Page 1 of 20 Service Manual: ENGINE - 5.4L (3V)- F-150 & MARK LT IN-VEHICLE SERVICING > VALVE COVER - RH 2008 Ford Pickup 5.4L Eng F150 Material Item Specification Motorcraft Metal Surface Prep ZC-31 PAG Refrigerant Compressor Oil R-134a Systems YN-12-D Silicone Gasket Remover ZC-30 Silicone Gasket and Sealant TA-30 - WSH-M1C231-B - WSE-M4G323-A4
Page 2 of 20 Fig 1: Exploded View Of Tube & Wiring Harness Retainer Connections With Torque Specifications Item Part Number Description 1 N804758 A/C compressor manifold tube assembly nut 2 19836 A/C compressor manifold tube assembly 3 - A/C compressor manifold tube O-ring seal 4 - Suction accumulator-to-a/c compressor manifold tube stud 5 6758 Crankcase vent tube assembly quick-connect fitting
Page 3 of 20 6 - Engine wiring harness retainers (part of 12B637) 7 - Variable camshaft timing (VCT) solenoid electrical connector (part of 12B637) Fig 2: Exploded View Of RH Valve Cover & Gasket Item Part Number Description 8 6582 RH valve cover 9 6584 RH valve cover gasket IN-VEHICLE SERVICING > VALVE COVER - RH > REMOVAL 1. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article. 2. Remove the PCM and bracket. For additional information, refer to ELECTRONIC ENGINE CONTROLS article. 3. Remove the RH ignition coils. For additional information, refer to ENGINE IGNITION - 5.4L (3V) article.
Page 4 of 20 4. Remove the nut and disconnect the A/C compressor manifold tube. 1. Discard the O-ring seals. 5. Remove the suction accumulator-to-a/c compressor manifold tube stud. 6. Disconnect the evaporator inlet tube fitting. 1. Discard the O-ring seals. Fig 1: Locating Evaporator Inlet Tube Fitting 7. Disconnect the quick connect couplings and remove the crankcase ventilation tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article. 8. If equipped, disconnect the vacuum tube.
Page 5 of 20 Fig 2: Vacuum Tube 9. Disconnect the variable camshaft timing (VCT) solenoid electrical connector. 10. Detach the engine harness retainer and position the harness aside.
Page 6 of 20 Fig 3: Positioning Engine Harness And Attaching Retainer 11. Remove the battery cover. 12. Remove the transmission fluid level indicator tube retaining bolt and position the fluid indicator tube aside.
Page 7 of 20 Fig 4: Identifying Transmission Filler Tube Retaining Bolt CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: The fasteners are part of the valve cover and should not be removed. 13. Loosen the fasteners and remove the RH valve cover and gasket. 1. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 2. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent. IN-VEHICLE SERVICING > VALVE COVER - RH > INSTALLATION
Page 8 of 20 NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. 1. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head. Fig 1: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid. 2. Position the RH valve cover and new gasket on the cylinder head and tighten the fasteners in the sequence shown. 1. Tighten to 10 Nm (89 lb-in).
Page 9 of 20 Fig 2: Tightening RH Valve Cover In Sequence 3. Position the transmission fluid level indicator tube and install the bolt. 1. Tighten to 20 Nm (15 lb-ft).
Page 10 of 20 Fig 3: Identifying Transmission Filler Tube Retaining Bolt 4. Install the battery cover. 5. Position the engine harness and attach the retainer.
Page 11 of 20 Fig 4: Positioning Engine Harness And Attaching Retainer 6. Connect the VCT solenoid electrical connector. 7. If equipped, connect the vacuum tube.
Page 12 of 20 Fig 5: Vacuum Tube 8. Position the crankcase ventilation tube and connect the quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article. 9. Using new O-rings, connect the evaporator inlet tube fitting.
