Left Side

REMOVAL

Accelerator Control Splash Shield:

1. Disconnect battery ground cable and remove accelerator control splash shield and air cleaner outlet tube.
2. Disconnect three vacuum hoses on the intake manifold vacuum outlet fitting.
3. Remove upper intake manifold.
4. Remove bolt from air conditioning pipe over upper intake manifold if not already done.

Air Conditioning Compressor Wiring:

5. Disconnect air conditioning compressor clutch connector and, using door trim panel remover tool, remove wiring harness from back of A/C compressor.

A/C Compressor Bolts:

6. Remove air conditioning compressor bolts, pull up tube that goes around back of engine and reposition A/C compressor and tube out of the way.
7. Remove power brake vacuum hose and disconnect the other five hoses from intake manifold vacuum outlet fitting and cap on plenum. Tag hoses to aid installation.

Upper Intake Manifold With PCV Valve And Hose:

8. Remove PCV hose and valve.
9. Remove wiring harness from valve cover with door trim panel remover tool and position out of the way.
10. Remove spark plug wires from the spark plugs and clips on valve cover.
11. Remove engine wiring harness clip from valve cover-to-intake manifold stud. Do not pull on harness. Lift up on clip with your thumb.
12. Remove retaining bolt from fuel hose clip to front of engine to allow fuel hoses to be moved enough to gain access to upper front valve cover bolt.
13. Remove bolts, rocker arm cover flange plates, and valve cover.

INSTALLATION
1. Clean valve cover, cylinder head, and intake manifold gasket surfaces.
2. Locate the valve cover gasket on the valve cover and push the valve cover screws through the bolt holes. The interference between the valve cover screws and valve cover gasket will hold the screws in place.
3. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G32-A to the left intake manifold-to-cylinder head parting seam and an 8 mm (1/8 inch) ball of sealer to valve cover bolt holes on exhaust side of cylinder head.

NOTE: Since silicone rubber will set up within 15 minutes, if you are installing both covers, apply to one side at a time.

4. Install the valve cover, rocker arm cover flange plates, and bolts. Snug bolts starting from center bolts and working in crisscross pattern to end bolts. Tighten in same pattern to 5-8 Nm (4.5-5.9 in lb).

NOTE: Stud goes in upper rear hole.

Upper Intake Manifold:

5. Install upper intake manifold and tighten nuts to 20-25 Nm (15-18 ft lb).

NOTE: Connect three vacuum hoses on the intake manifold vacuum outlet fitting.

6. Install fuel hose clip-to-front of engine retaining bolt.
7. Install the spark plug wires on spark plugs and clips.
8. Install wiring harness clips onto valve cover and rear valve cover stud.
9. Install positive crankcase ventilation valve and hose.
10. Put A/C compressor and tube that goes around back of engine back into place.
11. Install air conditioning compressor bolts and tighten to 24-30 Nm (18-22 ft lb).
12. Connect five vacuum hoses on intake manifold vacuum outlet fitting and cap on plenum and install power brake vacuum hose.
13. Install wiring harness and clip to back of A/C compressor and plug in air conditioning clutch connector.
14. Connect battery ground cable, start engine and check for leaks.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.