Workshop Service and Auto Repair Manuals for Ford Transit

Socket, Fuel Injector Remover/Installer

303-677 (21-236)

Valve Cover, Fuel Injector Seal, Installer

303-695 (21-248)

Aligner Plate, Injector

303-678 (21-237)

Timing Tool, Crankshaft TDC

303-675 (21-234)

1. Remove the intake manifold.
   For additional information, refer to Intake Manifold in this section.
   

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

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

4. Remove the high pressure fuel supply lines.
   • Discard the supply lines.

5. Disconnect the fuel injector return line. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information.

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

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

8. 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 a new fuel injector return line.
   Install the fuel injector return line.

5. Connect the fuel injector return line to the fuel injectors.

6. 

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

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

10. Install the intake manifold.
    For additional information, refer to Intake Manifold in this section.
    

11. Remove the crankshaft position (CKP) sensor. For additional information, refer to Section  303-14 Electronic Engine Controls.

12. 

    CAUTION:Do not turn the engine when the special tool is fully located into the flywheel. Failure to follow this instruction will cause damage to the CKP sensor hole.
    

    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine to 50 degrees before top dead center (TDC) and insert the special tool through the CKP sensor hole.

13. Using a suitable paint, mark the position of the crankshaft pulley in relation to the engine front cover.

14. Remove the special tool from the CKP sensor hole.

15. Install the CKP sensor. For additional information, refer to Section  303-14 Electronic Engine Controls.

16. Check the engine is still at 50 degrees before TDC by checking the paint marks on the crankshaft pulley and the engine front cover.

17. 

    NOTE:Only one high-pressure fuel supply line will show signs of fuel escaping.
    Operate the fuel hand primer pump (located on top of the fuel filter) and tighten the high-pressure fuel supply line union which shows signs of fuel escaping.

18. 

    NOTE:Only turn the engine in the normal direction of rotation.
    Turn the engine through 180 degrees.

19. Repeat steps 18 and 19 to bleed each of the remaining three high-pressure fuel supply lines.

20. Install the air cleaner outlet pipe and the intake air resonator assembly.

21. Install the intake air resonator retaining bolts.

22. Install the engine oil filler pipe.

23. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.