Valve Cover — RH

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 — RH (View 1 of 4)

Valve Cover — RH (View 2 of 4)

Valve Cover — RH (View 3 of 4)

Valve Cover — RH (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. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .

3. Disconnect the LH turbocharger bypass valve electrical connector.

4. Disconnect the turbocharger bypass valve hose from the RH Charge Air Cooler (CAC) tube.

5. Remove the turbocharger wastegate regulating valve hose from the RH CAC tube.

6. Disconnect the RH turbocharger bypass valve electrical connector.

7. Disconnect the RH turbocharger bypass valve hose from the RH turbocharger intake tube.

8. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

   Remove the RH CAC tube nut from the intake manifold.

9. Loosen the clamp and remove the RH CAC tube.

10. Loosen the clamp and remove the RH CAC tube.

11. Detach the 2 brake booster vacuum hose retainers from the strut tower brace and position aside.

12. Disconnect the fuel supply tube. For additional information, refer to Section 310-00 .

13. Remove the fuel tube-to-engine front cover bracket bolt and position the fuel tube aside.

14. Disconnect the RH fuel injector wiring harness electrical connector.

15. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling. For additional information, refer to Section 310-00 .

16. Disconnect the EVAP valve electrical connector and detach from the intake manifold.

17. Disconnect the quick connect coupling from the intake manifold and remove the EVAP tube assembly. For additional information, refer to Section 310-00 .

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

19. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector and detach the 2 wiring harness retainers.

20. Disconnect the 3 RH ignition coil-on-plugs electrical connectors.

21. Detach all of the wiring harness retainers from the RH valve cover and stud bolts position aside.

22. 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 RH ignition coil-on-plugs.

23. Loosen the clamp and remove the RH turbocharger intake tube from the RH turbocharger intake pipe.

24. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

    Remove the nut from the RH valve cover stud bolt and position the RH turbocharger intake tube off the RH valve cover stud bolt.

25. Loosen the 11 stud bolts and remove the RH valve cover.
    • Discard the gasket.

26. 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).

27. 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 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 this procedure 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-RH cylinder head joints.

3. Using a new gasket, install the RH valve cover and tighten the 11 stud bolts.
   • Tighten in the sequence shown to 10 Nm (89 lb-in).

4. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the turbocharger intake tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

   Position the RH turbocharger intake tube and install the nut to the RH valve cover stud bolt.
   • Tighten to 6 Nm (53 lb-in).

5. NOTE: Align the index marks for the RH turbocharger intake tube.

   Install the RH turbocharger intake tube to the RH turbocharger intake pipe and tighten the clamp.
   • Tighten to 5 Nm (44 lb-in).

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

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

8. Connect the 3 RH ignition coil-on-plug electrical connectors.

9. Connect the RH VCT solenoid electrical connector and attach the 2 wiring harness retainers.

10. Install the PCV tube and connect the 2 quick connect couplings. For additional information, refer to Section 310-00 .

11. Install the EVAP tube assembly and connect the quick connect coupling to the intake manifold. For additional information, refer to Section 310-00 .

12. Connect the EVAP valve electrical connector and attach to the intake manifold.

13. Connect the EVAP tube quick connect coupling. For additional information, refer to Section 310-00 .

14. Connect the RH fuel injector wiring harness electrical connector.

15. Position the fuel tube and install the fuel tube-to-engine front cover bracket bolt.
    • Tighten to 10 Nm (89 lb-in).

16. Connect the fuel supply tube. For additional information, refer to Section 310-00 .

17. Attach the 2 brake booster vacuum hose retainers to the strut tower brace.

18. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC tube to the RH turbocharger and tighten the clamp.
    • Tighten to 5 Nm (44 lb-in).

19. NOTE: Align the index marks for the RH CAC tube.

    Install the RH CAC tube and tighten the clamp.
    • Tighten to 5 Nm (44 lb-in).

20. NOTICE: The compression limiter bushing may fall out of the mounting bracket grommet on the Charge Air Cooler (CAC) tube during service. Make sure the bushing is in place when reinstalling the tube or damage to the tube may occur.

    Install the RH CAC tube and turbocharger intake tube as an assembly and install the RH CAC tube nut to the intake manifold.
    • Tighten to 6 Nm (53 lb-in).

21. Connect the RH turbocharger bypass valve hose to the RH turbocharger intake tube.

22. Connect the RH turbocharger bypass valve electrical connector.

23. Install the turbocharger wastegate regulating valve hose to the RH CAC tube.

24. Connect the turbocharger bypass valve hose to the RH CAC tube.

25. Connect the LH turbocharger bypass valve electrical connector.

26. Install the ACL outlet pipe. For additional information, refer to Section 303-12 .