This procedure covers removal and replacement of both valve cover gaskets on the 3.5L EcoBoost V6 engine, including ignition coil removal and proper torque sequence.

Warnings

Tools required

Parts

• Left valve cover gasket × 1 — Motorcraft OEM or equivalent
• Right valve cover gasket × 1 — Motorcraft OEM or equivalent
• Spark plug tube seals (set of 6) × 1 — Often included with valve cover gaskets
• Ignition coil boots (if damaged) × 6 — Inspect during removal

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery terminal and wait 5 minutes
3. Remove engine cover by pulling upward on front and rear lift points
4. Disconnect any wiring harness clips attached to valve covers
5. Label or photograph ignition coil positions for correct reinstallation

Procedure

1. 1

   Remove ignition coils - both banks
   Disconnect the electrical connector from each ignition coil by pressing the release tab. Remove the single bolt securing each coil using an 8mm socket. Carefully pull each coil straight up with a twisting motion to break the seal. If coils are stuck, use an ignition coil puller tool or carefully pry with pliers at the boot area only.
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
2. 2

   Remove spark plugs
   Use compressed air to blow out any debris from around spark plug wells. Remove all six spark plugs using a spark plug socket. Inspect plugs for condition and set aside if reusing. Cover spark plug holes with clean shop towels to prevent debris entry.
   Torque spec

   Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
3. 3

   Disconnect PCV hoses and breather tubes
   Disconnect the PCV hoses from both valve covers. On the driver side, disconnect the crankcase breather tube. Use a small flathead screwdriver to carefully release hose clamps if equipped. Note the routing of all hoses for reinstallation.
   ℹ️PCV hoses may be brittle. Inspect for cracks and replace if necessary.
4. 4

   Remove valve cover bolts - passenger side
   Remove all valve cover bolts in reverse of tightening sequence (outside to inside) using a 10mm socket. There are typically 9-11 bolts per cover. Keep bolts organized as some may be different lengths. Carefully lift the valve cover straight up. If stuck, gently tap with a rubber mallet at corners only, never pry at sealing surfaces.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
5. 5

   Remove valve cover bolts - driver side
   Repeat the removal process for the driver side valve cover. Remove all bolts in reverse sequence and lift cover straight up. The driver side may require moving additional wiring harnesses out of the way.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
6. 6

   Remove old spark plug tube seals
   Remove the old spark plug tube seals from each cylinder head. These are press-fit rubber seals in the spark plug wells. Use needlenose pliers or a pick tool to carefully extract them. Ensure no debris falls into the cylinder head during removal.
   Torque spec

   Spark Plug Tube Seals0 Nm (0 lb-ft)
7. 7

   Clean sealing surfaces
   Thoroughly clean all gasket mating surfaces on both valve covers and cylinder heads using a plastic scraper. Remove all old gasket material and oil residue. Spray with brake cleaner and wipe with lint-free towels. Inspect surfaces for damage or warping. The mating surfaces must be completely clean and dry.
   ⚠Do not use metal scrapers on aluminum surfaces. This will create scratches that cause leaks.
8. 8

   Install new spark plug tube seals
   Install new spark plug tube seals into each spark plug well on both cylinder heads. Lightly lubricate seals with clean engine oil. Press seals firmly into place by hand until fully seated. Verify each seal is seated evenly and flush with the cylinder head surface.
   Torque spec

   Spark Plug Tube Seals0 Nm (0 lb-ft)
9. 9

   Install new valve cover gaskets
   Position new valve cover gaskets onto the valve covers (not the cylinder heads). Ensure gaskets are properly seated in the valve cover grooves. Most gaskets have locating features or are adhesive-backed. Verify all bolt holes align correctly and gasket is not twisted or pinched anywhere.
10. 10

    Install valve covers
    Carefully position each valve cover onto its respective cylinder head, ensuring gaskets remain properly seated. Start all bolts by hand to ensure proper thread engagement. Tighten valve cover bolts in sequence from center outward using a torque wrench to specification. Follow the torque sequence pattern: start at center bolts and work outward in a criss-cross pattern.
    ⚠Over-tightening valve cover bolts will deform the cover and cause oil leaks. Use a torque wrench and follow proper sequence.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
11. 11

    Reinstall spark plugs
    Apply a small amount of anti-seize compound to spark plug threads (avoid getting on electrode end). Install spark plugs by hand first to avoid cross-threading. Tighten to specification using a torque wrench.
    ⚠Cross-threading spark plugs in aluminum heads will require expensive thread repair. Start all plugs by hand first.
    Torque spec

    Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
12. 12

    Reinstall ignition coils
    Inspect ignition coil boots for cracks or damage and replace if necessary. Apply a small amount of dielectric grease to inside of each boot. Press each ignition coil firmly into its spark plug well until fully seated. Install the retaining bolt and tighten to specification. Reconnect electrical connectors to each coil.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)
13. 13

    Reconnect PCV and breather systems
    Reconnect all PCV hoses and crankcase breather tubes to their original positions. Ensure all hose clamps are properly secured. Verify no hoses are kinked or pinched.
14. 14

    Reconnect electrical and install engine cover
    Reconnect any wiring harness clips that were removed from valve covers. Reconnect negative battery terminal. Reinstall engine cover by aligning mounting points and pressing down until clips engage.

Reassembly

1. Double-check that all electrical connectors are fully seated and locked
2. Verify all hoses are properly routed and not contacting hot exhaust components
3. Ensure no tools or shop towels were left in engine bay

Verification

• Start engine and allow to idle for 2-3 minutes while monitoring for oil leaks around valve cover perimeter
• Check for rough idle or misfire codes that would indicate ignition coil connection issues
• Rev engine to 2000 RPM briefly and recheck for leaks at operating pressure
• After test drive, recheck valve cover bolts for proper torque and inspect for any oil seepage

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