Valve Job - Complete

Complete valve job on the 3.5L EcoBoost V6 engine including valve grinding/lapping, seat machining, guide inspection, and cylinder head reinstallation with timing component service.

Warnings

Tools required

Parts

• Cylinder head gaskets (both banks) × 2 — Use OEM specification
• Valve cover gaskets (both banks) × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets (both banks) × 2 — Use OEM specification
• Valve stem seals (24 pieces) × 24 — Use OEM specification
• Cylinder head bolt set (TTY bolts) × 1 — Use OEM specification
• Timing chain tensioner gaskets × 2 — Use OEM specification
• VVT solenoid O-rings × 4 — Use OEM specification
• Camshaft position sensor O-rings × 4 — Use OEM specification
• Spark plugs (6 pieces) × 6 — Motorcraft SP-515 or equivalent
• Anti-seize compound × 1 — Nickel-based high-temp
• RTV silicone sealant (Motorcraft TA-357) × 1 — Use OEM specification

Fluids

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

Preparation

1. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
2. Drain engine coolant completely into suitable container
3. Drain engine oil and remove oil filter
4. Remove front grille, radiator, and intercooler assembly for access
5. Remove accessory drive belt and tensioner
6. Remove turbocharger air intake ducting and charge air coolers
7. Support engine from above with hoist or use support fixture across fender wells
8. Label all vacuum lines, electrical connectors, and hoses before disconnection
9. Clean entire engine exterior with degreaser to prevent contamination during disassembly

Procedure

1. 1

   Remove intake and exhaust systems
   Remove throttle body and upper intake manifold. Disconnect fuel lines (relieve fuel pressure first by removing fuel pump fuse and cranking engine). Remove lower intake manifold working from outside bolts to center. Remove both turbochargers with exhaust manifolds as assemblies. Cap all openings to prevent debris entry.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
2. 2

   Remove valve covers and timing components
   Remove ignition coils and spark plugs. Remove both valve covers. Rotate engine to TDC on cylinder #1 (both cam lobes on #1 cylinder pointing outward). Mark timing chain position relative to sprockets with paint pen. Remove timing cover front bolts and RTV sealed areas. Remove timing chain tensioners (left and right banks). Remove camshaft sprocket bolts while holding camshafts with wrench on hex section. Remove timing chains with sprockets as assemblies.
   ⚠Do not rotate crankshaft or camshafts once timing chains are removed. This will cause valve-to-piston contact.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
3. 3

   Remove camshafts and rocker arms
   Remove camshaft bearing caps by loosening bolts in reverse sequence (outward from center) in multiple passes to prevent warping. Keep caps in order as they are not interchangeable. Lift out camshafts and store safely. Remove rocker arms and hydraulic lash adjusters, keeping them in order for inspection and potential reuse.
   Torque spec

   Camshaft Cap Bolts14 Nm (10 lb-ft)

   Rocker Arm Bolts30 Nm (22 lb-ft)
4. 4

   Remove cylinder heads
   Disconnect remaining coolant hoses and electrical connectors from cylinder heads. Remove cylinder head bolts in reverse of tightening sequence (outside to inside pattern). Use hoist or assistant to lift heads off block - they are aluminum but still heavy. Place heads on clean padded surface with combustion chambers facing up. Remove and discard head gaskets. Cover block deck with clean shop towels to prevent debris entry.
   ⚠Do not pry between head and block surfaces. Tap gently with plastic mallet if stuck.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
5. 5

   Disassemble cylinder heads
   Using valve spring compressor, compress each valve spring and remove keepers. Release compressor and remove retainers, springs, and seals. Remove all 12 valves from each head, keeping them in order (intake vs exhaust, cylinder number). Inspect valve guides for wear using dial indicator (max 0.002 inch radial play). Measure valve stem diameter with micrometer - replace valves worn beyond 0.001 inch from specification.
   ⚠Valve keepers can fly out during spring compression. Keep face away from spring area.
6. 6

   Machine valve seats and grind valves
   Clean all carbon deposits from combustion chambers and valve seats. Using valve seat cutting tools or stones, cut 45-degree seat face first, then 30-degree top cut and 60-degree throat cut to achieve proper seat width (0.040-0.060 inch intake, 0.060-0.080 inch exhaust). Grind valve faces to 45 degrees on valve refacing machine or replace valves if pitted. Lap each valve to its seat using lapping compound and lapping tool with light pressure in rotational pattern. Clean thoroughly with brake cleaner. Verify seat contact with Prussian blue dye - contact band should be centered on valve face.
   ℹ️Seat width and concentricity are critical. If machining equipment not available, take heads to qualified machine shop.
7. 7

   Inspect and resurface cylinder heads
   Check cylinder head deck surface flatness using precision straightedge and feeler gauges. Maximum warpage is 0.003 inch overall. If warpage exceeds specification, resurface heads at machine shop. Maximum material removal is 0.010 inch. Check head height after resurfacing to ensure compression ratio remains within specification. Inspect valve guides - replace if worn (press-in type, requires machine shop).
   ⚠Excessive deck resurfacing will advance cam timing and may require revised timing chain components.
8. 8

