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    2002 Pontiac Grand Prix 3.8L FI OHV 6cyl

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    See Details

    Ford Mustang 1994-1998 Repair Guide

    Rocker Arm (Valve) Cover

    Print

    REMOVAL & INSTALLATION



    3.8L Engine

    See Figures 1 through 4

    1. Label and detach the spark plug wires from the plugs.
    2.  
    3. Remove the spark plug wire retaining clips from the valve cover mounting bolts.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of the left-hand cylinder head and valve cover assembly (right side is similar)-3.8L engine

    1. For the left-hand valve cover, remove the oil filler cap and detach the crankcase breather hose.
    2.  
    3. For the right-hand valve cover, remove the air inlet tube and the PCV valve.
    4.  
    5. Remove the valve cover mounting bolts, then lift the cover and old gasket up and off of the engine.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 2: After removing all necessary components, remove the valve cover mounting bolts ...



    Click image to see an enlarged view

    Fig. Fig. 3: ... and lift the cover up and off of the cylinder head



    Click image to see an enlarged view

    Fig. Fig. 4: Be sure to remove and discard the old gasket, and to install a new gasket prior to reassembly

    To install:

    Lightly oil the bolt threads prior to installation.

    1. Using solvent, clean the valve cover and cylinder head gasket surfaces of all old gasket material.
    2.  
    3. Place the new gasket on the cylinder head, then install the valve cover.
    4.  
    5. Install the cover mounting bolts, and tighten them to 71-106 inch lbs. (8-12 Nm).
    6.  
    7. If applicable, install the oil filler cap and the crankcase breather hose, or the PCV valve and air inlet tube.
    8.  
    9. Install the spark plug wire retaining clips, and attach the wires to their respective plugs.
    10.  
    11. Start the engine and check for oil leaks.
    12.  

    4.6L SOHC Engine

    See Figure 5

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the air inlet tube from the throttle body and air cleaner housing.
    4.  
    5. For the right-hand cover, perform the following:
      1. Detach the engine wiring from the Mass Air Flow (MAF) and Intake Air Temperature (IAT) sensors.
      2.  
      3. Remove the nut that holds the A/C line to the right-hand, front fender apron, then gently lift the A/C line and feed the MAF and IAT wiring connectors under it. Position the connector out of the way.
      4.  
      5. Relieve fuel system pressure, then detach the fuel lines from the engine.
      6.  
      7. Remove the PCV valve from the rocker arm grommet, and position it out of the way.
      8.  

    6.  
    7. For the left-hand cover, perform the following steps:
      1. Detach the speed control actuator cable from the throttle body and position it aside.
      2.  
      3. Disengage the engine control sensor extension wire connector from the electronic variable orifice sensor and oil pressure sender. Position the wiring out of the way.
      4.  

    8.  


    WARNING
    When separating the spark plug wires from the plugs, only pull on the plug wire boot. Otherwise, the ignition wire may separate from the connector inside the boot, which would require a replacement wire.

    1. Label and disconnect the spark plug wires from the plugs.
    2.  
    3. Remove the spark plug wires and wire retaining clips from the valve cover studs, then set them aside.
    4.  
    5. Remove the valve cover mounting bolts, then lift the cover and old gasket up and off of the cylinder head.
    6.  
    7. Remove the old gasket from the valve cover.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 5: Exploded view of a typical valve cover used on 4.6L SOHC engines

    To install:
    1. Clean the cylinder head and valve cover gasket surfaces of all old gasket material, then cement the new gasket into the groove on the cover. Use Ford Gasket and Trim Adhesive F3AZ-19B508-B, or equivalent.
    2.  
    3. Apply Silicone Gasket and Sealant F6AZ-19562-A, or equivalent, in both places where the engine front cover meets the cylinder head.
    4.  

    Install the valve cover and gasket no more than 4 minutes after applying the sealant.

