Valve Cover — LH

Special Tool(s)

	Handle 205-153 (T80T-4000-W)
	Installer, VCT Spark Plug Tube Seal 303-1247/2
	Remover, VCT Spark Plug Tube Seal 303-1247/1

Valve Cover — LH (View 1 of 4)

Valve Cover — LH (View 2 of 4)

Valve Cover — LH (View 3 of 4)

Valve Cover — LH (View 4 of 4)

Removal

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

1. Release the fuel system pressure. For additional information, refer to Section 310-00 .

2. Disconnect the Turbocharger Boost Pressure (TCBP)/Charge Air Cooler Temperature (CACT) sensor electrical connector.

3. Loosen the 2 clamps and remove the Charge Air Cooler (CAC) outlet pipe.

4. Disconnect the 2 quick connect couplings and remove the crankcase vent tube. For additional information, refer to Section 310-00 .

5. Remove the fuel injection pump noise insulator shield.

6. Remove the oil level indicator.

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

8. Remove the nut for the high-pressure fuel tube from the LH valve cover stud bolt.

9. NOTE: To release the fuel pressure in the high-pressure fuel tubes, wrap the flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the flare nuts.

   Remove the high-pressure fuel tube flare nut from the fuel injection pump. Remove the 2 high-pressure fuel tube flare nuts from the fuel rails and remove the high-pressure fuel tube assembly.

10. Remove the fuel injection pump. For additional information, refer to Section 303-04B .

11. Disconnect the LH Variable Camshaft Timing (VCT) solenoid electrical connector.

12. Remove the engine cover mounting stud from the LH valve cover stud bolt.

13. Detach all of the wiring harness retainers from the LH valve cover stud bolts.

14. Remove the nut and the oil supply tube bracket from the LH valve cover stud bolt.

15. Disconnect the 3 LH ignition coil-on-plug electrical connectors.

16. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Remove the 3 bolts and the 3 LH ignition coil-on-plugs.

17. Loosen the 10 stud bolts and remove the LH valve cover.
    • Discard the gasket.

18. NOTE: VCT solenoid seal removal shown, spark plug tube seal removal similar.

    Inspect the VCT solenoid seals and the spark plug tube seals. Remove any damaged seals.
    • Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).

19. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.

Installation

1. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

   NOTE: Spark plug tube seal installation shown, VCT solenoid seal installation similar.

   Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.

2. NOTICE: Failure to use the correct Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

   NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow these instructions can cause future oil leakage.

   Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

3. Using a new gasket, install the LH valve cover and tighten the 10 stud bolts.
   • Tighten in the sequence shown to 10 Nm (89 lb-in).

4. Install 3 LH ignition coil-on-plugs and the 3 bolts.
   • Tighten to 7 Nm (62 lb-in).

5. Connect the 3 LH ignition coil-on-plug electrical connectors.

6. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
   • Tighten to 8 Nm (71 lb-in).

7. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.

8. Install the engine cover mounting stud to the LH valve cover stud bolt.
   • Tighten to 6 Nm (53 lb-in).

9. Connect the LH VCT solenoid electrical connector.

10. Install the fuel injection pump. For additional information, refer to Section 303-04B .

11. NOTE: To install, apply clean engine oil to the threads of the 3 high-pressure fuel tube flare nuts.

    Install the high-pressure fuel tube and tighten the 3 flare nuts in the following 3 stages.
    • Stage 1: Tighten to 32 Nm (24 lb-ft).
    • Stage 2: Wait 10 minutes to minimize pre-stress.
    • Stage 3: Tighten to 32 Nm (24 lb-ft).

12. Install the high-pressure fuel tube bracket nut.
    • Tighten to 8 Nm (71 lb-in).

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

14. Install the oil level indicator.

15. Install the fuel injection pump noise insulator shield.

16. Install the crankcase vent tube and connect the 2 quick connect couplings. For additional information, refer to Section 310-00 .

17. NOTE: Align the index marks for the CAC outlet pipe.

    Install the CAC outlet pipe and tighten the 2 clamps.
    • Tighten to 5 Nm (44 lb-in).

18. Connect the TCBP / CACT sensor electrical connector.