The cylinder head cover consists of two parts, the upper and lower. If the oil leak from under the lower part of the cylinder head cover cannot be eliminated by tightening the cover mounting bolts, replace its seal. FORD WSE-M4G323-A4 sealant is used as a seal, since there is no gasket.
1. Reduce the pressure in the fuel system (see Reducing pressure in the engine fuel system).
2. Disconnect the wire from the negative terminal of the battery.
3. Remove the air filter and air supply hoses (see Removing and installing the air filter and intake silencer).
4. Remove the timing belt (see Replacing the timing belt of the 2.2L duratorq-tdci engine).
5. Remove the fuel injection manifold.
6. Remove the fuel injectors.
7. Remove the intake pipe.
Fig. 5.54. Seals of the upper part of the cylinder head cover.
8. Remove the upper part of the cylinder head cover by unscrewing the nine mounting bolts.
NOTE: There are gaskets between the upper and lower parts of the cylinder head cover (Fig. 5.54). Replace them if necessary.
9. Loosen the twenty-four bolts securing the lower part of the cylinder head cover in the order shown in Fig. 5.55, and then completely unscrew the bolts.
10. Clean the grooves of the lower part of the cylinder head cover and the mating surface of the cylinder head from the remains of the old seal.
11. Apply sealant-gasket (FORD WSE-M4G323-A4 or its equivalent) to the surface with a 3 mm diameter roller, and the line of application of the sealant-gasket should be on the inside of the mounting holes.
12. No later than 10 minutes after applying the sealant, install the lower part of the cylinder head cover.
13. Tighten the cover mounting bolts to a tightening torque of 11 N·m (1.1 kgf·m) in the reverse order to that shown in Fig. 5.55.
14. Install the parts in the reverse order of removal.
NOTE: Tighten the cylinder head cover upper part mounting bolts to 9 N·m (0.9 kgf·m).
15. Adjust the tension of the timing belt (see "Replacing the timing belt of the 2.2 l duratorq-tdci engine").
Fig. 5.55. The order of loosening the tightening of the bolts securing the lower part of the cylinder head cover
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