    1. Install the valve cover with the new gasket onto the cylinder head. Install the mounting bolts and tighten them to 71-106 inch lbs. (8-12 Nm).
    2.  
    3. Attach the spark plug wire retaining clips and the plug wires.
    4.  
    5. For the right-hand cover, install the PCV valve, connect the fuel lines to the engine, install the air inlet tube, and reattach the wiring to the MAF and IAT sensors. Refasten the A/C line to the fender apron with the retaining nut; tighten the nut until snug.
    6.  
    7. For the left-hand cover, attach the wiring to the electronic variable orifice sensor and oil pressure sender. Reconnect the speed control actuator cable.
    8.  
    9. Connect the negative battery cable, then start the engine and check for leaks.
    10.  

    4.6L DOHC Engine

    See Figures 6 and 7

    RIGHT-HAND VALVE COVER
    1. Remove the air inlet tube from the throttle body and air cleaner assembly.
    2.  
    3. Remove the four retaining nuts, then lift the spark plug wire cover off of the valve cover.
    4.  


    WARNING
    When separating the spark plug wires from the plugs, only pull on the plug wire boot. Otherwise, the ignition wire may separate from the connector inside the boot, which would require a replacement wire.

    1. Label, then disconnect the spark plug wires from the plugs with a gentle twist/pull motion.
    2.  
    3. Remove the spark plugs from the cylinder head.
    4.  
    5. Remove the spark plug wires from the valve cover, then set them aside.
    6.  
    7. Remove the valve cover mounting bolts.
    8.  


    WARNING
    The valve cover may be difficult to remove; do not pry or force the valve cover off of the cylinder head. Damage may occur.

    While the valve cover is removed, ensure that the spark plug bore-to-valve cover seals are installed correctly on the spark plug bore towers of the valve cover.

    1. Carefully lift the cover and old gasket up and off of the cylinder head.
    2.  
    3. Remove the old gasket and the spark plug bore seals from the valve cover.
    4.  

    To install:
    1. Clean the cylinder head and valve cover gasket surfaces of all old gasket material, then allow the valve cover and cylinder head to dry completely.
    2.  
    3. Install new spark plug bore-to-valve cover seals; use of sealant on these components is not necessary.
    4.  
    5. Cement the new gasket into the groove on the cover. Use Ford Gasket and Trim Adhesive F3AZ-19B508-B, or equivalent.
    6.  
    7. Apply Silicone Gasket and Sealant F6AZ-19562-A, or equivalent, in both places where the engine front cover meets the cylinder head.
    8.  

    Install the valve cover and gasket no more than 4 minutes after applying the sealant.

    1. Install the valve cover with the new gasket onto the cylinder head. Install the mounting bolts and tighten them in the sequence shown in the accompanying illustration to 71-106 inch lbs. (8-12 Nm).
    2.  
    3. Install the spark plugs and plug wires.
    4.  
    5. Install the spark plug wire cover and retaining nuts onto the valve cover studs. Tighten them to 45-60 inch lbs. (5-7 Nm).
    6.  
    7. Install the air inlet tube.
    8.  
    9. Start the engine and check for leaks.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 6: Exploded view of a typical valve cover used on 4.6L DOHC engines



    Click image to see an enlarged view

    Fig. Fig. 7: When installing the valve covers, be sure to tighten the mounting fasteners in the sequence shown to ensure proper sealing

    LEFT-HAND VALVE COVER

    See Figure 8

    1. Remove the windshield wiper module unit.
    2.  
    3. Detach the PCV valve from the grommet in the valve cover, then position it aside.
    4.  
    5. Remove the oil level dipstick tube retaining nut from the valve cover.
    6.  
    7. Remove the four retaining nuts, then lift the spark plug wire cover off of the valve cover.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 8: During valve cover removal, the PCV valve must be separated from the rubber grommet in the valve cover


    WARNING
    When separating the spark plug wires from the plugs, only pull on the plug wire boot. Otherwise, the ignition wire may separate from the connector inside the boot, which would require a replacement wire.

