Complete engine rebuild for the 3.5L EcoBoost V6, including disassembly, inspection, machining coordination, reassembly with new bearings, gaskets, seals, timing components, and turbochargers.

Warnings

Tools required

Parts

• Engine gasket set (complete) × 1 — Fel-Pro or OEM Ford complete gasket set
• Main bearing set (standard or oversized) × 1 — Use OEM specification after measuring
• Rod bearing set (standard or oversized) × 1 — Use OEM specification after measuring
• Camshaft bearing set × 2 — Use OEM specification
• Piston ring set × 1 — Matched to piston size
• Timing chain kit (primary and secondary chains) × 1 — Use OEM Ford kit with guides and tensioners
• Timing chain tensioners × 4 — Included in timing kit
• Timing chain guides × 6 — Included in timing kit
• VVT solenoids (cam phasers) × 4 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear crankshaft seal × 1 — Use OEM specification
• Valve stem seals × 24 — Use OEM specification
• Turbocharger gasket kit × 1 — Includes all turbo to manifold gaskets
• Oil pump (if worn) × 1 — Use OEM specification
• Water pump × 1 — Replace during rebuild
• Thermostat × 1 — Use OEM specification
• Spark plugs × 6 — Motorcraft SP-520 or equivalent
• Oil filter × 1 — Motorcraft FL-500S
• Engine oil × 6 — Motorcraft 5W-20
• Rod bolts (if reusing rods) × 12 — TTY bolts must be replaced
• Cylinder head bolts × 20 — TTY bolts must be replaced
• Main cap bolts × 20 — TTY bolts must be replaced
• Flywheel bolts × 8 — TTY bolts should be replaced
• RTV silicone sealant (high temp) × 2 — Permatex Ultra Black or OEM
• Assembly lube (moly-based) × 1 — Use OEM specification
• Anti-seize compound × 1 — For exhaust studs

Fluids

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

Preparation

1. Disconnect battery negative terminal and remove battery
2. Drain engine coolant completely from block and radiator
3. Drain engine oil and remove oil filter
4. Remove hood and mark hinge locations for reinstallation
5. Remove engine cover and intake tubing
6. Discharge and recover A/C refrigerant if removing engine with compressor attached
7. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
8. Position vehicle on level surface with adequate overhead clearance for engine removal
9. Have a clean workspace prepared for engine disassembly with engine stand ready
10. Obtain factory service manual for specific torque sequences and timing procedures

Procedure

1. 1

   Remove Engine from Vehicle
   Disconnect all electrical connectors, fuel lines, coolant hoses, and vacuum lines from engine. Label everything for reassembly. Remove turbocharger inlet and outlet pipes. Disconnect exhaust system at front flanges. Remove transmission bellhousing bolts. Support transmission with jack. Install engine support bar or attach engine hoist to lifting eyes. Remove engine mount bolts (note there are different specifications for mounting bolts). Carefully lift engine forward and upward, separating from transmission. Tilt as needed to clear firewall and turbochargers. Place engine on engine stand, securing at bellhousing bolt locations.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
2. 2

   External Component Removal
   With engine on stand, remove all external components: alternator, A/C compressor, power steering pump, fuel rails and injectors, ignition coils, wiring harness, throttle body, intake manifold (note torque sequence for reinstallation), both turbochargers with oil feed and drain lines, exhaust manifolds (note hot-to-cold removal pattern), valve covers, oil filter adapter, water pump, thermostat housing, front timing cover, oil pan, and oil pickup tube. Clean and inspect all bolt holes and mounting surfaces. Check studs for damage.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Exhaust Manifold Nuts30 Nm (22 lb-ft)

   Cover Bolts19 Nm (14 lb-ft)
3. 3

   Remove Timing Components and Front Accessories
   Use impact wrench to remove crankshaft pulley bolt (very tight, 133 lb-ft plus possible angle). Remove harmonic balancer using puller. Remove timing cover bolts in reverse sequence. Rotate engine to TDC cylinder #1 and verify all timing marks align using Ford timing tools. Note or photograph timing chain orientation and cam phaser positions. Release timing chain tensioners by compressing and locking with pins. Remove primary timing chains, then secondary chains. Remove cam phasers (VVT units) - these may be worn and should be inspected. Remove timing chain guides and tensioners. Remove balance shaft if equipped (verify with Ford tooling).
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

