Ford Workshop Service and Repair Manuals

Valve Cover, Fuel Injector Seal, Installer

303-695

1. Slide open the bolt cover.

2. Remove the accessory drive belt shield retaining bolts.

3. Detach the fuel charging wiring harness and remove the accessory drive belt shield.

4. Disconnect the cylinder head temperature (CHT) sensor electrical connector.

5. Remove the engine oil filler pipe.

6. Remove the intake manifold. For additional information, refer to: (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel)

   Intake Manifold - Vehicles Built Up To: 04/2003, Vehicles Without: Common Rail Fuel Injection (In-vehicle Repair),

   Intake Manifold - Vehicles Built From: 04/2003, Vehicles Without: Common Rail Fuel Injection (In-vehicle Repair).

7. Disconnect the high-pressure fuel supply lines from the fuel injectors.

8. Disconnect the high-pressure fuel supply lines from the fuel injection pump.

9. Remove the high-pressure fuel supply line support bracket.

10. Disconnect the fuel injector return line.
    For additional information, refer to: Quick Release Coupling (310-00A Fuel System - General Information, General Procedures).
    

11. Remove the high-pressure fuel supply lines.
    • Discard the supply lines.

12. Remove the fuel injector return line.
    • Discard the return line and the sealing washers.

13. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.

14. Remove the valve cover.
    • Discard the gasket and the seals.

1. 

   NOTE:Install a new valve cover gasket.
   Install the valve cover.

2. 

   NOTE:Install new valve cover fuel injector seals.
   Using the special tool, install the valve cover fuel injector seals.

3. Connect the PCV hose to the valve cover.

4. 

   NOTE:Install new fuel injector return line and sealing washers.
   Install the fuel injector return line to the fuel injectors.

5. 

   NOTE:Install new high-pressure fuel supply lines.
   Install the high-pressure fuel supply lines.

6. Connect the fuel injector return line.

7. 

   NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
   Connect the high-pressure fuel supply lines to the fuel injection pump.

8. 

   NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
   Connect the high-pressure fuel supply lines to the fuel injectors.

9. 

   NOTE:The starter motor must be removed in order to allow application of the correct torque to the high-pressure fuel supply line unions at the fuel injection pump.
   Remove the starter motor.
   For additional information, refer to: Starter Motor - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-06 Starting System, Removal and Installation).
   

10. Tighten the high-pressure fuel supply line unions to the fuel injection pump.

11. Install the starter motor.
    For additional information, refer to: Starter Motor - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-06 Starting System, Removal and Installation).
    

12. Install the intake manifold. For additional information, refer to: (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel)

    Intake Manifold - Vehicles Built Up To: 04/2003, Vehicles Without: Common Rail Fuel Injection (In-vehicle Repair),

    Intake Manifold - Vehicles Built From: 04/2003, Vehicles Without: Common Rail Fuel Injection (In-vehicle Repair).

    .

13. Install the engine oil filler pipe.

14. Connect the CHT sensor electrical connector.

15. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
    

16. Bleed the fuel system.
    For additional information, refer to: Fuel System Bleeding - Vehicles Without: Common Rail Fuel Injection (310-00A Fuel System - General Information, General Procedures).
    

17. Crank the engine until fuel is observed at each injector and tighten each union as and when fuel is observed.

18. 

    NOTE:Only one high-pressure fuel supply line will show signs of fuel escaping.
    Turn the ignition and visually inspect the high-pressure fuel supply lines and tighten the high-pressure fuel supply line union which shows signs of fuel escaping.

19. 

    NOTE:Make sure the two halves of the high-pressure fuel supply line support bracket are just loose enough to slide relative to each other.
    

    NOTE:Do not tighten the high-pressure fuel supply line support bracket to high-pressure fuel supply line nuts at this stage.
    Install the high-pressure fuel supply line support bracket to the high-pressure fuel supply lines.

20. 

    NOTE:Do not tighten the high-pressure fuel supply line support bracket to cylinder head bolt at this stage.
    Install the high-pressure fuel supply line support bracket to cylinder head bolt.

21. Tighten the high-pressure fuel supply line support bracket to the high-pressure fuel supply line retaining nuts.

22. Tighten the high-pressure fuel supply line support bracket to cylinder head bolt.

23. Tighten the two halves of the high-pressure fuel supply line support bracket.

24. Attach the fuel charging wiring harness and install the accessory drive belt shield.

25. Install the accessory drive belt shield retaining bolts.

26. Close the bolt cover.