Zetec Contour Metal Valve Cover Painting (Fits The Focus)

I'm working on a project that I started back a few weeks ago.  Me and a buddy of mine hit up the local U-Pull-It (pull it yourself junkyard) in search of pretty much anything.  Now, it turns out that the Ford Contour shares a lot of parts with our Focus.  I guess the valve cover is one of them. 

Anyway, the fact that it's different is not what makes it cool -- it's the fact that it's metal, which means you can paint it with engine enamel ... and very easily.

Fyi, I got both valve covers pictured below and all necessary parts (gaskets, screws, washers) for 25 bucks.  My DOHC one was in great condition ... had a little corrosion, but nothing that some elbow grease couldn't fix.  As for the Zetec one, mine was disgusting, covered in dried oil.  And it still cleaned up to what you see below.

1)  Go to a junkyard and locate any year Ford Contour with the Zetec motor.  If the yardmaster won't let you go digging for it yourself, check for any 4-cyl Contours because some of the oldest ones weren't tagged as Zetecs.  (In fact, the pic above has an older "non-Zetec" valve cover on it.)  The two different ones are pictured below. 

2)  Get it out.  You'll need 10mm sockets to remove the 10 bolts on the top of the valve cover.  You'll also need 8mm sockets (or 5/16th ... I needed both) to remove the plastic cover that goes over the cam gears. 

When you remove the valve cover, make sure that you get:
- all 10 bolts and any washers that are attached to them ... do not discard ANYTHING
- the gasket ... two different Ford dealers down here had some difficulty finding the proper gasket for an 8 year old Contour valve cover that isn't made anymore
- the 10 bolts you pull out go thru 10 washers respectively that slide into the valve cover (pictured below).  make sure you get all 10 of them ... they fall out somewhat easily if you flip the cover upside down.  you may want to take them out immediately because you got to take them out before you clean it up anyway
- the oil cap ... don't know if Focus Zetec one fits (yet)

Older style DOHC 16v

Newer style 16v Zetec

The project table (not to be confused with a plastic patio table)

A blurry pic of the washer for the 10mm bolts that you need to save

It goes here, and slides down flush

3)  Cleaning time.  I wish I had a pic of what these looked like before.  Anyway, all you really need is Simple Green and a toothbrush.  They both cleaned up very nicely.  You may have some difficulty getting down in the corners with the toothbrush in the channel where the sparkplug wires go.  but if you get enough Simple Green on it and let it sit there, you should be able to hose if off.  If that fails, try mineral spirits (paint thinner).

4)  Clean some more.  You can also take a Brillo pad to it if there's any rust.  Get off as much as you can.  Check down where the screws go too and make sure there's no dried oil or dirt down in there.  It'll only bubble your paint.

5)  Painting ... the fun part!  I used Duplicolor Engine Enamel.  Any brand engine enamel will do.  Do NOT use Rustoleum or Krylon or anything that doesn't say "engine enamel" (or engine paint).  Otherwise it will not stick to the valve cover when it heats up!

I would recommend going to Wal-Mart and picking up one of these paint can guns too.  This one cost me one whole dollar and cuts down on the strain put on your finger by pushing down on the nozzle on the top of the can.  you can use it more like a airbrush now and get a more even paint job.  This just snaps right onto the top of the can.

When you paint, make sure there is no water or debris (dirt, whatever) on there or else you're just going to paint over it and it's gonna bubble up (and effectively look stupid).  Use short even sweeps of paint.  Do NOT try to paint it all in one shot.  Take your time, and it will come out better.  I plan to use 4 coats ... here it is just after the second coat.

As for the bolts, I discovered that the 10mm bolts from the Contour will NOT work due to the fact that they are a different length then the Focus ones.  But you can recycle the Focus 8mm ones, but you will still need the little washer grommet things mentioned above.

Also, you cannot recycle the Focus gasket because it's a slightly different shape.  So make sure you get your hands on a Contour one.

Also, I'm going to get a can of another color and hand paint the tops of the letters of the Ford logo and the Zetec badge.  I already have red, so I might just do that.  Otherwise, white or black.  I should be able to do this by making a small pool of spray paint in a bottle lid and then using a q-tip or a small brush to brush it on.  We shall see.  If I screw it up, I can always give it another coat of yellow.

And the Focus oil cap does NOT fit, so make sure you get the Contour one.

Here it is actually on the car.

How-To Courtesy Of TF Member TwoPiMinus100th