    1. Label, then disconnect the spark plug wires from the plugs with a gentle twist/pull motion.
    2.  
    3. Remove the spark plugs from the cylinder head.
    4.  
    5. Remove the spark plug wires from the valve cover, then set them aside.
    6.  
    7. Remove the valve cover mounting bolts.
    8.  


    WARNING
    The valve cover may be difficult to remove; do not pry or force the valve cover off of the cylinder head. Damage may occur.

    1. Carefully lift the cover and old gasket up and off of the cylinder head.
    2.  
    3. Remove the old gasket and the spark plug bore seals from the valve cover.
    4.  

    To install:
    1. Clean the cylinder head and valve cover gasket surfaces of all old gasket material, then allow the valve cover and cylinder head to dry completely.
    2.  
    3. Install new spark plug bore-to-valve cover seals; use of sealant on these components is not necessary.
    4.  
    5. Cement the new gasket into the groove on the cover. Use Ford Gasket and Trim Adhesive F3AZ-19B508-B, or equivalent.
    6.  
    7. Apply Silicone Gasket and Sealant F6AZ-19562-A, or equivalent, in both places where the engine front cover meets the cylinder head.
    8.  

    Install the valve cover and gasket no more than 4 minutes after applying the sealant.

    1. Install the valve cover with the new gasket onto the cylinder head. Install the mounting bolts and tighten them in the sequence shown in the accompanying illustration to 71-106 inch lbs. (8-12 Nm).
    2.  
    3. Install the spark plugs and plug wires.
    4.  
    5. Install the spark plug wire cover and retaining nuts onto the valve cover studs. Tighten them to 45-60 inch lbs. (5-7 Nm).
    6.  
    7. Situate the oil level dipstick tube bracket onto the valve cover stud, then install the retaining nut and tighten it to 71-106 inch lbs. (8-12 Nm).
    8.  
    9. Install the PCV valve into the valve cover grommet.
    10.  
    11. Install the windshield wiper module unit.
    12.  
    13. Start the engine and check for leaks.
    14.  

    5.0L Engine

    See Figures 9 through 12

    1. Disconnect the negative battery cable for safety purposes.
    2.  
    3. Remove the upper intake manifold assembly from the vehicle. For details, please refer to the intake manifold procedure later in this section.
    4.  
    5. If you are removing the right valve cover, disconnect the PCV closure tube from the oil fill stand pipe at the valve cover.
    6.  
    7. Remove the Thermactor/secondary air bypass valve and air supply hoses, as necessary, to gain clearance.
    8.  
    9. Loosen and remove the valve cover bolts.
    10.  
    11. Lift off the valve cover from the engine. It may be necessary to break the cover loose by rapping on it with a rubber mallet. NEVER pry the cover off, as you could damage the gasket sealing surfaces!
    12.  



    Click image to see an enlarged view

    Fig. Fig. 9: Exploded view of the valve covers and gasket mounting-5.0L engine



    Click image to see an enlarged view

    Fig. Fig. 10: Once access to the valve covers is clear, loosen and remove the retaining bolts



    Click image to see an enlarged view

    Fig. Fig. 11: Carefully break the gasket seal and remove the valve cover from the engine



    Click image to see an enlarged view

    Fig. Fig. 12: Clean the gasket mating surfaces, taking care to keep debris out of the engine

    To install:
    1. Thoroughly clean the mating surfaces of both the valve cover and cylinder head.
    2.  
    3. Place the new gasket on the valve cover with the locating tabs engaging the slots.
    4.  
    5. Place the valve cover on the cylinder head, making sure the gasket is evenly seated. Tighten the valve cover retaining bolts to 12-15 ft. lbs. (16-20 Nm).
    6.  
    7. If removed for access, install the Thermactor/secondary air bypass valve and air supply hoses.
    8.  
    9. If you are installing the right valve cover, connect the PCV closure tube to the oil fill stand pipe.
    10.  
    11. Install the upper intake manifold assembly.
    12.  
    13. Connect the negative battery cable.
    14.  

     
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