Ford Explorer: Engine - 2.3L EcoBoost (201kW/273PS) / Removal and Installation - Valve Cover

Special Tool(s) / General Equipment

	205-153 (T80T-4000-W) Handle
	303-1687 Installer, VCT Solenoid Seal
Side Cutter Pliers
Hose Clamp Remover/Installer

Materials

Removal

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Release the fuel system pressure.
   Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 2.3L EcoBoost (201kW/273PS), General Procedures).
   

1. Disconnect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Remove the bolts and the suspension support bar.
   

1. NOTICE: Do not pull the engine appearance cover forward or sideways to remove. Failure to press straight upward on the underside of the cover at the attachment points may result in damage to the cover or engine components.

   1. Remove the engine appearance cover nuts.
      
   2. Place your hand under the engine appearance cover at the grommet location and push straight up to release the grommet from the stud.
      
   3. After the grommet has been released from the stud, remove the appearance cover from the engine.
      

1. Drain the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling - 2.3L EcoBoost (201kW/273PS), General Procedures).
   

1. Remove the following items:
   1. Remove the cowl panel.
      Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
      
   2. Remove the air cleaner.
      Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
      

1. Remove the oil level indicator.
   

1. 1. Disconnect the coolant hoses from the coolant tubes.
      
   2. Detach the fuel tube retainer.
      
   3. Remove the coolant tube bolt.
      
   4. Remove the coolant tube nut and position the coolant tubes aside.
      

1. Remove the following items:
   1. Remove the high-pressure fuel pump.
      Refer to: High-Pressure Fuel Pump (303-04A Fuel Charging and Controls - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
      
   2. Remove the ignition coil-on-plugs.
      Refer to: Ignition Coil-On-Plug (303-07A Engine Ignition - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
      

1. NOTE: The crankcase vent tube may have either a permanent or quick connect connector at one or both ends. If the tube needs to be removed for any reason, the permanent connector(s) must be cut to remove the tube. The tube will then need to be replaced.

   NOTE: If the crankcase vent tube is replaced, the replacement part may not come with a crankcase pressure sensor. If so, the PCM will need to be reprogrammed.

   • If equipped, disconnect the wiring harness electrical connector.
     
   • If necessary, cut the lock tab.
     Use the General Equipment: Side Cutter Pliers
   • If either crankcase vent tube connector was cut, remove and discard the crankcase vent tube.
     

1. • Disconnect the wiring harness electrical connectors and retainer.
     
   • Detach the HO2S electrical connector from the bracket.
     

1. 1. Release the clamp and remove coolant hose from coolant tube.
      Use the General Equipment: Hose Clamp Remover/Installer
   2. Remove the coolant tube bracket bolt.
      
   3. Remove the coolant tube bolt and the bracket.
      

1. Disconnect the CHT sensor wiring harness electrical connector and detach the retainers.
   

1. • Disconnect the wiring harness electrical connectors.
     
   • Detach the wiring harness retainers.
     
   • Position the wiring harness aside.
     

1. Loosen the fasteners and remove the valve cover.
   

1. Remove and discard the valve cover gaskets.
   

1. NOTE: The VCT solenoid seals should only be replaced if they are damaged.

   • Inspect the VCT oil control solenoid seals for damage.
     
   • If damaged, using the special tools, remove and discard the VCT oil control solenoid seals.
     Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 303-1687  Installer, VCT Solenoid Seal.

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.
   

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.
   

Installation

1. NOTE: Installation of new seals is only required if damaged seals were removed during removal.

   If removed, using the special tools, install the VCT oil control solenoid seals.
   Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 303-1687  Installer, VCT Solenoid Seal.

1. Install a new valve cover gaskets.
   

1. Apply a 5.5 mm (0.22 in) bead of silicone sealant in the 4 places shown.
   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

1. NOTE: The valve cover must be secured within 10 minutes of silicone gasket application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned.

   Install the valve cover and tighten the fasteners in sequence shown.
   Torque: 97 lb.in (11 Nm)

1. • Position the wiring harness.
     
   • Attach the wiring harness retainers.
     
   • Connect the wiring harness electrical connectors.
     

1. Connect the CHT sensor wiring harness electrical connector and attach the retainers.
   

1. 1. Install the coolant tube bracket and the bolt.
      Torque: 97 lb.in (11 Nm)
   2. Install the coolant tube bracket bolt.
      Torque: 53 lb.in (6 Nm)
   3. Install coolant hose to coolant tube and position clamp.
      Use the General Equipment: Hose Clamp Remover/Installer

1. • Attach the HO2S electrical connector to the bracket.
     
   • Connect the wiring harness electrical connectors and retainer.
     

1. • Install the new crankcase vent tube.
     
   • If the replacement crankcase vent tube part comes with no crankcase pressure sensor, reprogram the PCM.
     Refer to: Module Programming (418-01 Module Configuration, General Procedures).
     
   • If the replacement crankcase vent tube came without a crankcase pressure sensor, tape the wiring harness electrical connector back to the wiring harness.
     
   • If the replacement crankcase vent tube comes with a crankcase pressure sensor, connect the wiring harness electrical connector.
     

1. Install the following items:
   1. Install the ignition coil-on-plugs.
      Refer to: Ignition Coil-On-Plug (303-07A Engine Ignition - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
      
   2. Install the high-pressure fuel pump.
      Refer to: High-Pressure Fuel Pump (303-04A Fuel Charging and Controls - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
      

1. 1. Position the coolant tubes and install the nut.
      Torque: 62 lb.in (7 Nm)
   2. Install the coolant tube bolt.
      Torque: 124 lb.in (14 Nm)
   3. Attach the fuel tube retainer.
      
   4. Connect the coolant hoses to the coolant tubes.
      

1. Remove the oil level indicator.
   

1. Install the following items:
   1. Install the air cleaner.
      Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
      
   2. Install the cowl panel.
      Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
      

1. Connect the battery ground cable.
   Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
   

1. Fill the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling - 2.3L EcoBoost (201kW/273PS), General Procedures).
   

1. 1. NOTE: Lubricating the grommets with silicone grease will aid in the installation of the engine appearance cover, and any future removal and installation of the cover.

      Lubricate each grommet with silicone grease.
      Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)
   2. Position the engine appearance cover onto engine with the grommet aligned with the stud.
      
   3. Press down on the engine appearance cover at the grommet location to attach the grommet onto the stud and install the nuts.
      Torque: 44 lb.in (5 Nm)

1. Install the suspension support bar and the bolts.
   Torque: 22 lb.ft (30 Nm)

1. Pressurize the fuel system.
   Refer to: Fuel System Pressure Release (310-00A Fuel System - General Information - 2.3L EcoBoost (201kW/273PS), General Procedures).