Aerostar 2WD V6-183 3.0L (1991)
Valve Cover: Service and Repair
Right Side
NOTE: The rocker covers installed on the engine incorporate integral (built-in) gaskets which should last the life of the vehicle. Be sure to adhere to the
following steps when removing and replacing rocker covers. Replacement gaskets are available if required.
REMOVAL
1. Disconnect negative battery terminal and set aside.
2. Remove air cleaner fresh air hose.
3. With a turning motion, disconnect ignition wires from spark plugs.
4. Remove ignition wire/separator assembly from rocker arm cover retaining studs and move out of the way.
5. Perform the following:
a. Remove oil filler tube assembly.
b. Remove fuel injector harness stand-offs from inboard rocker arm cover studs. Move harness out of the way.
c. Remove air cleaner closure hose from oil fill adapter.
6. Remove rocker cover retaining bolts and studs noting their location.
7. Using caution, slide a sharp, thin bladed knife between cylinder head gasket surface and rocker cover gasket at four RTV junctions. Cut only the
RTV sealer and avoid cutting the integral gasket. Carefully lift the cover from the cylinder head ensuring RTV sealer is not pulling the gasket from
the cover.
8. Remove integral gasket by pulling from rocker cover gasket channel. Note bolt/stud locations before removing gasket as fasteners are secured by
gasket.
9. Clean gasket channel with soft cloth to remove all dirt.
10. Using a suitable solvent, clean off any remaining RTV sealant.
INSTALLATION
1. Aligning fastener holes, lay new gasket onto channel and install with finger.
2. Install gasket to each fastener by securing fastener head with a nut driver or socket. Seat fastener against cover and, at the same time, roll gasket
around fastener collar. If installed correctly, all fasteners will be secured by gasket and will not fall out.
NOTE: Check gasket for correct installation. New gasket will lay flat to the rocker cover in both the channel and fastener areas. If the gasket is
installed incorrectly, oil leakage will occur.
Valve Cover Assembly
3. Apply bead of silicone sealant (ESE-M4G195-B) at cylinder head to intake manifold rail step (two places per rail) as illustrated.
4. Carefully position cover on the cylinder head and install two retaining bolts and six studs. Tighten to 10-14 Nm (7-10 ft lb).
NOTE: Lightly oil all bolt and stud threads before installation. Using solvent, clean cylinder head and rocker arm cover sealing surfaces to
