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Home >> Ford >> 2004 >> Explorer 4.6 W, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1745 (Engine - 6.0L Diesel -- F250-F550 Super Duty 6.0L (99P F450/550)) >> In-Vehicle Servicing >> Valve Cover - LH >> Removal And Installation

Removal And Installation

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
    2. Fig 1: Locating Engine Vent And Radiator Vent Hoses
    GF0005686Courtesy of FORD MOTOR CO.
    WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or result in personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When certain all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions can result in personal injury.
    CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly and the system filled with new coolant.
    CAUTION: Always fill the cooling system with the same type of coolant that was drained from the system. Do not mix coolant types.
    CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle.

    When adding engine coolant, use a 50/50 mixture of engine coolant and distilled water.

    To maintain the integrity of the coolant and the cooling system:

    • Add Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) meeting Ford specification WSS-M97B51-A1. Always fill the cooling system with the same type of coolant that was drained from the system. Do not mix coolant types.
    • Do not add orange-colored Motorcraft Specialty Orange Engine Coolant with Bittering Agent (US); Motorcraft Extended Lift Engine Coolant (Canada) VC-3 (US); CXC-209 (Canada); or equivalent meeting WSS-M97B44-D. Mixing coolants may degrade the coolant's corrosion protection.
    • Do not add alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol anti-freeze. These can cause engine damage from overheating or freezing.
  2. Relieve the cooling system pressure and disconnect and cap the engine vent hose and the radiator vent hose.
    3. Fig 2: Degas Bottle Bolts
    GF0005687Courtesy of FORD MOTOR CO.
  3. Remove the 2 bolts and position the degas bottle aside.
    4. Fig 3: Locating Exhaust Pressure (EP) Sensor Harness Pin-Type Retainers
    GF0005688Courtesy of FORD MOTOR CO.
  4. Release the 2 exhaust pressure (EP) sensor harness pin-type retainers.
    5. Fig 4: Locating EP Sensor Electrical Connector
    GF0005689Courtesy of FORD MOTOR CO.
  5. Disconnect the EP sensor electrical connector and position the harness aside.
    6. Fig 5: EP Sensor Tube & Nut
    GF0005690Courtesy of FORD MOTOR CO.
  6. Disconnect the fitting at the exhaust manifold and remove the nut and the EP sensor tube.
    • To install, tighten the EP sensor tube support bracket nut to 13 Nm (10 lb-ft).
    • To install, tighten the EP sensor tube fitting at the exhaust manifold to 30 Nm (22 lb-ft).
    7. Fig 6: Vent Tube & Turbocharger Intake Tube
    GF0005691Courtesy of FORD MOTOR CO.
  7. Loosen the clamp at the turbocharger. Disconnect the vent tube and remove the turbocharger intake tube.
    8. Fig 7: Fuel Injector Control Module Fasteners
    GF0005692Courtesy of FORD MOTOR CO.
  8. Remove the fuel injector control module mounting nuts and bolts. Position the module for access to the electrical connectors.
    • To install, tighten to 13 Nm (10 lb-ft).
    9. Fig 8: Fuel Injector Control Module Electrical Connectors
    GF0005693Courtesy of FORD MOTOR CO.
  9. Disconnect the fuel injector control module electrical connectors and remove the fuel injector control module.
    10. Fig 9: Fuel Injector Control Module Mounting Bracket Nuts
    GF0005694Courtesy of FORD MOTOR CO.
  10. Remove the nuts and the fuel injector control module mounting bracket.
    • To install, tighten to 8 Nm (71 lb-in).
    11. Fig 10: Locating Wire Harness Retainer
    G03907047Courtesy of FORD MOTOR CO.
  11. Disconnect the wiring harness retainer and remove the nut and position the oil level indicator and tube aside.
    12. Fig 11: Valve Cover Fasteners
    GF0005695Courtesy of FORD MOTOR CO.
    CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
    NOTE: Mark the position of the valve cover bolts for valve cover bolt installation.
  12. Remove the 5 bolts, the 6 stud bolts and the valve cover. Clean and inspect the valve cover gasket, and install a new gasket if necessary.
    • To install, tighten to 9 Nm (80 lb-in).
    13. CAUTION: With the engine cold, fill vehicles with a yellow fill level decal to within the yellow cold fill range shown on the decal. If the decal is missing, fill the degas bottle only to the molded line. The correct fill level on these vehicles is between the molded line and 15 mm (0.59 in) below the line. These fill levels will allow for coolant expansion. Overfilling the degas bottle may result in damage to the pressure cap, which can cause the engine to overheat.
  13. To install, reverse the removal procedure.
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