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Clatter from under the valve cover in Ford Transit 2.2 TDCi - injector blow-by

A metallic clatter from the top of the 2.2/2.4 TDCi engine, combined with oily tar-like deposits around the injectors, is a typical sign of injector blow-by. The MK7 design has a weak point: one injector clamp bolt holds two injectors and can crack or loosen. The injector then lifts in its seat and combustion gases blow upwards. Repair means replacing the copper washer under the injector, always with a new one, checking the clamp and bolt, and cleaning the injector seat. Ignored blow-by burns the seat in the cylinder head and seizes the injector.

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