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    2009 Ford Truck F450 Super Duty P/U 4WD 6.4L Turbo Diesel 8cyl

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    Use Code: SEECLEAR

    See Details

    Ford Sable, Taurus 2000-05

    Valve Covers

    Print

    Removal & Installation



    3.0L DOHC Engine
    Left Side
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the crankcase ventilation tube from the vehicle.
    4.  
    5. Unfasten the nuts that attach the engine wiring to the studs on the valve cover. Position wiring aside.
    6.  
    7. Tag and disconnect the spark plug wires from the spark plugs and valve cover.
    8.  
    9. Unfasten the valve cover retainers in the sequence shown.
    10.  
    11. Remove the valve cover from the cylinder head, then remove the gasket from the valve cover.

      Click image to see an enlarged view

      Fig. Remove the left hand valve cover retainers in the sequence shown-3.0L DOHC engines

    12.  

    To install:

    1. Clean the valve cover sealing surfaces using a clean shop towel and metal surface cleaner F4AZ-19A536-RA or its equivalent to remove all residues that would interfere with the sealers ability to adhere.
    2.  
    3. Apply a 0.31 inch (8mm) bead of silicone gasket and sealant F6AZ-19562-AA or its equivalent at the two places on the valve cover sealing surfaces where the engine front cover and the cylinder head contact. Refer to the accompanying illustration.
    4.  
    5. Install the valve cover gaskets onto the valve cover.
    6.  
    7. Place the valve cover into position and install the cover retainers. Tighten the retainers to 71-106 inch lbs. (8-12 Nm) within 6 minutes of applying the sealer.
    8.  
    9. Connect the spark plug wires to the plugs and position the wires on the valve cover.
    10.  
    11. Place the wiring in position and install the retaining nuts.
    12.  
    13. Install the crankcase ventilation tube.
    14.  
    15. Connect the negative battery cable.

      Click image to see an enlarged view

      Fig. Tighten the left hand valve cover retainers in the sequence shown-3.0L DOHC engines

    16.  

    Right Side
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the upper intake manifold.
    4.  
    5. Tag and disconnect the spark plug wires from the spark plugs and the ignition coil.
    6.  
    7. Remove the ignition coil.
    8.  
    9. Remove the crankcase ventilation tube from the vehicle.
    10.  
    11. Unfasten the nuts that attach the engine wiring and the evaporative emission return tube to the studs on the valve cover. Position wiring and tube aside.
    12.  
    13. Unfasten the valve cover retainers in the sequence shown.
    14.  
    15. Remove the valve cover from the cylinder head, then remove the gasket from the valve cover.

      Click image to see an enlarged view

      Fig. Remove the right hand valve cover retainers in the sequence shown-3.0L DOHC engines

    16.  

    To install:

    1. Clean the valve cover sealing surfaces using a clean shop towel and metal surface cleaner F4AZ-19A536-RA or its equivalent to remove all residues that would interfere with the sealers ability to adhere.
    2.  
    3. Apply a 0.31 inch (8mm) bead of silicone gasket and sealant F6AZ-19562-AA or its equivalent at the two places on the valve cover sealing surfaces where the engine front cover and the cylinder head contact. Refer to the accompanying illustration.
    4.  
    5. Install the valve cover gaskets onto the valve cover.
    6.  
    7. Place the valve cover into position and install the cover retainers. Tighten the retainers to 71-106 inch lbs. (8-12 Nm) within 6 minutes of applying the sealer.
    8.  
    9. Place the return tube and wiring in position and install the retaining nuts.
    10.  
    11. Install the crankcase ventilation tube.
    12.  
    13. Install the ignition coil and connect the spark plug wires.
    14.  
    15. Install the upper intake manifold.
    16.  
    17. Connect the negative battery cable.

      Click image to see an enlarged view

      Fig. Apply a bead of silicone sealant at the two places on the valve cover sealing surfaces where the engine front cover and the cylinder head contact-3.0L DOHC engines



      Click image to see an enlarged view

      Fig. Tighten the right hand valve cover retainers in the sequence shown-3.0L DOHC engines

    18.  

    3.0L Ohv Engine
    1. Disconnect the negative battery cable.
    2.  
    3. Tag and disconnect the spark plug wires.
    4.  
    5. Remove the ignition wire/separator assembly from the rocker arm attaching bolt studs.
    6.  
    7. Remove the left rocker arm cover as follows:
      1. Remove the oil fill cap.
      2.  
      3. Disconnect the crankcase ventilation hose.
      4.  
      5. Remove the engine control sensor wiring from the valve cover studs.
      6.  
      7. Unfasten the engine sensor control wiring retaining nuts from the valve cover and position the wiring out of the way.
      8.  
      9. Loosen the valve cover retaining bolts and studs, then carefully slide a sharp thin bladed putty knife between the valve cover gasket and the cylinder head at the step where the intake manifold mates to the cylinder head (two places on each side). Make sure you cut only the gasket sealer and not the integral valve cover gasket.
      10.  
      11. Remove the valve cover making sure the gasket sealer does not pull off the valve cover gasket from the gasket.
      12.  
      13. If necessary, remove the valve cover gasket by pulling it from the channel in the cover. Note the bolt and stud locations before removing the gasket as the fasteners are secured by the gasket.
      14.  
      15. Clean the valve cover gasket channel with a soft cloth to remove any dirt, then using a suitable solvent clean off any remaining silicone sealant.
      16.  

