ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Engine Front Cover - 75 PS > < Crankshaft Front Seal

Transit 2000.5 (01.2000-05.2006)

Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel - Valve Cover—135 PS Transit 2000.5 (01/2000-05/2006)
In-vehicle Repair

Special Tool(s)

Valve Cover, Fuel Injector Seal, Installer

303-1055
General Equipment
Pneumatic Vacuum Gun

Removal

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.
  1. Slide open the bolt cover.

  1. Remove the accessory drive belt shield retaining bolts.

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

  1. Remove the engine oil filler pipe.

  1. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
  1. CAUTION:
    CAUTION:Protect the fuel injector electrical connectors with lint-free material to prevent contamination from the cleaning fluid.
    Clean the fuel injectors, high-pressure fuel supply lines and surrounding areas.
CAUTION:
CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
CAUTION:
CAUTION:Make sure the tool used to loosen the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions.
CAUTION:
CAUTION:Make sure that the fuel injector does not move when loosening the high-pressure fuel supply lines. Failure to follow this instruction will result in damage to the fuel injector and the fuel injector sealing washer.
  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Loosen the high-pressure fuel supply lines from the fuel injectors.

  1. CAUTION:
    CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel injector and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
    Loosen the high-pressure fuel supply lines from the fuel injection supply manifold.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel injector and the fuel injection supply manifold.
  1. Remove and discard the high-pressure fuel supply lines.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the fuel injectors and the fuel injection supply manifold.
  1. Install blanking caps to the open threaded ports on the fuel injectors and the fuel injection supply manifold.

  1. Disconnect the fuel injector electrical connectors.

  1. Disconnect the fuel return lines from the fuel injectors.
    • Position the fuel injector fuel return lines to one side.
    • Discard the fuel return line O-ring seals.

  1. CAUTION:
    CAUTION:The blanking cap will have to be removed from the fuel injector for the fuel return line retaining collar to be removed. Once this is done re-install the blanking cap to the fuel injector.
    Remove the fuel return line retaining collars.

  1. Remove the valve cover fuel injector seals.
    • Discard the valve cover fuel injector seals.

  1. Remove the valve cover.
    • Discard the gasket.

Installation

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.
  1. NOTE:
    NOTE:Install a new valve cover gasket.
    Install the valve cover.

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

  1. Install the fuel return line retaining collars.

  1. NOTE:
    NOTE:An audible click should be heard when the fuel return line is pushed fully into the fuel injector.
    Connect the fuel return lines to the fuel injectors.

  1. Connect the fuel injector electrical connectors.

  1. Loosen the fuel injection supply manifold retaining bolt (all high-pressure fuel supply lines shown removed for clarity).
  1. CAUTION:
    CAUTION:Do not allow the unions to hit the olive ends of the high-pressure fuel supply line as this may damage the ends of the line and allow foreign matter enter the fuel injection system.
    NOTE:
    NOTE:The yellow colored collar is fitted at the fuel injector end and the blue colored collar is fitted at the fuel supply manifold end of the high-pressure fuel supply line.
    NOTE:
    NOTE:To aid identification of the high-pressure fuel supply line, the union at the fuel injector end is etched with the cylinder number.
    Position the high-pressure fuel supply lines as near to the final installation position as possible and then remove and discard the blanking plugs from the high-pressure fuel supply lines.

  1. CAUTION:
    CAUTION:Maintain pressure on the high-pressure fuel supply line to keep the olives in contact with the fuel injectors and the fuel injection supply manifold cones while installing the unions.
    NOTE:
    NOTE:Install the high-pressure fuel supply lines to the fuel injection supply manifold end first followed by the fuel injector end.
    NOTE:
    NOTE:Do not tighten the high-pressure fuel supply line unions at this stage.
    Install new high-pressure fuel supply lines.

  1. Tighten the fuel injection supply manifold retaining bolts.

  1. CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions.
    Tighten the high-pressure fuel supply line unions at the fuel injection supply manifold.

  1. CAUTION:
    CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions.
    Tighten the high-pressure fuel supply line unions at the fuel injectors.

  1. Connect the CHT sensor electrical connector.

  1. Install the engine oil filler pipe.

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

  1. Install the accessory drive belt shield retaining bolts.

  1. Close the bolt cover.

Engine Front Cover - 75 PS > < Crankshaft Front Seal