Cylinder Head Resurface

This procedure covers removal, machine shop resurfacing, and reinstallation of cylinder heads on the 3.5L EcoBoost V6, including timing chain removal and valve train disassembly.

Warnings

Tools required

Parts

• Cylinder head gasket (left) × 1 — Use OEM specification
• Cylinder head gasket (right) × 1 — Use OEM specification
• Cylinder head bolts (TTY) × 20 — Use OEM specification
• Valve cover gasket (left) × 1 — Use OEM specification
• Valve cover gasket (right) × 1 — Use OEM specification
• Timing chain tensioner gaskets × 2 — Use OEM specification
• Timing chain guide gaskets × 4 — Use OEM specification
• Intake manifold gaskets × 2 — Use OEM specification
• Exhaust manifold gaskets (left) × 1 — Use OEM specification
• Exhaust manifold gaskets (right) × 1 — Use OEM specification
• Turbocharger gaskets and seals kit × 1 — Use OEM specification
• Coolant thermostat housing gasket × 1 — Use OEM specification
• Oil filter × 1 — Motorcraft FL-910S or equivalent

Fluids

• Motorcraft 5W-20 Synthetic Blend engine oil — 6 qt
• Motorcraft Orange Coolant — 13 qt

Preparation

1. Ensure engine is completely cold (minimum 4 hours after last operation)
2. Position vehicle on level surface and engage parking brake
3. Disconnect negative battery cable and isolate terminal
4. Remove engine cover and beauty covers
5. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
6. Drain engine coolant completely into appropriate container
7. Drain engine oil and remove oil filter
8. Remove air intake system from air filter housing to throttle body
9. Label and photograph all vacuum lines, electrical connectors, and hose routing
10. Support engine from above using engine support bar or hoist with load leveler

Procedure

1. 1

   Remove turbocharger and exhaust system components
   Disconnect both turbocharger oil feed and drain lines. Remove heat shields from both turbos. Disconnect exhaust downpipes from turbochargers. Remove turbocharger-to-exhaust manifold mounting bolts and carefully remove both turbochargers as assemblies. Cap all openings to prevent debris entry.
   ⚠Turbocharger shaft bearings are extremely sensitive to contamination. Keep all openings covered and clean.
2. 2

   Remove intake manifold assembly
   Disconnect throttle body electrical connector and all vacuum lines from intake manifold. Remove PCV hoses and breather tubes. Remove fuel rail with injectors (do not disconnect individual injectors). Remove intake manifold bolts in reverse sequence (outside to inside pattern) and lift manifold assembly away. Keep fuel rail and injectors together as assembly.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
3. 3

   Remove valve covers and accessory components
   Disconnect ignition coil connectors and remove all six coils. Remove valve cover bolts in reverse sequence (outside to center). Carefully remove both valve covers. Remove accessory drive belt. Remove power steering pump and secure aside without disconnecting hydraulic lines. Remove A/C compressor and secure aside without disconnecting refrigerant lines.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
4. 4

   Remove exhaust manifolds
   Working from the hot center exhaust ports toward the cooler outer ports, remove exhaust manifold nuts from both cylinder heads. Remove exhaust manifolds and gaskets. Inspect studs for damage and replace if threads are damaged or studs are loose in cylinder head.
   ℹ️Working hot-to-cold on exhaust manifolds prevents warping and stud damage during removal.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
5. 5

   Set engine to TDC and lock timing position
   Rotate crankshaft to bring cylinder #1 to TDC on compression stroke. Verify timing marks on camshaft sprockets align with cylinder head surface marks. Install camshaft holding tools on both intake and exhaust camshafts to lock position. Mark timing chain relationship to all sprockets with paint pen.
   ⚠Camshaft position MUST be locked before removing timing components. Movement during disassembly will result in incorrect timing during reassembly.
6. 6

   Remove timing chain front cover and timing components
   Remove crankshaft pulley and damper. Remove timing chain front cover bolts and carefully pry cover away from engine block. Remove timing chain tensioners and compress them for reinstallation. Remove timing chain guides. Carefully remove timing chains from both camshaft sprockets while maintaining sprocket position with holding tools. Do NOT rotate crankshaft or camshafts once chains are removed.
   ⚠️Once timing chains are removed, any crankshaft or camshaft rotation will cause valve-to-piston contact and severe engine damage.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
7. 7

   Remove camshafts and rocker arms
   With camshaft holding tools still in place, remove camshaft bearing cap bolts in reverse sequence (outside to center, multiple passes to release valve spring pressure evenly). Remove bearing caps keeping them in order. Carefully lift camshafts from cylinder heads. Remove rocker arms and hydraulic lash adjusters, keeping them organized by cylinder position for reinstallation in original locations.
   ℹ️Rocker arms and lash adjusters must be reinstalled in their original positions to maintain proper wear patterns.
8. 8

   Remove cylinder heads
   Remove coolant crossover tube between cylinder heads. Disconnect remaining coolant hoses and temperature sensors from heads. Remove cylinder head bolts in reverse sequence (outside to inside in multiple passes). Use proper lifting technique or hoist to remove cylinder heads from engine block. Place heads on clean wooden blocks with combustion chambers facing up.
   ⚠Cylinder heads weigh approximately 50 lbs each. Use proper lifting technique or assistance to prevent injury.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
9. 9

