Ford Fusion: Engine - 1.5L EcoBoost (118kW/160PS) – I4 / Valve Cover. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1. Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 1.5L EcoBoost (118kW/160PS) – I4, General Procedures).
   

1. Remove the engine appearance cover.
   

1. Disconnect the EVAP canister purge valve tubes from the TC inlet pipe.
   

1. • Remove the oil level indicator.
     
   • Disconnect the couplings and remove the hose.
     

1. • Detach the wiring harness retainer from the hose.
     
   • Release the clamps and position the hoses aside.
     Use the General Equipment: Hose Clamp Remover/Installer

1. Remove the fuel rail.
   Refer to: Fuel Rail (303-04A Fuel Charging and Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. NOTE: Note the position of the VCT oil control solenoids before removal.

   • Detach the wiring harness retainers and disconnect the wiring harness electrical connectors.
     
   • Remove the bolts and the VCT oil control solenoids.
     
   • Remove the bolt and the intake CMP sensor.
     

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

   Inspect the VCT oil control solenoid O-ring seal.
   

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.

   Remove the bolts in sequence shown and the valve cover.
   

1. Remove and discard the valve cover gasket.
   

Installation

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.

   Make sure that the mating faces are clean and free of foreign material.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

1. Install the new valve cover gasket.
   

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

   Apply a 1.5 mm (0.059 in) beads of gasket maker as shown.
   Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

1. Apply a 1.5 mm (0.059 in) beads of gasket maker as shown.
   Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

1. Install the valve cover and the bolts in sequence shown in 3 stages.
   Torque:
     Stage 1:  44 lb.in (5 Nm)
     Stage 2:  80 lb.in (9 Nm)
     Stage 3:  89 lb.in (10 Nm)

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

   Lubricate the VCT oil control solenoid O-ring seal.
   Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

1. NOTE: Note the position of the VCT oil control solenoids before removal.

   1. Install the intake CMP sensor and the bolt.
      Torque: 80 lb.in (9 Nm)
   2. Install the VCT oil control solenoids and the bolts.
      Torque: 71 lb.in (8 Nm)
   • Attach the wiring harness retainers and connect the wiring harness electrical connectors.
     

1. Install the fuel rail.
   Refer to: Fuel Rail (303-04A Fuel Charging and Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   

1. • Position the hoses and release the clamps.
     Use the General Equipment: Hose Clamp Remover/Installer
   • Attach the wiring harness retainer to the hose.
     

1. • Install the hose and connect the couplings.
     
   • Install the oil level indicator.
     

1. Connect the EVAP canister purge valve tubes to the TC inlet pipe.
   

1. Install the engine appearance cover.