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Valve Cover LH: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    ALL ENGINES 

  1. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the valve cover. Install the new valve cover gasket.
    Fig 1: Applying Adhesive To Valve Cover Gasket Groove
    G01536266Courtesy of FORD MOTOR CO.
    2. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 2: Applying Bead Of Silicone Gasket And Sealant In Two Places
    G01536267Courtesy of FORD MOTOR CO.
  2. Apply a bead of silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
  3. Position the valve cover and gasket on the cylinder head. Loosely install the bolts.
    Fig 3: Installing Valve Cover And Gasket On Cylinder Head
    G01536268Courtesy of FORD MOTOR CO.

    4. ROMEO ENGINE (4.6L) 

  4. Tighten the bolts in the sequence shown.
    Fig 4: Identifying Bolts Tightening Sequence (ROMEO ENGINE 4.6L)
    G01536269Courtesy of FORD MOTOR CO.

    5. WINDSOR ENGINE (5.4L) 

  5. Tighten the bolts in the sequence shown.
    Fig 5: Identifying Bolts Tightening Sequence (WINDSOR ENGINE 5.4L)
    G01536270Courtesy of FORD MOTOR CO.

    6. ALL ENGINES 

  6. Position the engine control wiring harness onto the valve cover studs.
  7. Connect the LH radio interference capacitor electrical connector.
    Fig 6: Connecting LH Radio Interference Capacitor Electrical Connector
    G01536271Courtesy of FORD MOTOR CO.
  8. Connect the CMP electrical connector.
    Fig 7: Connecting CMP Electrical Connector
    G01536272Courtesy of FORD MOTOR CO.
  9. Connect the LH ignition coil electrical connectors.
    Fig 8: Connecting LH Ignition Coil Electrical Connectors
    G01536273Courtesy of FORD MOTOR CO.
  10. Connect the LH fuel injector electrical connectors.
    Fig 9: Connecting LH Fuel Injector Electrical Connectors
    G01536274Courtesy of FORD MOTOR CO.

    11. ROMEO ENGINE (4.6L) 

  11. Connect the exhaust manifold to EGR valve tube.
    • Hand-tighten the upper and lower fittings.
    • Tighten to 35-45 Nm (26-33 lb-ft).
    Fig 10: Connecting Exhaust Manifold To EGR Valve Tube
    G01536275Courtesy of FORD MOTOR CO.
  12. Install the differential pressure feedback EGR sensor.
    • Install the sensor and hoses on the exhaust manifold to EGR valve tube.
    • Connect the electrical connector.
    Fig 11: Connecting Electrical Connector
    G01536276Courtesy of FORD MOTOR CO.

    13. WINDSOR ENGINE (5.4L) 

  13. Connect the exhaust manifold to EGR valve tube.
    • Hand-tighten the upper and lower fittings.
    • Tighten to 40-60 Nm (30-44 lb-ft).
    • Connect the hoses.
    Fig 12: Connecting Exhaust Manifold To EGR Valve Tube
    G01536277Courtesy of FORD MOTOR CO.

    ALL ENGINES 

    14. NOTE: 4.6L engine shown; 5.4L engine similar.
    Fig 13: Connecting Crankcase Ventilation Tube To Valve Cover
    G01536278Courtesy of FORD MOTOR CO.
  14. Connect the crankcase ventilation tube to the valve cover.
  15. Install the engine air cleaner and air cleaner outlet pipe.
  16. Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  17. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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