   Prepare heads for machine shop and inspect
   Remove any remaining carbon deposits from combustion chambers using approved cleaning methods. Inspect valve seats for pitting, cracks, or burning. Check valve guides for excessive wear. Measure cylinder head flatness with straightedge and feeler gauge. Transport heads to machine shop for resurfacing. Specify maximum material removal of 0.010 inch. Have machine shop verify head thickness after resurfacing meets Ford specifications.
10. 10

    Clean and prepare engine block deck surface
    Thoroughly clean cylinder head gasket surfaces on engine block using plastic scraper and approved gasket remover. Do NOT use metal scrapers that can gouge aluminum surfaces. Clean all coolant and oil passages. Verify block deck surface flatness. Stuff clean rags into cylinders to prevent debris entry, then use compressed air to clean block deck. Remove rags and verify no debris remains in cylinders or coolant passages.
    ⚠Any debris left in engine will cause immediate failure upon startup. Ensure all passages and cylinder bores are completely clean.
11. 11

    Install resurfaced cylinder heads
    Install new cylinder head gaskets on block with orientation marks facing up. Verify gaskets are positioned correctly on alignment dowels. Carefully lower resurfaced cylinder heads onto block. Install NEW cylinder head bolts finger tight. Following Ford tightening sequence (center to outside pattern), torque all head bolts to 48 lb-ft in sequence. Then tighten an additional 90 degrees in sequence. Finally tighten an additional 90 degrees (total 180 degrees additional rotation). Verify all bolts were tightened in correct sequence.
    ⚠️Torque-to-yield bolts must follow exact torque plus angle procedure. Skipping angle steps or reusing bolts will result in head gasket failure and possible engine damage.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
12. 12

    Reinstall camshafts and valve train
    Lubricate all camshaft bearing surfaces and lobes with clean engine oil. Reinstall hydraulic lash adjusters and rocker arms in their original positions. Install camshafts with timing marks in TDC position. Install bearing caps in correct positions and orientation. Torque bearing cap bolts in sequence from center outward in multiple passes to final specification. Verify camshafts rotate freely without binding.
    ℹ️Camshaft bearing caps are numbered and directional. Installing in wrong position will cause oil starvation and rapid camshaft failure.
13. 13

    Reinstall timing chains and synchronize timing
    Verify crankshaft is still at TDC position for cylinder #1. Install camshaft holding tools to lock camshaft position. Route timing chains over camshaft sprockets aligning paint marks made during disassembly. Install timing chain guides with new gaskets. Install timing chain tensioners with new gaskets (tensioners should still be in compressed position). Remove compression pins from tensioners to apply tension. Verify all timing marks align correctly before proceeding.
    ⚠️Incorrect timing chain installation will cause immediate valve-to-piston contact when engine is started. Triple-check all timing marks before proceeding.
    Torque spec

    Gasket Bolts23 Nm (17 lb-ft)
14. 14

    Install timing cover and rotate engine through two complete cycles
    Clean timing cover gasket surface and apply fresh RTV silicone to specified areas. Install timing cover with new gasket and torque bolts to specification. Install crankshaft damper and pulley. Remove camshaft holding tools. Slowly rotate crankshaft by hand through two complete revolutions. Verify engine rotates smoothly without binding. Reinstall camshaft holding tools and verify timing marks still align at TDC. If marks do not align, timing chain installation is incorrect and must be redone.
    ⚠If any resistance or binding is felt during crankshaft rotation, STOP immediately and investigate. Forcing rotation can cause valve damage.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
15. 15

    Reinstall exhaust manifolds and remaining components
    Apply anti-seize compound to exhaust manifold studs. Install new exhaust manifold gaskets and manifolds. Working from hot center ports to cooler outer ports, torque exhaust manifold nuts to specification. Install new intake manifold gaskets and reinstall intake manifold, torquing bolts in sequence from center outward. Reinstall fuel rail assembly. Install new valve cover gaskets and reinstall valve covers with bolts torqued in sequence. Reinstall ignition coils. Reinstall turbochargers with new gaskets and reconnect oil lines. Reinstall all accessory components, hoses, and electrical connectors per photos taken during disassembly.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Cover Bolts19 Nm (14 lb-ft)

Reassembly

1. Reinstall air intake system from throttle body to air filter housing
2. Reinstall engine covers and beauty covers
3. Fill engine with 6 quarts of Motorcraft 5W-20 synthetic blend engine oil and new oil filter
4. Fill cooling system with 13 quarts of Motorcraft Orange coolant using proper bleeding procedure to remove air pockets
5. Reinstall fuel pump fuse
6. Reconnect negative battery cable

Verification

• Perform visual inspection of all connections, ensuring no hoses, wires, or fasteners were missed during reassembly
• Check for proper coolant level and absence of leaks around cylinder heads and intake manifold
• Check engine oil level on dipstick
• Prime oil system by disabling ignition and cranking engine for 10-15 seconds, repeat 3 times with 30 second breaks
• Start engine and verify oil pressure builds immediately (within 2-3 seconds)
• Allow engine to reach operating temperature while monitoring for coolant, oil, or exhaust leaks
• Listen for abnormal noises including ticking, knocking, or rattling that could indicate timing or valve train issues
• Verify smooth idle and proper throttle response
• Scan for diagnostic trouble codes and verify no misfires or timing-related codes are present
• Road test vehicle under various loads and monitor engine performance, boost pressure, and temperature
• Re-check all fluid levels after test drive and inspect for any new leaks
• Allow engine to cool and re-torque cylinder head bolts is NOT required with TTY bolts - do not re-torque

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