   Cover Bolts19 Nm (14 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
4. 4

   Remove Cylinder Heads and Valvetrain
   Remove camshaft bearing cap bolts in reverse sequence (from outer caps to center, reverse of installation). Carefully lift out camshafts - mark intake and exhaust for each bank. Remove rocker arms and lash adjusters, keeping them in order by cylinder and valve. Remove cylinder head bolts in reverse of tightening sequence (consult service manual for exact pattern). Carefully lift cylinder heads off block - they are heavy. If heads are stuck, gently tap with plastic mallet, never pry between sealing surfaces. Place heads on clean surface, valve-side up. Inspect head gaskets and note any failure patterns.
   ⚠Cylinder heads are heavy (approximately 50 lbs each). Use proper lifting technique or assistance.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
5. 5

   Disassemble Block and Remove Pistons
   Remove oil pump bolts and oil pump assembly. Inspect pump gears for wear. Use ridge reamer to remove any cylinder ridge at top of bore before removing pistons. Rotate crankshaft to access rod bolts. Mark connecting rods and caps with cylinder number and orientation (factory marks should be visible). Remove connecting rod bolts - these are TTY and must be replaced. Push piston/rod assembly out top of cylinder. Keep rod caps with correct rods. Remove main bearing cap bolts in reverse sequence - these are also TTY. Carefully remove main caps, marking orientation. Lift crankshaft from block. Remove main bearings and rod bearings, inspecting for wear patterns. Remove rear main seal.
   ⚠Keep all bearing caps with their original journals. Never mix caps or install backwards.
   Torque spec

   Oil Pump Bolts12 Nm (9 lb-ft)

   Connecting Rod Bolts45 Nm (33 lb-ft)

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
6. 6

   Clean and Inspect All Components
   Thoroughly clean block, heads, crankshaft, pistons, and all components. Use proper cleaning solution for aluminum (block and heads) versus steel (crankshaft). Remove all gasket material from sealing surfaces using plastic scrapers only - never metal tools on aluminum. Clean all oil passages with rifle brushes and compressed air. Inspect cylinder bores for scoring, taper, and out-of-round using bore gauge. Measure crankshaft journals with micrometer for wear and out-of-round. Check piston-to-bore clearance. Inspect camshafts for lobe wear and journal scoring. Check cylinder head flatness with straightedge and feeler gauge. Inspect valves, seats, and guides. Pressure test heads for cracks if overheating history exists. Magnaflux or dye-penetrant test crankshaft if high mileage.
   ℹ️Document all measurements and compare to Ford specifications. This determines what machine work is needed.
7. 7

   Machine Shop Services and Parts Procurement
   Based on measurements, send block and heads to qualified machine shop for required services: cylinder boring/honing if taper or wear exceeds spec, cylinder head resurfacing if warped, valve job (grind seats and valves), crankshaft grinding if journals worn, connecting rod reconditioning if needed. Have machine shop install new camshaft bearings (requires special tooling). Have shop clean and hot-tank components. Order correct size bearings (standard, 0.001", 0.010", 0.020", etc.) based on final machined dimensions. Order pistons if bore was increased. Ensure all new rings are matched to final bore size. Replace all TTY bolts: cylinder head bolts, main cap bolts, connecting rod bolts, flywheel bolts.
   ℹ️A reputable machine shop familiar with EcoBoost engines is critical. Improper machining will cause rebuild failure.
8. 8

   Reassemble Short Block - Install Crankshaft
   With block and crankshaft returned from machine shop, install new freeze plugs if removed. Install new rear main seal using seal installer tool. Thoroughly lubricate main bearing journals with assembly lube. Install upper main bearings (with oil holes) into block saddles, ensuring tabs are properly seated. Apply thin coat of assembly lube to bearings. Carefully lower crankshaft into block. Install lower main bearings into caps. Install main caps in correct orientation - most have directional arrows. Install new main cap bolts (TTY). Torque main cap bolts to 75 Nm (55 lb-ft) in sequence from center outward, then tighten additional angle per Ford specification (typically 90 degrees in multiple steps). Verify crankshaft rotates freely. Check crankshaft endplay with dial indicator (should be 0.002"-0.008"). Measure bearing clearance using Plastigage if not already verified.
   ⚠Main cap bolt sequence and angle specifications are critical. Follow factory service manual exactly.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
9. 9

   Install Pistons and Connecting Rods
   Install piston rings on pistons using ring expander tool. Install oil control ring first (expander and rails), then lower compression ring, then top compression ring. Verify ring gaps are properly staggered per Ford specification (typically 120 degrees apart). Install rod bearings in connecting rods and caps. Lubricate bearings thoroughly with assembly lube. Lubricate cylinder walls. Stagger ring gaps and compress rings using ring compressor. Install piston/rod assembly into correct cylinder, ensuring rod orientation is correct (typically bearing tab faces front). Tap piston carefully into bore with hammer handle. Pull rod down onto crankshaft journal. Install rod cap in correct orientation. Install new rod bolts (TTY). Torque to 45 Nm (33 lb-ft) plus additional angle per specification (typically 90 degrees). Verify connecting rod side clearance (0.006"-0.014"). Repeat for all cylinders.
   ⚠Ring gap alignment is critical. Improper alignment can cause excessive oil consumption or ring breakage.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
10. 10

    Install Oil Pump and Oil Pan
    Install new front crankshaft seal using seal installer. Lubricate oil pump gears and install oil pump to block, aligning with crankshaft. Install oil pump bolts and torque to 12 Nm (9 lb-ft). Install oil pump pickup tube with new O-ring, torque bolts to 12 Nm (9 lb-ft). Clean oil pan sealing surface thoroughly. Apply thin bead of RTV sealant to block at front and rear main cap junctions (where timing cover and rear seal housing meet). Install new oil pan gasket or apply RTV per Ford specification. Install oil pan and torque bolts in sequence from center outward to 12 Nm (9 lb-ft). Allow RTV to cure per manufacturer instructions before filling with oil.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
11. 11

    Install Cylinder Heads and Valvetrain
    If heads were sent out, inspect valve job quality and verify new valve stem seals are installed. Clean cylinder head and block mating surfaces with brake cleaner. Install new head gaskets - verify correct orientation and any dowel pins are in place. Carefully lower cylinder heads onto block. Install new cylinder head bolts (TTY). Following factory torque sequence, torque head bolts to 65 Nm (48 lb-ft), then tighten additional angle in multiple steps per Ford specification (typically 90 degrees + 90 degrees + 45 degrees). Install lash adjusters in original positions (or new if worn). Install rocker arms. Lubricate camshaft journals and lobes thoroughly with assembly lube. Install camshafts in correct positions (intake/exhaust, bank 1/bank 2). Install camshaft bearing caps in sequence, starting from center and working outward. Torque camshaft cap bolts to 14 Nm (10 lb-ft) in 3 progressive passes.
    ⚠Cylinder head bolt sequence and angle torque are extremely critical. Incorrect procedure will cause head gasket failure.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)

    Camshaft Cap Bolts14 Nm (10 lb-ft)
12. 12

    Install Timing Components and Set Timing
    Install balance shaft if equipped, torque bolts to 25 Nm (18 lb-ft) with shaft properly timed. Install timing chain guides, torque bolts to 12 Nm (9 lb-ft). Compress timing chain tensioners and lock with pins or clips. Install cam phasers (VVT units) on camshafts - use new units if old ones showed wear. Rotate crankshaft to TDC position using timing marks. Install Ford camshaft timing tools to lock camshafts in position. Install primary timing chains over crankshaft sprockets and cam phasers, following factory routing diagram exactly. Install secondary chains if applicable. Verify all timing marks align correctly with tools installed. Install timing chain tensioners, torque bolts to 25 Nm (18 lb-ft), then carefully release tensioner pins to apply tension. Remove timing tools and rotate crankshaft 2 complete revolutions by hand. Reinstall timing tools - all marks should still align perfectly. If not, disassemble and correct timing.
    ⚠️Incorrect timing will cause piston-to-valve contact when engine is started, destroying the engine. Triple-check all timing marks.
    Torque spec

