Right Side

REMOVAL
1. Disconnect battery ground cable. Refer to Starting and Charging.
2. Disconnect ignition wires from spark plugs. Refer to Powertrain Management.
3. Remove ignition wire and bracket from valve cover retaining studs and move out of the way.
4. Remove upper intake manifold.
5. Loosen lower EGR valve to exhaust manifold tube retaining nut and rotate EGR valve to exhaust manifold tube out of the way.
6. Remove positive crankcase ventilation valve (PCV) (if replacing valve cover).
7. Remove engine control sensor wiring stand-offs from valve cover studs.
8. Remove engine control sensor wiring retaining nuts from valve cover.
9. Move engine control sensor wiring out of the way.
10. Loosen valve cover retaining bolts and studs.

CAUTION: Cut only the silicone sealer and not the integral valve cover gasket

11. Carefully slide a sharp, thin bladed knife between cylinder head and valve cover gasket at the step where the intake manifold mates to the cylinder head (two places each side).

CAUTION: Make sure the silicone sealer does not pull the integral valve cover gasket from the valve cover.

12. Remove valve cover making sure the silicone sealer does not pull the integral valve cover gasket from the valve cover.

NOTE: Observe bolt and stud bolt locations before removing valve cover gasket as fasteners are secured by valve cover gasket.

13. If required, remove integral valve cover gasket by pulling from valve cover gasket channel.

INSTALLATION

NOTE: Lightly oil all bolt and stud bolt threads before installation.

1. Clean valve cover gasket channel with soft cloth to remove all dirt.
2. Using a suitable solvent, clean off any remaining silicone sealant.

CAUTION: Check valve cover gasket for correct installation. New valve cover gasket will lay flat to the valve cover in both the channel and fastener areas. If the valve cover gasket is installed incorrectly, oil leakage WILL occur.

3. If required, aligning fastener holes, lay new valve cover gasket onto channel.
4. If required, install valve cover gasket to each fastener by securing fastener head with a nut driver or socket. Seat fastener against valve cover and, at the same time, roll valve cover gasket around fastener collar. If installed correctly, all fasteners will be secured by valve cover gasket and will not fall out.

NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.

5. Apply bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 at cylinder head to intake manifold step (two places per side) as shown.

CAUTION: Use a straight-down approach when installing valve cover. Any adjustment after sealer contact can roll valve cover gasket from valve cover channel resulting in leaks.





6. Position valve cover on the cylinder head and hand tighten retaining bolts and stud bolts. Then, tighten in sequence to 10-14 Nm (89-123 inch lbs.).
7. Install engine control sensor wiring stand-offs to the appropriate valve cover stud bolts.
8. Install engine control sensor wiring through to valve cover studs. Tighten retaining nuts to 2.5-3.5 Nm (23-30 inch lbs.).
9. Install upper intake manifold.
10. Install positive crankcase ventilation valve and connect crankcase ventilation tube.
11. Connect EGR valve to exhaust manifold tube to EGR valve (EGR valve). Tighten both retaining nuts to 35-65 Nm (26-47 ft. lbs.).