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How to replace Valve Covers on Ford Truck 6.8L Engine?



The procedure is similar for both ford and Lincoln car models:-----

Ford Truck 4.2L engine Valve Cover removal procedure is as follows.
Its for

F150 1/2 ton P/U 2WD/ 4WD
F250 Super Duty P/U 2WD/4WD
F350 Super Duty P/U 2WD/4WD
F450 Super Duty P/U 2WD/4WD
F550 Super Duty P/U 2WD/4WD
And Lincoln Mark LT car models.


The Valve Covers removal and installation procedure for

6.8L Engine
Left Side
  1. Remove the air cleaner outlet pipe.
  2. Remove the left side ignition coils.
  3. Remove the oil level indicator and tube.
  4. Disconnect the quick connect couplings and remove the positive crankcase ventilation (PCV) tube.
  5. Remove the 2 bolts and position the degas bottle (coolant reservoir) aside.
  6. Disconnect the engine wiring harness retainers from the valve cover studs and position out of the way.
    WARNING
    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. Use a plastic scraping tool to remove all traces of old sealant.


    NOTE
    The bolts are part of the valve cover and should not be removed.
  7. Loosen the 17 fasteners in the sequence shown and remove the left side valve cover and gasket. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent. 

    image
    Fig. Left side valve cover loosening and tightening sequence-6.8L engine


    image
    Fig. Left side valve cover-6.8L engine-1. Wiring retainers, 2. PCV tube, 3. Valve cover, 4. Gasket
To install:

NOTE
If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.

  1. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

    Click image to see an enlarged view
    Fig. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head-6.8L engine
  2. Position the left side valve cover and new gasket on the cylinder head and tighten the 17 fasteners in the sequence shown. Tighten to 10 Nm (89 inch lbs.).
  3. Position the engine wiring harness retainers onto the valve cover studs.
  4. Position the positive crankcase ventilation (PCV) tube and connect the quick connect couplings.
  5. Position the degas bottle (coolant reservoir) and install the 2 bolts. Tighten to 10 Nm (89 inch lbs.).
  6. Install the left side ignition coils.
  7. Install the oil level indicator and tube.
  8. Install the air cleaner outlet tube.
Right Side
  1. Remove the right side ignition coils.
  2. If equipped, remove the automatic transmission filler tube.
    CAUTION
    Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury.



    Click image to see an enlarged view
    Fig. 1. Main vacuum harness 2. Positive crankcase ventilation (PCV) tube 3. Evaporative emission (EVAP) canister purge valve vacuum hose 4. Brake booster vacuum hose 5. PCV heater element screws 6. PCV heater element 7. Upper throttle body (TB) spacer bolts 8. Lower TB spacer bolts 9. TB spacer 10. TB spacer gasket Throttle body spacer and related parts-6.8L engine
  3. Disconnect the battery ground cable.
  4. Remove the throttle body (TB):
    1. Disconnect the main vacuum harness from the TB spacer.
    2. Disconnect the PCV tube from the TB spacer.
    3. Disconnect the EVAP canister purge valve vacuum hose from the TB spacer.
    4. Disconnect the brake booster vacuum hose.
    5. Remove the 2 PCV heated element screws.
    6. Remove the PCV heated element.
    7. Remove the 2 upper TB spacer bolts.
    8. Remove the 4 lower TB spacer bolts and the TB. Discard the TB spacer gasket.

      Click image to see an enlarged view
      Fig. Right side valve cover-6.8L engine-1. PCV tube, 2. valve cover, 3. gasket
  5. Remove the alternator.
  6. Remove the cooling fan shroud.
  7. Install the special tools shown, or their equivalents.
    WARNING
    Only use hand tools when removing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur.



    Click image to see an enlarged view
    Fig. Engine support fixture-6.8L engine
  8. Loosen the transmission mount-to-crossmember nuts.
    WARNING
    Only use hand tools when installing the right side engine mount nut or damage to the engine mount can occur.



    Click image to see an enlarged view
    Fig. Transmission mount-to-crossmember nuts-6.8L engine
  9. Remove the 3 right side engine mount nuts and loosen the 3 left side engine mount nuts.

    Click image to see an enlarged view
    Fig. Right side engine mount nuts; left side similar-6.8L engine
  10. Remove the 4 exhaust manifold-to-catalytic converter nuts.
  11. Disconnect the quick connect couplings and remove the evaporative emissions (EVAP) tube.
  12. Disconnect the engine wiring harness retainers from the valve cover and position out of the way.
  13. Disconnect the quick connect coupling and remove the positive crankcase ventilation (PCV) tube from the valve cover.
  14. Using the special tools, raise the engine.
    WARNING
    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. Use a plastic scraping tool to remove all traces of old sealant.


    NOTE
    The bolts are part of the valve cover and should not be removed.
  15. Loosen the 16 fasteners in the sequence shown and remove the right side valve cover and gasket.
  16. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  17. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

    Click image to see an enlarged view
    Fig. Right side valve cover loosening/tightening sequence-6.8L engine
To install:

NOTE
If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Failure to follow this procedure can cause future oil leakage.



Click image to see an enlarged view
Fig. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head-6.8L engine
  1. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
  2. Position the right side valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown Tighten to 10 Nm (89 inch lbs.).
  3. Lower the engine into position.
    WARNING
    Only use hand tools when installing the right side engine mount nut or damage to the engine mount can occur.
  4. Install the 6 engine mount nuts. Tighten to 175 Nm (129 ft. lbs.).
  5. Position the Y-pipe and install the 4 nuts. Tighten to 40 Nm (30 ft. lbs.).
    WARNING
    Only use hand tools when installing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur.
  6. Tighten the transmission mount-to-crossmember nuts. Tighten to 103 Nm (76 ft. lbs.).
  7. Position the positive crankcase ventilation (PCV) tube and connect the quick connect coupling to the valve cover.
  8. Position the engine wiring harness retainers onto the valve cover.
  9. Position the evaporative emissions (EVAP) tube and connect the quick connect couplings.
  10. Remove the special tools.
  11. Install the generator.
  12. Install the cooling fan shroud.
  13. Install the throttle body adapter. Use new gaskets. Tighten the 2 upper TB spacer bolts to 9 Nm (80 inch lbs.). Tighten an additional 90 degrees. Tighten the 4 lower TB spacer bolts to 9 Nm (80 inch lbs.). Tighten an additional 90 degrees.
  14. Install the right side ignition coils.
  15. If equipped, install the automatic transmission filler tube.




These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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