Replace both valve cover gaskets on the 3.5L EcoBoost V6 engine to eliminate oil leaks and restore proper sealing of the cylinder heads.

Warnings

Tools required

Parts

• Driver side valve cover gasket × 1 — Use OEM Ford specification
• Passenger side valve cover gasket × 1 — Use OEM Ford specification
• Spark plug tube seals (set of 6) × 1 — Use OEM Ford specification
• Ignition coil boots (if damaged) × 6 — Inspect before ordering

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal and wait 2 minutes for system discharge
4. Remove engine cover by pulling upward on front clips and lifting away
5. Take photos of wire routing and connector positions for reference during reassembly

Procedure

1. 1

   Remove ignition coils
   Disconnect the electrical connectors from all six ignition coils by pressing the release tab and pulling straight up. Remove the ignition coil mounting bolt from each coil using an 8mm socket. Firmly grasp each coil and pull straight up with a twisting motion to break the seal and remove from the spark plug tube. Inspect coil boots for damage or cracking.
   Torque spec

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

   Remove spark plugs
   Use a spark plug socket to remove all six spark plugs. Turn counterclockwise to loosen and remove completely. Inspect spark plug condition and set aside in order if planning to reuse. Clean any debris from around spark plug tubes using compressed air or shop vacuum before proceeding.
   ⚠Do not drop anything into spark plug holes as debris can damage pistons or valves.
   Torque spec

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

   Disconnect electrical connections
   Disconnect all electrical connectors attached to or crossing over the valve covers. This includes camshaft position sensors, variable cam timing solenoids, and any wiring harnesses clipped to the valve covers. Remove any electrical connector mounting bolts and carefully move harnesses aside to provide clearance.
   Torque spec

   Electrical Connector Bolts8 Nm (6 lb-ft)

   Mounting Bolts55 Nm (40 lb-ft)
4. 4

   Remove PCV hoses and breather tubes
   Disconnect the PCV hose from the passenger side valve cover and the breather tube from the driver side valve cover. These may have quick-disconnect fittings or hose clamps depending on configuration. Note routing for reinstallation.
5. 5

   Remove driver side valve cover
   Remove all valve cover bolts using a 10mm socket. There are typically 11 bolts per cover arranged around the perimeter. Gently pry the valve cover loose using a plastic scraper or flathead screwdriver at the designated pry points (usually at the rear). Lift the cover straight up and away. Avoid bending or warping the aluminum cover.
   ⚠Do not pry between mating surfaces as this can damage sealing surfaces. Use only designated pry points.
   Torque spec

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

   Remove passenger side valve cover
   Remove all valve cover bolts using a 10mm socket. Carefully work around any remaining hoses or wiring. Gently pry the valve cover loose at designated pry points and lift straight up to remove. Set covers on a clean surface with gasket side facing up.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
7. 7

   Remove old gaskets and spark plug tube seals
   Carefully remove the old valve cover gaskets from both covers. Remove the old spark plug tube seals from the cylinder heads using a small flathead screwdriver or seal removal tool. Be careful not to damage the aluminum spark plug tube bores in the cylinder head.
   ⚠Spark plug tube seals must be completely removed. Leaving old seal material can cause oil leaks into spark plug tubes.
   Torque spec

   Spark Plug Tube Seals0 Nm (0 lb-ft)
8. 8

   Clean all mating surfaces
   Thoroughly clean the valve cover mating surfaces on both covers and cylinder heads using a plastic gasket scraper. Remove all old gasket material, oil residue, and debris. Clean surfaces with brake cleaner and lint-free rags until completely clean and dry. Inspect for any damage, warping, or deep scratches that could prevent proper sealing.
   ⚠Do not use metal scrapers on aluminum surfaces as they can cause gouges that prevent proper sealing.
   Torque spec

   Gasket Surface Bolts23 Nm (17 lb-ft)
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 using a suitable driver or deep socket slightly smaller than the seal outer diameter. Press until the seal is fully seated and flush with the head surface. Ensure all six seals per side are properly installed.
   Torque spec

   Spark Plug Tube Seals0 Nm (0 lb-ft)
10. 10

    Install new valve cover gaskets
    Position the new gaskets into the grooves in each valve cover. Ensure gaskets are fully seated in the grooves around the entire perimeter and around each bolt hole. The gaskets should fit snugly without adhesive, but a small amount of oil can help them stay in place during installation.
11. 11

    Install valve covers
    Carefully position each valve cover onto its respective cylinder head, ensuring the gasket stays in place and all bolt holes align. Start all valve cover bolts by hand to ensure proper thread engagement. Tighten the bolts in a spiral pattern from the center outward to the specified torque. Follow the tightening sequence stamped on the valve covers or in the service manual.
    ⚠Do not overtighten valve cover bolts as this can distort the cover and cause leaks. Use a torque wrench and follow the proper sequence.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
12. 12

    Reinstall spark plugs
    Apply a small amount of anti-seize compound to the threads of each spark plug, avoiding the electrode area. Thread each spark plug into its respective cylinder by hand until finger-tight to avoid cross-threading. Torque spark plugs to specification using a torque wrench.
    Torque spec

    Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
13. 13

    Reinstall ignition coils
    Apply a thin coat of dielectric grease to the inside of each ignition coil boot. Push each coil firmly into its spark plug tube until it seats on the spark plug. Install the mounting bolt and torque to specification. Reconnect all ignition coil electrical connectors.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)
14. 14

    Reconnect all electrical connections and hoses
    Reinstall all sensor mounting bolts and electrical connector bolts to their proper locations. Reconnect camshaft position sensors, variable cam timing solenoids, and all wiring harnesses using your reference photos. Reconnect PCV hose and breather tubes, ensuring proper routing and secure connections.
    Torque spec

    Electrical Connector Bolts8 Nm (6 lb-ft)

    Mounting Bolts55 Nm (40 lb-ft)
15. 15

    Final inspection and battery reconnection
    Verify all electrical connectors are fully seated and locked. Check that all hoses are properly connected and clamped. Ensure no tools or rags were left in the engine bay. Reinstall engine cover. Reconnect the negative battery terminal.

Reassembly

1. Double-check that all electrical connectors are fully engaged with audible clicks
2. Verify PCV and breather hoses are properly routed and not kinked
3. Ensure engine cover is properly seated on all mounting points

Verification

• Start the engine and allow it to idle for several minutes while monitoring for oil leaks around valve cover perimeters
• Check for any unusual noises or misfires that could indicate improper ignition coil installation
• Inspect valve cover areas after the engine reaches operating temperature and again after a short test drive
• Monitor oil consumption and valve cover area for signs of leakage over the next few hundred miles

More procedures for this vehicle