Valve covers — removal and installation Ford F150
Removal
1. If you’re going to be removing the left valve cover on a 3.5L turbochaged engine or a 3.3L engine, relieve the fuel system pressure (see Fuel and exhaust systems).
2. Disconnect the cable from the negative battery terminal (see Battery – disconnection and reconnection).
3. Remove the engine cover, if equipped.
Left (driver’s side) valve cover
4. Remove the air filter housing (see Fuel and exhaust systems).
2.7L engine
5. Remove the charge air cooler intake pipe (see Fuel and exhaust systems).
6. Remove the throttle body (see Fuel and exhaust systems).
7. Disconnect the quick-connect fittings to the EVAP purge control valve then remove the purge valve from the intake manifold (see Emissions and engine control systems).
8. Disconnect the vacuum hose retainers and wire harness retainers then remove the turbocharger control solenoid bolts (see Fuel and exhaust systems) and move the solenoid out of the way.
9. Remove the engine lifting bracket and
charge air cooler bracket nut/bolts and brackets.
10. Remove the engine oil dipstick.
3.3L Duratec and 3.5L non-turbocharged engines
Detach the vent tube from the valve cover — 3.5L non-turbocharged model shown
11. Disconnect the vent tube from the valve cover.
12. Remove the dipstick.
13. On 3.3L models, remove the high-pressure fuel pump (see High-pressure fuel pump – removal and installation).
3.5L turbocharged engines
14. Remove the dipstick, then disconnect the quick-connectors for the PCV hose and detach the PCV hose from the valve cover and manifold.
15. Remove the nuts securing the charge air cooler bracket from the cylinder head.
16. Disconnect the quick-connectors for the two turbocharger regulator tubes and set them aside then remove the inlet and outlet tube from the turbocharger (see Fuel and exhaust systems).
17. Remove the high-pressure fuel pump (see Fuel and exhaust systems).
Right (passenger’s side) valve cover 2.7L engines
Warning: Wait until the engine is completely cool before beginning this procedure.
18. Drain the cooling system (see Tune-up and routine maintenance).
19. Disconnect the quick-connector fittings for the PCV hose then detach the PCV hose from the valve cover and manifold.
20. Disconnect the main engine wiring harness connectors from the PCM (see Emissions and engine control systems) and move the harness out of the way.
2.1 Disconnect the heater hoses around the right valve cover and cap the hoses.
22. Remove the bracket fasteners and bracket from the front corner of the cylinder head.
23. Remove the coolant pipe mounting bolts and move the coolant pipe out of the way.
3.3L Duratec and 3.5L non-turbocharged engines
Detach the PCV hose from the valve cover
24. Detach the PCV hose from the valve cover.
25. Remove the heater hose retaining nut and move the hose out of the way.
Both valve covers
26. Remove the ignition coils from the cover to be removed (see Engine electrical systems).
Disconnect the electrical connectors from the VCT oil control solenoids in each valve cover. It’s a good idea to mark one of the electrical connectors and solenoids to prevent mixing up the connectors on reassembly
27. Disconnect the two electrical connectors at the valve cover for the VCT solenoids (being careful not to twist the solenoids) and the electrical connectors from the camshaft position sensors (CMP).
Valve cover fasteners — 2.7L turbocharged model shown
Valve cover fasteners — 3.5L non-turbocharged model shown. 3.3L Duratec similar
28. Remove the valve cover fasteners, then separate the wiring/clips and remove the valve cover from the cylinder head. Wiggle the valve cover by hand to detach it from the cylinder head if it’s stuck.
Caution: Do not use a hammer to knock the cover loose. Try to slip a flexible putty knife between the cylinder head and cover to break the gasket seal. Don’t pry at the cover-to-cylinder head joint or damage to the sealing surfaces may occur (leading to oil leaks in the future).
Installation
29. The mating surfaces of each cylinder head and valve cover must be perfectly clean when the covers are installed. Remove all traces of sealant and old gasket material, then clean the mating surfaces with brake cleaner. If there’s sealant or oil on the mating surfaces when the cover is installed, oil leaks may develop.
Check the spark plug tube seals, VCT solenoid seals and valve cover gasket.
If they are in good condition they can be reused
30. Inspect the spark plug seals, the seals for the VCT solenoids and the valve cover gasket. Do not replace them unless necessary.
Check the bolt seals — replace them if they’re not in good condition
31. Make sure the bolt seals are in good condition, too.
Apply RTV sealant to the seams where the front cover meets the cylinder head
32. Apply a bead of RTV sealant to the joints where the engine front cover meets the cylinder head and install the valve cover within four minutes.
33. Carefully position the cover on the cylinder head and install the bolts.
Valve cover bolt tightening sequence — 2.7L engines (left side shown, right side similar)
Valve cover bolt tightening sequence 3.3L and 3.5L engines (left side shown, right side similar)
34. Tighten the bolts a little at a time, in the proper sequence, to the torque listed in this Chapter’s Specifications.
35. The remaining installation steps are the reverse of removal.
36. Start the engine and check carefully for oil leaks as the engine warms up.