Valve Cover Gasket - Single

This procedure covers replacement of a single valve cover gasket on the 3.5L EcoBoost V6 engine, including removal of ignition coils, spark plugs, and associated hardware.

Warnings

Tools required

Parts

• Valve cover gasket × 1 — Use OEM Motorcraft specification
• Spark plug tube seals × 3 — Use OEM specification
• Valve cover bolt grommets (if damaged) × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cold to the touch
2. Disconnect negative battery terminal and wait 2 minutes for capacitor discharge
3. If replacing passenger side cover: remove engine air filter housing and intake tube
4. Remove engine cover by pulling upward on front clips
5. If replacing driver side cover: disconnect any hoses or wiring harnesses blocking access
6. Have clean shop towels ready to cover open spark plug holes

Procedure

1. 1

   Remove ignition coils
   Disconnect the electrical connector from each ignition coil by pressing the release tab and pulling straight up. Remove the single bolt securing each coil using an 8mm socket. Grasp each coil firmly and pull straight up with a twisting motion to break the seal. Remove all three coils from the valve cover you're servicing.
2. 2

   Remove spark plugs
   Using compressed air or a vacuum, clean debris from around each spark plug before removal. Use a spark plug socket with extension to carefully remove all three spark plugs. Inspect plugs for wear or fouling. Cover the spark plug holes with clean shop rags to prevent debris entry.
   ⚠Do not allow any debris, tools, or parts to fall into spark plug holes. Even small objects can damage pistons or valves.
3. 3

   Disconnect PCV hose and breather tube
   Locate the PCV (Positive Crankcase Ventilation) hose connected to the valve cover. Squeeze the quick-disconnect collar and pull the hose free. Disconnect the breather tube from the opposite side of the cover in the same manner. Note the routing for reinstallation.
4. 4

   Remove electrical harness bracket
   Locate the wiring harness bracket(s) bolted to the valve cover. Remove the mounting bolt(s) and carefully move the harness aside without straining wires. Some harnesses may have clips that snap onto the cover - carefully pry these free.
5. 5

   Remove valve cover bolts
   Remove all valve cover bolts in a criss-cross pattern starting from the outside and working inward. There are typically 11 bolts per cover on the EcoBoost. Keep the bolts organized and inspect the rubber grommets on each bolt - replace if cracked or compressed. Note the locations of any stud bolts versus standard bolts.
   Torque spec

   Valve Cover Bolts10 Nm (7 lb-ft)
6. 6

   Remove valve cover
   Gently tap the valve cover with a rubber mallet to break the gasket seal. Do not pry between the cover and cylinder head as this can damage sealing surfaces. Lift the cover straight up and away. The gasket may stick to either the cover or head.
7. 7

   Remove old spark plug tube seals
   Using needle-nose pliers or a seal removal tool, carefully extract the three spark plug tube seals from the cylinder head. These are press-fit rubber seals that sit in the valve cover recess around each spark plug tube. Inspect the tubes for any oil residue indicating a previous leak.
   Torque spec

   Spark Plug Tube Seals12 Nm (9 lb-ft)
8. 8

   Clean sealing surfaces
   Remove all old gasket material from both the valve cover and cylinder head using a plastic scraper. Do not use metal tools that could gouge aluminum surfaces. Clean both surfaces thoroughly with brake cleaner and lint-free rags. Ensure no debris falls into the engine. Inspect the cylinder head surface for warping or damage.
   ⚠Ensure all gasket material and cleaning solvent residue is completely removed. Any remaining debris will cause oil leaks.
9. 9

   Install new spark plug tube seals
   Lightly oil the outer diameter of the new spark plug tube seals. Press each seal squarely into its bore in the cylinder head by hand until fully seated. The seals should sit flush or slightly below the head surface. Do not use excessive force or tools that could damage the seals.
   Torque spec

   Spark Plug Tube Seals12 Nm (9 lb-ft)
10. 10

    Install new valve cover gasket
    Position the new gasket onto the valve cover, ensuring it seats properly in the cover groove. The gasket should snap into place and stay positioned. Verify all bolt holes align and the gasket is not twisted or pinched anywhere. Some technicians apply a small dab of RTV at the front corners where the timing cover meets the head for added sealing.
11. 11

    Install valve cover
    Carefully position the valve cover with new gasket onto the cylinder head, ensuring the spark plug tube seals align with the cover recesses. Install all bolts with their grommets finger-tight first. Verify the cover is seated evenly all around before tightening.
12. 12

    Torque valve cover bolts in sequence
    Tighten the valve cover bolts in the proper sequence: start at the center and work outward in a spiral pattern. Torque all bolts to 10 Nm (7 lb-ft) in two stages - first to 5 Nm, then final torque to 10 Nm. Do not over-torque as this will distort the cover and cause leaks.
    ⚠Exceeding specified torque will compress the gasket unevenly and may cause oil leaks or cover warping.
    Torque spec

    Valve Cover Bolts10 Nm (7 lb-ft)
13. 13

    Reinstall electrical harness and hoses
    Reattach the wiring harness bracket(s) to the valve cover. Reconnect the PCV hose and breather tube, ensuring both click securely into place. Verify no hoses are kinked or strained.
14. 14

    Install spark plugs
    Apply a small amount of anti-seize compound to the threads of each spark plug (avoid getting any on the electrode). Thread each plug by hand first to prevent cross-threading. Use the torque wrench to tighten spark plugs to exactly 20 Nm (15 lb-ft). Do not exceed this torque on aluminum heads.
    ⚠Cross-threading or over-torquing spark plugs in aluminum heads can strip threads, requiring expensive thread repair or head replacement.
15. 15

    Reinstall ignition coils
    Apply a thin coat of dielectric grease to the inside of each ignition coil boot. Push each coil straight down onto its spark plug until fully seated - you should feel it snap into place. Install the coil retaining bolt and torque to 8 Nm (6 lb-ft). Reconnect all electrical connectors until they click.

Reassembly

1. Reinstall any intake components or air filter housing that were removed for access
2. Reinstall engine cover by aligning clips and pressing down firmly until seated
3. Reconnect negative battery terminal and torque to specifications
4. Double-check all electrical connectors are fully seated and locked

Verification

• Start the engine and inspect for oil leaks around the valve cover perimeter, paying special attention to corners and spark plug tube areas
• Allow engine to reach operating temperature and verify no leaks develop
• Check for any unusual engine noises or misfires that could indicate improper coil or spark plug installation
• Verify engine runs smoothly at idle and under acceleration
• Re-inspect for leaks after 50-100 miles of driving and retorque valve cover bolts if necessary

More procedures for this vehicle