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Valve Cover: Installation

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  1. NOTE: 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.

    Clean and inspect the sealing surfaces.

  2. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

    Using the 205-153  (T80T-4000-W) and 303-1247/2  , install new VCT solenoid seals.

    Fig 1: Installing VCT Solenoid Seals Using Adapter
    G08028536Courtesy of FORD MOTOR CO.
  3. NOTE: The valve cover must be secured within 10 minutes of sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep.

    Apply a 5.5 mm (0.216 in) drop of Silicone Gasket and Sealant to the 6 locations shown in illustration.

    Fig 2: Identifying Drop Of Silicone Gasket And Sealant On Engine
    G08028537Courtesy of FORD MOTOR CO.
  4. Using a new gasket install the valve cover.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
    Fig 3: Identifying Valve Cover Bolt Tightening Sequence
    G08028538Courtesy of FORD MOTOR CO.
  5. Connect the 2 vacuum hoses to the vacuum reservoir.
    • Connect the vacuum tube quick connect coupling. REFER to QUICK CONNECT COUPLING .
    • Attach the 3 vacuum hose retainers.
    Fig 4: Locating Vacuum Reservoir Hoses And Retainers
    G08028533Courtesy of FORD MOTOR CO.
  6. Connect the 5 engine wiring harness electrical connectors.
    • Attach the 6 wiring harness retainers.
    Fig 5: Locating Engine Wiring Harness Electrical Connectors And Retainers
    G08028532Courtesy of FORD MOTOR CO.
  7. Connect the FRP  sensor and the MAP sensor electrical connectors.
    Fig 6: Locating FRP Sensor And MAP Sensor Electrical Connectors
    G08028531Courtesy of FORD MOTOR CO.
  8. Install the CAC  intermediate tube mounting bracket, the nut and the bolt.
    • Tighten to 8 Nm (71 lb-in).
      • Install the oil level indicator.
    Fig 7: Locating CAC Intermediate Tube Mounting Bracket Bolt And Nut
    G08028530Courtesy of FORD MOTOR CO.
  9. Connect the fuel supply tube from the fuel jumper tube and the fuel jumper tube from the fuel injection pump. REFER to QUICK CONNECT COUPLING .
    • Attach the 2 fuel tube retainers to the intake manifold.
    • Install the fuel jumper tube bolt.
    • Tighten to 8 Nm (71 lb-in).
    Fig 8: Locating Fuel Jumper Tube Bolt And Retainers
    G08028529Courtesy of FORD MOTOR CO.
  10. Install the coil-on-plug assemblies. REFER to ENGINE IGNITION SYSTEM - 2.0L-GTDI
  11. Install the ACL  outlet pipe, the turbocharger inlet pipe and the CAC  inlet/intermediate inlet tube assembly. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
  12. Install the underbody shield and the 4 retainers.
    Fig 9: Locating Underbody Shield Retainers
    G08030560Courtesy of FORD MOTOR CO.
  13. Connect the EVAP  canister purge valve electrical connector and vapor tube. REFER to QUICK CONNECT COUPLING .
    Fig 10: Identifying EVAP Canister Purge Valve Electrical Connectors
    G08028527Courtesy of FORD MOTOR CO.
  14. Connect the battery ground cable. REFER to BATTERY DISCONNECT .
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