How to replace Valve Covers on 2005 Ford Explorer?

Valve Covers

Removal & Installation

4.0L (VIN E) SOHC Engine

NOTE

Always use new gaskets when installing the valve covers.

Left Hand Cover

1. Disconnect the negative battery cable.
2. Remove the upper intake manifold.
3. Remove the two fuel line upper bracket bolts.
4. Detach the Camshaft Position (CMP) sensor electrical connection.
5. Disconnect the wire harness from the Differential Pressure Feedback (DPFE) transducer, which is mounted to the valve cover.
6. Label and detach the two vacuum lines connected to the DPFE transducer.
7. Disconnect the engine electrical multi-plug and remove it from the valve cover.
8. Detach the wire harness connections on the coil pack.
9. Label and remove the spark plug cables from the coil pack.
10. Remove the valve cover hold-down bolts and remove the valve cover. Discard the old valve cover gasket.
    
    NOTE

    A gentle tap with a soft hammer may help to break the seal on the gasket.
    
    
    
    WARNING

    Never pry between the valve cover and the cylinder head. Damage to the machined sealing surface, or distortion to the valve cover could occur, resulting in an oil leak.

To install:

1. Thoroughly clean the mating surfaces of the engine and cover.
2. Install a new gasket to the cover and place the cover in position on the engine.
3. Install all of the hold-down bolts and tighten to 80 inch lbs (9 Nm).
4. Attach the spark plug cables to the coil pack.
5. Attach the wire harness connections to the coil pack.
6. Install and connect the engine electrical multi-plug to the valve cover.
7. Attach the vacuum lines and electrical connections to the DPFE transducer.
8. Connect the CMP sensor harness.
9. Install the two fuel line upper bracket bolts.
10. Install the upper intake manifold.
11. Connect the negative battery cable.
12. Allow the engine to reach normal operating temperature (upper radiator hose hot) and check for leaks.

Right Hand Cover

1. Disconnect the negative battery cable.
2. Remove the upper intake manifold.
   
   CAUTION

   When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
3. Drain the cooling system until the coolant is below the upper radiator hose.
4. Remove the upper radiator hose and the connector tube behind the alternator.
5. Remove the bolts securing the heater hose bracket and the transmission dipstick tube.
6. Label and disconnect the spark plug cables from their plugs and wire looms.
7. Remove the valve cover hold-down bolts and remove the cover from the engine. Discard the old valve cover gasket.
   
   NOTE

   A gentle tap with a soft hammer may help to break the seal on the gasket.
   
   
   
   WARNING

   Never pry between the valve cover and the cylinder head. Damage to the machined sealing surface, or distortion to the valve cover could occur, resulting in an oil leak.

To install:

1. Thoroughly clean the mating surfaces of the engine and cover.
2. Install a new gasket to the cover and place the cover in position on the engine.
3. Install all of the hold-down bolts and tighten to 80 inch lbs (9 Nm).
4. Attach the spark plug cables to their wire looms and plugs.
5. Install the upper radiator hose assembly and the tube securing bolt.
6. Install the upper intake manifold.
7. Refill the cooling system and run the engine.
8. Connect the negative battery cable.
9. Allow the engine to reach normal operating temperature (upper radiator hose hot) and check for leaks.

4.0L Ohv Engine (VIN X)

NOTE

Failure to install new valve cover gaskets and valve cover reinforcement pieces will result in oil leaks.

1. Disconnect the negative battery cable. Tag and remove the spark plug wires.
2. Disconnect and remove the fuel supply and return lines.
3. For left valve cover removal, remove the upper intake manifold.
4. For right valve cover removal, remove the air inlet duct and hose to oil fill tube and the alternator. Drain the cooling system and remove the upper radiator hose from the engine. Remove the EDIS ignition coil and bracket assembly. Remove the A/C low pressure hose bracket if so equipped. Remove the PCV valve hose and breather.
   
   
   

   

   Fig. To remove the valve cover, first disconnect the crankcase breather vent tube
   
   
   
   

   

   Fig. Label and unplug any electrical connections . . .
   
   
   
   

   

   Fig. . . . as well as vacuum fittings which will inhibit valve cover removal
   
   
   
   

   

   Fig. Remove the coil pack mounting bracket attaching bolts . . .
   
   
   
   

   

   Fig. . . . then remove the coil pack and bracket from the engine
5. Remove the valve cover bolts and load distribution pieces. The washers must be installed in their original positions, so keep track of them.
6. Remove the valve cover. It will probably be necessary to tap the cover loose with a plastic or rubber mallet.
7. Remove the valve cover gaskets.
   
   
   

   

   Fig. Remove the valve cover hold-down bolts . . .
   
   
   
   

   

   Fig. . . . then remove the cover from the engine. A slight tap with a soft-faced hammer helps to break the seal
   
   
   
   

   

   Fig. Remove the old valve cover gasket and discard

To install:

1. Clean all gasket material from the cover and head.
   
   
   

   

   Fig. Rocker arm cover installation on 4.0L engines
2. Installation is the reverse of removal. Always use a new gasket coated with sealer. If any of the RTV silicone gasket material was removed from the mating area of the head(s) and intake manifold, replace it. Torque the bolts to 3-5 ft. lbs.
3. Reconnect the negative battery cable. Start the engine and run to normal operating temperature and check for oil and fuel leaks.