Right Side

Removal
1. Disconnect battery ground cable.
2. Remove engine appearance cover.
3. Remove right half of cowl vent screen.





4. Disconnect the main emission vacuum supply hose from the surge tank vacuum fitting and EGR valve. Position vacuum supply hose out of the way.
5. Disconnect vacuum tube from intake manifold vacuum union.
6. Disconnect EGR valve to exhaust manifold tube from bottom of EGR valve.
7. Remove power steering left turn pressure hose bracket nut. Position POWER steering left turn pressure hose aside.








8. Remove the two retaining bolts for the transducer mounting bracket from the surge tank. Position the transducer mounting bracket out of the way.
9. Remove the two intake manifold supports from the surge tank and cylinder head.
10. Remove retaining bolts and surge tank stay from front of surge tank.
11. Remove bolt, nuts and surge tank stay from rear of surge tank.





12. Disconnect crankcase ventilation hose.
13. Disconnect intake manifold to surge tank ventilation tube.
14. Disconnect vacuum tube to fuel pressure regulator.

Surge Tank:

15. Loosen intake air connector hose clamps and remove surge tank from engine.
16. Disconnect engine control sensor wiring connector from ignition coils.





17. Remove retaining bolts and ignition coil.
18. Remove two wiring harness guide retaining bolts.
19. Remove two engine sensor control wiring bracket bolts.
20. Remove radio interference capacitor bracket retaining nut.
21. Disconnect crankcase ventilation tube from valve cover.
22. Position engine control sensor wiring aside.

23. NOTE: Valve cover gasket is reusable if not damaged.








Loosen valve cover retaining bolts and stud bolts and carefully remove valve cover from cylinder head. Remove integral valve cover gasket from RH valve cover.

Installation

1. NOTE: Prior to installation, clean valve cover sealing surfaces using a shop towel and Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A.






Apply 8 mm (0.31 inch) diameter bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent sealant meeting Ford specification WSE-M4G323-A6 at two places on the valve cover sealing surfaces where the engine front cover and cylinder heads contact.
2. Install new valve cover gaskets onto RH valve cover.








3. Position valve cover on RH cylinder head. Install eight valve cover bolts. Tighten valve cover bolts and stud bolts to 8-12 Nm (71-106 inch lbs.) within six minutes of applying sealer. Position intake air connector hose clamps as indicated.
4. Connect crankcase ventilation tube to valve cover.
5. Position radio ignition interference capacitor bracket on valve cover. Install retaining nut. Tighten retaining nut to 8-12 Nm (71-106 inch lbs.)
6. Position engine control sensor wiring on valve cover and install two engine sensor control wiring brackets. Install and tighten bracket retaining bolts to 8-12 Nm 71-105 inch lbs.)
7. Install two wiring harness guide retaining bolts. Tighten bolts to 8-12 Nm (71-106 inch lbs.)
8. Install four ignition coils and eight ignition coil retaining bolts. Tighten bolts to 8-12 Nm (71-106 inch lbs.)
9. Connect engine control sensor wiring to four ignition coils.





10. Position surge tank on engine. Align and tighten clamps.





11. Connect intake manifold ventilation tube to surge tank vacuum port.
12. Connect crankcase ventilation hose to valve cover.
13. Position rear surge tank stay and install retaining bolt and two retaining nuts. Tighten retainers to 18-28 Nm (14-20 ft. lbs.)
14. Position front surge tank stay and install retaining bolts. Tighten bolts to 18-28 Nm (14-20 ft. lbs.)
15. Install two intake manifold supports on the surge tank and cylinder head. Install and tighten retaining nuts and bolts to 18-28 Nm (14-20 ft. lbs.)





16. Position transducer mounting bracket to surge tank and install two retaining bolts. Tighten bolt's to 18-28 Nm (14-20 ft. lbs.)
17. Position power steering left turn pressure hose on surge tank stud bolt and install retaining nut. Tighten nut to 8-12 Nm (71-106 inch lbs.)
18. Connect EGR valve to exhaust manifold tube to EGR valve. Tighten fitting to 25-35 Nm (19-25 ft. lbs.)
19. Connect vacuum tube to intake manifold vacuum union.
20. Connect main emission vacuum supply hose to surge tank vacuum fitting and EGR valve.
21. Install cowl vent screen.
22. Install engine appearance cover.
23. Connect battery ground cable.