HowToRepairGuide.com: How to replace Valve Covers on Ford Truck 6.0L Diesel 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 details for

6.0L Diesel Engine
Left Side

CAUTION

Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or result in personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle (coolant reservoir) when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When certain all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions can result in personal injury.

The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly and the system filled with new coolant.

Always fill the cooling system with the same type of coolant that was drained from the system. Do not mix coolant types.

Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle (coolant reservoir).

When adding engine coolant, use a 50/50 mixture of engine coolant and distilled water.

To maintain the integrity of the coolant and the cooling system:

Add Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) meeting Ford specification WSS-M97B51-A1. Always fill the cooling system with the same type of coolant that was drained from the system. Do not mix coolant types.

Do not add orange-colored Motorcraft Specialty Orange Engine Coolant VC-2 or equivalent meeting WSS-M97B44-D. Mixing coolants may degrade the coolant's corrosion protection.

Do not add alcohol, methanol, brine, or any engine coolants mixed with alcohol or methanol anti-freeze. These can cause engine damage from overheating or freezing.

All vehicles:

Remove the air cleaner assembly.

Relieve the cooling system pressure and disconnect and cap the engine vent hose and the radiator vent hose.

Remove the bolts and position the degas bottle (coolant reservoir) aside.

Release the two exhaust pressure sensor harness pin-type retainers.

Disconnect the exhaust pressure sensor electrical connector and position the harness aside.

To remove the exhaust pressure sensor tube assembly, remove the exhaust pressure sensor tube retaining nut and disconnect the exhaust pressure sensor tube fitting at the exhaust manifold.

Fig. Exhaust pressure sensor tube-6.0L Diesel Engine

Loosen the clamp at the turbocharger. Disconnect the vent tube and remove the turbocharger intake tube.

Remove the fuel injector control module retaining nuts and bracket.

Fig. Fuel injector control module-6.0L Diesel Engine

All vehicles:

Remove the fuel injector control module mounting bolts and position the module for access to the electrical connectors.

Disconnect the fuel injector control module electrical connectors. Remove the fuel injector control module.

Remove the fuel injector control module mounting bracket.

Disconnect the wiring retainer. Remove the nut and position the oil level indicator and tube aside.

WARNING
To prevent engine damage, do not use air-powered tools when installing the valve cover.

NOTE
Mark the position of the valve cover bolts for valve cover bolt installation.

Remove the 11 bolts and the valve cover. Clean and inspect the valve cover gasket, and install a new gasket if necessary.

Fig. Left side valve cover-6.0L Diesel Engine

To install:

To install, reverse the removal procedure.

Tighten the valve cover bolts to 80 inch lbs. (9 Nm).

Right Side

All vehicles:

Remove the wheel and tire assembly.

If equipped with running boards, loosen the running board bolts.

Remove the front fender splash shield pin-type retainers.

Remove the front fender splash shield.

Fig. Fender splash shield fasteners, (1) screws, (2) nuts, (3) bolts-F-250 and F-350 6.0L Diesel Engine

Loosen the clamp at the charge-air-cooler (CAC).

NOTE
If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler duct to prevent the duct from blowing off.

Fig. CAC clamp-F-250 and F-350 6.0L Diesel Engine

Loosen the clamp at the turbocharger and remove the CAC duct.

Disconnect the wiring retainers from the studs. Disconnect the pushpin retainer and injection control pressure (ICP) electrical connector. Disconnect the glow plug module electrical connectors.

Disconnect the wire retainers.

Remove the four nuts and the glow plug module mounting bracket.

Remove the ICP sensor.

Fig. Glow plug module mounting bracket-F-250 and F-350 6.0L Diesel Engine

Fig. ICP sensor-F-250 and F-350 6.0L Diesel Engine

Vehicles with automatic transmission:

Remove the nut and position the transmission fluid indicator and tube assembly aside.

All vehicles:

WARNING

To prevent engine damage, do not use air-powered tools when installing the valve cover.

NOTE

Mark the position of the valve cover bolts for valve cover bolt installation.

Remove the 11 bolts and the valve cover. Clean and inspect the valve cover gasket and install a new gasket, if necessary.

Fig. Right side valve cover-F-250 and F-350 6.0L Diesel Engine

Remove the high-pressure oil manifold to valve cover gasket.

Fig. High-pressure oil manifold to valve cover gasket-F-250 and F-350 6.0L Diesel Engine