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Valve Cover - RH: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Apply instant adhesive completely around the gasket groove in the valve cover. Install the new valve cover gasket.
  2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: If the valve cover is 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 1: Applying A Bead Of Silicone Gasket And Sealant In Two Places
    G02763823Courtesy of FORD MOTOR CO.
  3. Apply a bead of silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
  4. Position the valve cover and the valve cover gasket on the cylinder head and loosely install the bolts.
    Fig 2: Positioning Valve Cover And Valve Cover Gasket On Cylinder Head
    G02763824Courtesy of FORD MOTOR CO.
  5. Tighten the bolts in the sequence shown.
    Fig 3: Valve Cover Bolt Tightening Sequence
    G02763825Courtesy of FORD MOTOR CO.
  6. Position the RH fuel charge wiring harness and install the nuts.
    Fig 4: Positioning RH Fuel Charge Wiring Harness
    G02763826Courtesy of FORD MOTOR CO.
  7. Connect the wiring harness retainer to the RH valve cover stud.
    Fig 5: Connecting Wiring Harness Retainer To RH Valve Cover Stud
    G02763827Courtesy of FORD MOTOR CO.
  8. Connect the PCV tube and electrical connector.
    Fig 6: Connecting PCV Tube And Electrical Connector
    G02763828Courtesy of FORD MOTOR CO.
  9. Connect the oil fill tube to the RH valve cover.
    Fig 7: Connecting Oil Fill Tube To RH Valve Cover
    G02763829Courtesy of FORD MOTOR CO.
  10. Install the oil fill tube support bracket bolt.
    Fig 8: Installing Oil Fill Tube Support Bracket
    G02763830Courtesy of FORD MOTOR CO.
  11. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  12. Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  13. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .