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, cleaning mating surfaces, and proper torque sequence installation.

Warnings

Tools required

Parts

• Valve cover gasket kit × 1 — Use OEM Ford specification
• Spark plug tube seals × 6 — Included in gasket kit or separate
• Ignition coil boots (if damaged) × 6 — Inspect during removal

Preparation

1. Park vehicle on level surface and allow engine to cool completely
2. Disconnect negative battery cable and wait 2 minutes for airbag system capacitor discharge
3. Identify which valve cover requires replacement (driver or passenger side)
4. Remove engine cover by pulling upward on front clips and lifting assembly
5. Have valve cover gasket kit and replacement spark plug tube seals ready

Procedure

1. 1

   Remove ignition coil electrical connectors
   Press the locking tab on each ignition coil electrical connector and disconnect all six coils on the affected bank. Mark or photograph connector positions if desired for reference during reassembly.
2. 2

   Remove ignition coils
   Remove the single 8mm bolt from each of the six ignition coils. Carefully twist and pull each coil straight up to remove from spark plug tube. Inspect rubber boots for damage or tearing.
3. 3

   Remove spark plugs (if replacing tube seals)
   If replacing spark plug tube seals, remove all six spark plugs using a spark plug socket. Note that tube seal replacement requires spark plug removal. Clean any debris from spark plug wells before removal to prevent contamination.
   ℹ️Use compressed air to blow out spark plug wells before removing plugs to prevent debris from entering cylinders
4. 4

   Disconnect PCV hose and breather connections
   Disconnect the PCV hose from the valve cover fitting by releasing the quick-connect or clamp. Disconnect any breather hoses or vacuum lines attached to the valve cover. Note positions for reassembly.
5. 5

   Remove valve cover bolts
   Remove all valve cover bolts in reverse of the tightening sequence (outside to inside pattern). There are typically 11 bolts per valve cover on the 3.5L EcoBoost. Keep bolts organized as some may be different lengths.
   ⚠Do not pry on valve cover with metal tools as this can damage the aluminum sealing surface
   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 if stuck. Lift the valve cover straight up and away from the cylinder head. If spark plugs are still installed, work carefully around the tubes.
7. 7

   Remove old spark plug tube seals
   Using needle-nose pliers or a seal pick tool, carefully extract the old spark plug tube seals from the valve cover. These are press-fit seals. Inspect the cylinder head spark plug tube areas for oil pooling or damage.
   Torque spec

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

   Clean all mating surfaces
   Thoroughly clean the valve cover gasket surface and cylinder head mating surface using a plastic gasket scraper. Remove all old gasket material completely. Wipe surfaces clean with brake cleaner and lint-free rags. Ensure no debris falls into the engine.
   ⚠Never use metal scrapers on aluminum valve cover or head surfaces as gouges will cause leaks
   ⚠Cover open cylinder head ports with clean rags to prevent debris from entering engine
9. 9

   Install new spark plug tube seals
   Lightly lubricate new spark plug tube seals with clean engine oil. Press new seals into the valve cover bore by hand until fully seated and flush with the valve cover surface. Ensure seals are straight and not cocked during installation.
   Torque spec

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

    Install new valve cover gasket
    Position the new valve cover gasket into the valve cover groove. Ensure the gasket is fully seated in the channel all the way around with no twists or folds. The gasket should fit snugly without adhesive.
    ℹ️Do not use RTV silicone or gasket adhesive unless specifically required by gasket instructions
11. 11

    Install valve cover
    Carefully position the valve cover onto the cylinder head, aligning all bolt holes and ensuring spark plug tubes slide into their seals properly. Start all valve cover bolts by hand before tightening any of them.
12. 12

    Torque valve cover bolts in sequence
    Tighten valve cover bolts in the proper sequence (center outward pattern) to 10 Nm (7 lb-ft). Use a torque wrench and tighten in at least two stages: first to 5 Nm, then final torque to 10 Nm in the same sequence.
    ⚠Over-torquing valve cover bolts can warp the cover and cause leaks. Follow the center-to-outside sequence precisely
    Torque spec

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

    Install spark plugs
    If spark plugs were removed, apply a small amount of anti-seize to the threads (avoiding the electrode end). Install spark plugs by hand first, then torque to 20 Nm (15 lb-ft) using a torque wrench.
14. 14

    Install ignition coils
    Apply a thin layer of dielectric grease to the inside of each ignition coil boot if desired. Carefully press each coil down into its spark plug tube until fully seated. Install and torque the 8mm coil bolt to 8 Nm (6 lb-ft).
15. 15

    Reconnect electrical and hoses
    Reconnect all six ignition coil electrical connectors, ensuring each locks into place with an audible click. Reconnect PCV hose and any breather or vacuum lines to the valve cover fittings. Reconnect battery negative cable.

Reassembly

1. Reinstall engine cover by aligning rear tabs first, then pressing down on front clips until seated
2. Double-check all electrical connections are secure and hoses are properly routed
3. Verify no tools or rags were left in engine compartment

Verification

• Start engine and listen for any abnormal sounds or misfires
• Inspect valve cover area for oil leaks while engine is running
• Allow engine to reach operating temperature and recheck for leaks
• Check for proper engine idle and smooth operation
• Scan for diagnostic trouble codes if check engine light illuminates

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