Valve Cover

Removal

Valve Cover Only

1. Refer to: Fuel Rail (303-04B Fuel Charging and Controls - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
   

1. General Equipment : Hose Clamp Remover/Installer

1. NOTE: Note the position of the components before removal.

1. NOTE: The O-ring seals are to be reused unless damaged.

1. NOTE: Do not set the valve cover sealing surface face down on a bench as the check valve and splitter leg is susceptible to breakage.

Fuel Pump and Brake Vacuum Pump Mounting Brackets

1. Remove the following items:
   1. Refer to: Fuel Pump (303-04B Fuel Charging and Controls - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
      
   2. Refer to: Brake Vacuum Pump - 1.6L EcoBoost (132kW/180PS) - Sigma (206-07 Power Brake Actuation, Removal and Installation).
      

1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the fuel pump mounting bracket. Failure to follow these directions may result in damage to the fuel pump mounting bracket.

   General Equipment : Hot Air Gun

1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the brake vacuum pump mounting bracket. Failure to follow these directions may result in damage to the brake vacuum pump mounting bracket.

   General Equipment : Hot Air Gun

Installation

Fuel Pump and Brake Vacuum Pump Mounting Brackets

1. NOTICE: 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.

   Material : Motorcraft® Metal Surface Prep / ZC-31-A

1. NOTICE: 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.

   Material : Motorcraft® Metal Surface Prep / ZC-31-A

1. NOTICE: 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.

   Material : Motorcraft® Metal Surface Prep / ZC-31-A

1. NOTE: The components must be installed within 5 minutes of applying the sealant.

   Material : Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

1. Torque : 10 Nm

1. NOTE: Use a new O-ring seal.

   Tighten bolts 1 through 10 to:
   Torque :
     Stage 1:  3 Nm
     Stage 2:  9 Nm
     Stage 3:  11 Nm
     Stage 4:  Tighten bolts 1, 2, 5, 6, 7, 8, 9 and 10 to 14 Nm

1. Torque : 9 Nm

1. Install the following items:
   1. Refer to: Brake Vacuum Pump - 1.6L EcoBoost (132kW/180PS) - Sigma (206-07 Power Brake Actuation, Removal and Installation).
      
   2. Refer to: Fuel Pump (303-04B Fuel Charging and Controls - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
      

Valve Cover Only

1. NOTICE: 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.

   NOTE: Clean if replacing the valve cover gasket only.

   Material : Motorcraft® Metal Surface Prep / ZC-31-A

1. NOTE: The components must be installed within 5 minutes of applying the sealant.

   Material : Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

1. Material : Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

1. Torque :
     Stage 1:  5 Nm
     Stage 2:  9 Nm
     Stage 3:  10 Nm

1. NOTE: The O-ring seals are to be reused unless damaged.

   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. Torque : 8 Nm

1. General Equipment : Hose Clamp Remover/Installer
   Torque : 9 Nm

1. Refer to: Fuel Rail (303-04B Fuel Charging and Controls - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
   

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