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Valve Cover - LH: Installation

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
  1. Clean the valve cover, cylinder head and front cover sealing surfaces with silicone gasket remover and metal surface prep.
  2. Install new gaskets.
    Fig 1: Installing New Gaskets
    G03996284Courtesy of FORD MOTOR CO.
    3. NOTE: The valve cover must be installed and the bolts and stud bolts tightened within 4 minutes of sealant application.
    Fig 2: Identifying Silicone Gasket And Sealant Application Points
    G03996285Courtesy of FORD MOTOR CO.
  3. Apply a 3-mm (0.12-in) dot of silicone gasket sealant to the front cover-to-cylinder head joints.
  4. Install the LH valve cover.
    • Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
    Fig 3: Tightening LH Valve Cover Bolts In Sequence
    G03996768Courtesy of FORD MOTOR CO.
  5. Install the power steering pump reservoir.
    • Tighten upper bolt to 6 Nm (53 lb-in).
    • Tighten lower bolt to 12 Nm (9 lb-ft).
  6. Install the fuel hose bracket bolt to the LH shock tower.
    • Tighten to 11 Nm (8 lb-ft).
    Fig 4: Locating Fuel Hose Bracket Bolt At Left Shock Tower
    G03996282Courtesy of FORD MOTOR CO.
    7. CAUTION: Failure to lubricate the O-ring seal and the oil level indicator tube-to-engine block mating surface with clean engine oil can result in engine oil leaks.
    CAUTION: Make sure the O-ring seal remains in position and does not roll up the indicator tube during installation.
  7. Install a new O-ring seal, the oil level indicator tube and bolt.
    • Lubricate the new O-ring seal and engine mating surface with clean engine oil.
    • Tighten the bolt to 6 Nm (53 lb-in).
  8. Position the power steering fluid reservoir on the isolator bolts.
  9. Tighten the lower power steering fluid reservoir isolator bolt.
    • Tighten to 10 Nm (89 lb-in).
  10. Tighten the upper power steering fluid reservoir isolator bolt.
    • Tighten to 4 Nm (35 lb-in).
  11. Connect the EVAP hose to the intake manifold.
  12. Connect the crankcase ventilation tube to the valve cover.
  13. Install LH engine appearance cover bracket and the 2 nuts.
    • Tighten to 6 Nm (53 lb-in).
  14. Position the wiring harness and attach the 4 wiring harness retainers.
  15. Attach the vacuum harness retainers to the LH engine appearance cover bracket.
  16. Connect the VCT solenoid electrical connector.
  17. Install the LH ignition coil-on-plugs. For additional information, refer to ENGINE IGNITION - 3.9L .
  18. Connect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  19. Install the air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
    20. CAUTION: The engine appearance cover is equipped with a noise suppressor. If the noise suppressor becomes separated from the engine appearance cover it must be positioned on the intake manifold prior to installing the engine appearance cover.
    Fig 5: Identifying Engine Appearance Cover/Noise Suppressor
    G03996267Courtesy of FORD MOTOR CO.
  20. Install the noise suppressor (if detached) and the engine appearance cover.
  21. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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