Valve Cover: Installation

Fuel Pump and Brake Vacuum Pump Mounting Brackets 

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.

   Make sure that the mating faces are clean and free of foreign material.

   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

   Courtesy of FORD MOTOR COMPANY

2. 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.

   Make sure that the mating faces are clean and free of foreign material.

   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

   Courtesy of FORD MOTOR COMPANY

3. 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.

   Make sure that the mating faces are clean and free of foreign material.

   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

   Courtesy of FORD MOTOR COMPANY

4. NOTE: The components must be installed within 5 minutes of applying the sealant.

   Apply a 1.5 mm (0.059 in) beads of gasket maker as shown.

   Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

   Courtesy of FORD MOTOR COMPANY

5. • Install the brake vacuum pump cap, bolts and the stud.

     Torque: 89 lb.in (10 Nm)

   • Install the engine cover mounting stud.

     Torque: 89 lb.in (10 Nm)

   Courtesy of FORD MOTOR COMPANY

6. NOTE: Use a new O-ring seal.
   • Tighten the fuel pump bracket bolts in sequence shown in 4 stages.

     Torque: Stage 1: 27 lb.in (3 Nm) Stage 2: 80 lb.in (9 Nm) Stage 3: 97 lb.in (11 Nm) Stage 4: Tighten bolts 1, 2, 5, 6, 7, 8, 9 and 10 to: 124 lb.in (14 Nm)

   Fig 1: Fuel Pump Mounting Bracket Tightening Sequence

   Courtesy of FORD MOTOR COMPANY
7. • Install the CMP sensor and the bolt.

     Torque: 80 lb.in (9 Nm)

   • Connect the electrical connector and slide the protective cover onto connector.

   Courtesy of FORD MOTOR COMPANY

8. Install the following items:
   1. Install the brake vacuum pump. Refer to: Brake Vacuum Pump - 1.6L EcoBoost (132kW/180PS) - Sigma .
   2. Install the fuel pump. Refer to: Fuel Pump .

   Valve Cover Only 

9. 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.
   NOTE: Clean if replacing the valve cover gasket only.

   Make sure that the mating faces are clean and free of foreign material.

   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

   Courtesy of FORD MOTOR COMPANY

10. Install the new valve cover gasket.

    Courtesy of FORD MOTOR COMPANY

11. NOTE: The components must be installed within 5 minutes of applying the sealant.

    Apply a 1.5 mm (0.059 in) beads of gasket maker as shown.

    Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

    Courtesy of FORD MOTOR COMPANY

12. Apply a 1.5 mm (0.059 in) beads of gasket maker as shown.

    Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

    Courtesy of FORD MOTOR COMPANY

13. Install the valve cover and the bolts in sequence shown in 3 stages.

    Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 80 lb.in (9 Nm) Stage 3: 89 lb.in (10 Nm)

    Fig 2: Valve Cover Tightening Sequence

    Courtesy of FORD MOTOR COMPANY
14. NOTE: The O-ring seals are to be reused unless damaged.

    Lubricate the VCT oil control solenoid O-ring seal.

    Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    Courtesy of FORD MOTOR COMPANY

15. Install the VCT oil control solenoids, bolts and connect the electrical connectors.

    Torque: 71 lb.in (8 Nm)

    Courtesy of FORD MOTOR COMPANY

16. • Install the PCV hose, connect the couplings and attach the retainer.
    • Install the oil level indicator. Connect the breather hose. Use the General Equipment: Hose Clamp Remover/Installer
    • Install the CMP sensor and the bolt. Connect the electrical connector.

      Torque: 80 lb.in (9 Nm)

    Courtesy of FORD MOTOR COMPANY

17. 1. Install the PCV hose and the clamp. Use the General Equipment: Hose Clamp Remover/Installer
    2. If equipped. Connect the electrical connector.

    Courtesy of FORD MOTOR COMPANY

18. Install the fuel rail. Refer to: Fuel Rail .