Page 13 of 20 Fig 6: Locating Evaporator Inlet Tube Fitting 10. Install the suction accumulator-to-a/c compressor manifold tube stud. 1. Tighten to 8 Nm (71 lb-in). 11. Lubricate the new A/C compressor manifold tube O-ring seals with refrigerant compressor oil. Position the A/C compressor manifold tube and install the nut. 1. Tighten to 25 Nm (18 lb-ft). 12. Install the RH ignition coils. For additional information, refer to ENGINE IGNITION - 5.4L (3V) article. 13. Install the PCM bracket and the PCM. For additional information, refer to ELECTRONIC ENGINE CONTROLS article. 14. Evacuate, leak test and charge the refrigerant system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article. IN-VEHICLE SERVICING > VALVE COVER - LH Material Item Specification
Page 14 of 20 Motorcraft Metal Surface Prep ZC-31 Silicone Gasket and Sealant TA-30 Silicone Gasket Remover ZC-30 - WSE-M4G323-A4 - Fig 1: Exploded View Of Power Steering Pump Reservoir With Torque Specifications Item Part Number Description 1 180101 Power steering reservoir support bracket nut 2 N806155 Power steering reservoir support bracket bolt 3 9A758 Power steering reservoir support bracket and reservoir assembly
Page 15 of 20 Fig 2: Exploded View Of Tube & Electrical Connections Item Part Number Description 4 6K817 PCV tube 5 - Intake manifold vacuum tube-to-brake booster hose clamp 6 - Intake manifold vacuum tube-to-brake booster hose 7 9D446 Intake manifold vacuum tube 8 - Engine wiring harness retainers (part of 12B637) 9 -
Page 16 of 20 LH variable camshaft timing (VCT) solenoid electrical connector (part of 12B637) 10 - LH radio ignition interference capacitor electrical connector (part of 12B637) Fig 3: Exploded View Of LH Valve Cover & Gasket Item Part Number Description 11 6A505 LH valve cover 12 6A559 LH valve cover gasket IN-VEHICLE SERVICING > VALVE COVER - LH > REMOVAL 1. Remove the air cleaner intake pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article. 2. Remove the LH ignition coils. For additional information, refer to ENGINE IGNITION - 5.4L (3V) article. 3. Remove the oil level indicator and tube. For additional information, refer to Oil Level Indicator and Tube.
Page 17 of 20 4. Remove the bolt and the nut and position the power steering reservoir and bracket assembly aside. 5. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article. 6. Disconnect the intake manifold vacuum tube hose from the brake booster. 7. Disconnect the intake manifold vacuum tube from the support bracket and the valve cover stud. 8. Disconnect the radio ignition interference capacitor electrical connector. 9. Disconnect the variable camshaft timing (VCT) solenoid electrical connector and the wiring harness retainers. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: The fasteners are part of the valve cover and should not be removed. 10. Loosen the fasteners and remove the LH valve cover and gasket. 1. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 2. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent. IN-VEHICLE SERVICING > VALVE COVER - LH > INSTALLATION NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. 1. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
Page 18 of 20 Fig 1: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head CAUTION: When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid. 2. Position the LH valve cover and new gasket on the cylinder head and tighten the fasteners in the sequence shown. 1. Tighten to 10 Nm (89 lb-in).
Page 19 of 20 Fig 2: Tightening LH Valve Cover In Sequence 3. Position the intake manifold vacuum tube assembly onto the support bracket and the valve cover stud. 4. Connect the VCT solenoid electrical connector and the wiring harness retainers.
Page 20 of 20 5. Connect the radio ignition interference capacitor electrical connector. 6. Position the PCV tube and connect the quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article. 7. Connect the intake manifold vacuum tube hose to the brake booster. 8. Position the power steering reservoir and bracket assembly and install the bolt. 1. Tighten to 25 N.m (18 lb-ft). 9. Install the power steering reservoir and bracket assembly nut. 1. Tighten to 10 N.m (89 lb-in). 10. Install the oil level indicator and tube. For additional information, refer to Oil Level Indicator and Tube. 11. Install the LH ignition coils. For additional information, refer to ENGINE IGNITION - 5.4L (3V) article. 12. Install the air cleaner intake pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.