembly plant in South Africa
2. It has produced 11 different engine programmes over the past 60 years: Essex V6, V4, Kent, 2.0L OHC, CVH, Pte, Mazda B-Series, RoCam, and current production of the 2.2L/3.2L Duratorq TDCi, 2.0L Single Turbo/Bi-Turbo and 3.0L V6 Diesel
3. The Struandale plant machines the cylinder heads for the 3.0L V6 Diesel engine, and assembles the engines
4. In a Ford-first, the same assembly line also produces the 2.2L and 3.2L Duratorq TDCi engines. The combined installed capacity of this line is 130 000 engines per annum. It can produce one engine every 120 seconds
5. Production of the Duratorq TDCi engines includes component machining of the cylinder head, block and crankshaft
6. The popular 2.0L Single Turbo and 2.0L Bi-Turbo engines are produced on a separate assembly line with an installed capacity of 120 000 engines per year – or one engine every 134 seconds
7. The assembly lines feature multiple fully automated robotic and camera stations that ensure the highest level of production quality
8. Every engine produced is subjected to a Cold Test cycle to validate quality. In this test the engine is run at pressure without being started. Additionally, rigorous dynamometer testing is conducted on-site at scheduled intervals to evaluate performance and durability
9. The entire birth history of each engine is recorded with Ford’s online Quality Management Systems. This documents each step of the manufacturing and assembly process for traceability and quality
10. In August 2023, the Struandale plant produced its 4-millionth engine – a remarkable achievement!