    Balance Shaft Bolts25 Nm (18 lb-ft)

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
13. 13

    Install Front Cover and Accessories
    Clean timing cover and block mating surfaces. Apply RTV sealant at cylinder head-to-block junctions. Install new timing cover gasket or apply RTV per Ford specification. Install timing cover, ensuring it seats properly over crankshaft seal. Install timing cover bolts (8mm) and torque in sequence to 25 Nm (18 lb-ft). Install harmonic balancer using balancer installer tool - never hammer it on. Install crankshaft pulley bolt, torque to 180 Nm (133 lb-ft). If TTY specification requires angle, add specified degrees. Install water pump with new gasket, torque bolts per specification. Install thermostat. Install valve covers with new gaskets, torque bolts in sequence to 10 Nm (7 lb-ft). Install oil filter adapter with new gaskets.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
14. 14

    Install Exhaust Manifolds, Turbochargers, and Intake
    Apply anti-seize to exhaust manifold studs. Install exhaust manifolds with new gaskets, torque nuts to 30 Nm (22 lb-ft) in hot-to-cold pattern (center to outer bolts). Install turbochargers with new gaskets and oil feed/drain lines. Use new gaskets for all turbo connections. Install intake manifold with new gaskets, torque bolts in sequence to 25 Nm (18 lb-ft). Install fuel rails, injectors with new O-rings, ignition coils, and all sensors. Install throttle body with new gasket. Reinstall all external accessories: alternator, A/C compressor, power steering pump. Ensure all mounting bolts are torqued properly - use 31 Nm (23 lb-ft) or 55 Nm (40 lb-ft) as applicable per component.
    ℹ️Exhaust manifold hot-to-cold torque pattern prevents warping. Start from center studs and work outward.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Mounting Bolts31 Nm (23 lb-ft)
15. 15

    Install Engine and Final Assembly
    Attach engine hoist to lifting eyes on rebuilt engine. Carefully lower engine into vehicle, guiding it onto transmission input shaft. Install engine mount bolts and torque appropriately (31 Nm or 55 Nm depending on location). Install transmission bellhousing bolts. Reconnect exhaust system at flanges. Reconnect all electrical connectors, fuel lines, coolant hoses, and vacuum lines using photographs and labels from disassembly. Install turbo inlet and outlet piping. Install new oil filter. Install engine cover. Reinstall hood, aligning with original marks. Reconnect battery. Fill engine with 6 quarts Motorcraft 5W-20 oil. Fill cooling system with 13 quarts Motorcraft Orange coolant, burp air from system. Double-check all connections, torques, and routing.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Check for any tools or parts left in engine bay
3. Verify all fluid levels: engine oil, coolant, power steering, brake fluid
4. Check all belt routing and tension
5. Ensure no wiring is routed near hot exhaust components or moving parts
6. Verify turbo oil feed and drain lines are not kinked or restricted
7. Double-check that all intercooler piping and clamps are tight

Verification

• Perform initial start procedure: Turn key to ON position without starting, verify no warning lights indicating sensor disconnection
• Prime oil system by cranking engine with fuel pump fuse removed until oil pressure builds (may take 10-20 seconds)
• Reinstall fuel pump fuse and start engine. Monitor for immediate oil pressure on gauge
• Listen for abnormal noises: knocking, ticking, or rattling may indicate timing or bearing issues
• Watch for leaks: oil, coolant, fuel, or exhaust. Address immediately if found
• Allow engine to reach operating temperature while monitoring coolant level and temperature gauge
• Verify both turbochargers are building boost properly under light acceleration
• Check for diagnostic trouble codes using scan tool
• Perform initial 20-minute break-in at varying RPM (2000-4000) with no load
• After cool-down, re-torque cylinder head bolts if manufacturer specifies (some EcoBoost applications require this)
• Change oil and filter after first 500 miles of break-in period
• Monitor oil consumption and performance for first 1000 miles
• Perform leak-down test and compression test after break-in to verify ring seal

More procedures for this vehicle