    8.  
    9. Remove the right rocker arm cover as follows:
      1. Remove the upper intake manifold.
      2.  
      3. Loosen the EGR valve-to-exhaust manifold tube nut and rotate the tube aside.
      4.  
      5. Remove the PCV valve.
      6.  
      7. Remove the engine control sensor wiring harness from the valve cover studs
      8.  
      9. Unfasten the engine sensor control wiring retaining nuts from the valve cover and position the wiring out of the way.
      10.  
      11. Loosen the valve cover retaining bolts and studs, then carefully slide a sharp thin bladed putty knife between the valve cover gasket and the cylinder head at the step where the intake manifold mates to the cylinder head (two places on each side). Make sure you cut only the gasket sealer and not the integral valve cover gasket.
      12.  
      13. Remove the valve cover making sure the gasket sealer does not pull off the valve cover gasket from the gasket.
      14.  
      15. If necessary, remove the valve cover gasket by pulling it from the channel in the cover. Note the bolt and stud locations before removing the gasket as the fasteners are secured by the gasket.
      16.  
      17. Clean the valve cover gasket channel with a soft cloth to remove any dirt, then using a suitable solvent clean off any remaining silicone sealant.
      18.  

    10.  

    To install:

    1. Lightly oil the valve cover retaining bolts and studs before installation.
    2.  
    3. Check the valve cover gasket for correct installation. The new valve cover gasket will lay flat to the valve cover in both the channel and fastener areas. If the gasket is installed incorrectly oil leakage will occur.
    4.  
    5. While aligning the fastener holes, lay the new gasket into the cover channel.
    6.  
    7. Install the valve cover gasket to each fastener by securing the fastener head with a nut driver or with a socket. Seat the fastener against the valve cover and at the same time, roll the gasket around the fastener collar. If the gasket is installed correctly, the fasteners will be secured by the gasket and not fall out.
      NOTE
      Prior to installing sealer, clean the sealing surfaces using metal surface cleaner F4AZ-19A536-RA or its equivalent to remove all residues that would interfere with the sealers ability to adhere.

    8.  
    9. Apply a 1 / 4 inch (6mm) bead of silicone gasket and sealant F6AZ-19562-AA or its equivalent at the cylinder head-to-intake manifold step (two places per side) as shown in the accompanying illustration.
      NOTE
      Use a straight down approach when installing the valve cover. Any adjustments mad after the sealer has made contact may roll over the gasket from the cover channel, which will result in a leak.

    10.  
    11. Position the valve cover onto the cylinder head and install its retainers. Tighten the retainers in the sequence illustrated to 89-123 inch lbs. (10-14 Nm).
    12.  
    13. Install the remaining components to left hand valve cover as follows:
      1. Install the oil filler cap.
      2.  
      3. Attach the crankcase ventilation tube to the connector
      4.  
      5. Attach the engine control sensor wiring harness-s to the appropriate stud.
      6.  
      7. Install the wiring-to-valve cover stud retainers and tighten to 23-30 inch lbs. (2.5-3.5 Nm).
      8.  

    14.  
    15. Install the remaining components to right hand valve cover as follows:
      1. Attach the engine control sensor wiring harness-s to the appropriate stud.
      2.  
      3. Install the wiring-to-valve cover stud retainers and tighten to 23-30 inch lbs. (2.5-3.5 Nm).
      4.  
      5. Install the PCV valve and connect the crankcase ventilation tube.
      6.  
      7. Connect the EGR valve-to-exhaust tube to the EGR valve. Tighten the retaining nuts to 26-47 ft. lbs. (35-65 Nm).

        Click image to see an enlarged view

        Fig. Remove the spark plug wire retainers from the valve cover retaining studs



        Click image to see an enlarged view

        Fig. Remove the oil separator hose from the oil fill cap opening (LH valve cover only)



        Click image to see an enlarged view

        Fig. Remove the fuel injector harness retaining nuts and . . .



        Click image to see an enlarged view

        Fig. . . . remove the harness from the valve cover retaining studs



        Click image to see an enlarged view

        Fig. Remove the retaining bolts/studs and remove the valve cover from the cylinder head



        Click image to see an enlarged view

        Fig. Remove the valve cover gasket from the valve cover



        Click image to see an enlarged view

        Fig. Thoroughly clean the cylinder head-to-valve cover mating surface before installing the valve cover



        Click image to see an enlarged view

        Fig. Apply silicone sealant to the ends of the cylinder head



        Click image to see an enlarged view

        Fig. Valve cover tightening sequence-3.0L OHV engines



        Click image to see an enlarged view

        Fig. Exploded view of the valve cover assembly and valve cover sealer application location-3.0L OHV engines

      8.  

    16.  

     
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