   Reassemble cylinder heads with new seals
   Install new valve stem seals on guides using seal installation tool (tap gently, do not hammer). Lubricate valve stems with clean engine oil. Install valves into their original positions. Install springs with closer-wound coils toward cylinder head. Compress springs and install retainers and keepers, ensuring keepers are fully seated in valve stem grooves. Tap valve stems lightly with plastic mallet to verify keeper seating.
   ℹ️Valve springs have directional installation. Verify proper orientation before installation.
9. 9

   Prepare block and install cylinder heads
   Clean block deck surface thoroughly with plastic scraper and brake cleaner. Ensure all coolant and oil passages are clear. Verify block deck flatness (max 0.002 inch warpage). Chase cylinder head bolt threads with tap to remove any debris or corrosion. Install new head gaskets with orientation marks facing up (TOP or FRONT markings). Carefully lower cylinder heads onto block, aligning dowel pins. Install NEW cylinder head bolts finger-tight.
   ⚠️Do not use sealant on head gaskets. Do not reuse TTY head bolts under any circumstances.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
10. 10

    Torque cylinder head bolts
    Torque cylinder head bolts in proper sequence (center outward pattern per Ford specification): Step 1 - Tighten all bolts to 65 Nm (48 lb-ft). Step 2 - Loosen all bolts one full turn. Step 3 - Tighten all bolts to 50 Nm (37 lb-ft). Step 4 - Rotate all bolts an additional 90 degrees. Step 5 - Rotate all bolts another 90 degrees (180 degrees total angle). Verify all bolts have equal final rotation using angle gauge.
    ⚠️Follow torque sequence exactly. Skipping steps or improper sequence will cause head gasket failure.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
11. 11

    Install rocker arms and camshafts
    Lubricate hydraulic lash adjusters with clean engine oil and install into bores. Install rocker arms with cam follower on lash adjuster. Lubricate camshaft journals and lobes with assembly lube or engine oil. Position camshafts with timing marks aligned (lobes on cylinder #1 pointing outward for TDC). Install bearing caps in original positions, ensuring directional arrows point toward front of engine. Tighten camshaft cap bolts in sequence from center outward in 3-4 passes to final torque.
    ⚠Camshaft caps are matched to heads and not interchangeable. Install in original positions only.
    Torque spec

    Camshaft Cap Bolts14 Nm (10 lb-ft)

    Rocker Arm Bolts30 Nm (22 lb-ft)
12. 12

    Install timing chains and components
    Verify crankshaft is still at TDC position. Install timing chain guides and tensioner mounting brackets. Position timing chains on crankshaft sprocket, aligning colored links with marks. Route chains around camshaft sprockets, aligning colored links with sprocket timing marks. Install camshaft sprocket bolts while holding camshafts with wrench on hex section - torque to specification. Compress timing chain tensioners using pin or clip, install with new gaskets, and torque bolts. Remove tensioner pins/clips to activate tensioners. Rotate engine two complete revolutions by hand and verify all timing marks realign correctly.
    ⚠️Verify timing marks alignment three times before proceeding. Incorrect timing will destroy engine.
    Torque spec

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)

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

    Install timing cover and valve covers
    Clean timing cover mating surfaces. Apply 3mm bead of RTV silicone at block-to-head joints where timing cover seals. Install new timing cover gasket and position cover. Install timing cover bolts in sequence, tightening 8mm bolts to specification. Install new valve cover gaskets and position valve covers. Tighten valve cover bolts in sequence from center outward to prevent gasket distortion.
    Torque spec

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

    Install intake, exhaust, and remaining components
    Install exhaust manifolds with new gaskets using anti-seize on studs. Torque manifold nuts in sequence from hot center runners to cold outer runners. Install turbochargers to manifolds. Install lower intake manifold with new gaskets, torquing bolts in sequence from center outward. Install upper intake manifold and throttle body. Reconnect all fuel lines, vacuum lines, coolant hoses, and electrical connectors per earlier labeling. Install new spark plugs and ignition coils. Install accessory drive components.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
15. 15

    Final assembly and fluid fill
    Install radiator, intercooler, and front grille assembly. Install new oil filter and fill engine with 6 quarts of Motorcraft 5W-20 oil. Fill cooling system with 13 quarts of Motorcraft Orange coolant mixture (50/50 with distilled water). Reconnect battery negative cable. Prime fuel system by cycling ignition on/off three times without cranking. Start engine and verify oil pressure within 5 seconds. Allow engine to reach operating temperature while monitoring for leaks. Burp cooling system by opening bleeder valves or loosening upper hose until air-free coolant flows.
    ⚠Monitor oil pressure immediately on startup. Shut down immediately if oil pressure does not register.

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify all coolant hoses are properly clamped and tight
3. Ensure no tools or shop towels remain in engine bay
4. Check all fluid levels after initial run and top off as needed
5. Inspect for any oil or coolant leaks after first heat cycle

Verification

• Perform cylinder leak-down test on all cylinders - should have less than 10% leakage with good valve sealing
• Verify engine idles smoothly with no misfires or abnormal noises
• Check for proper oil pressure at idle (minimum 40 psi hot) and elevated RPM
• Scan for diagnostic trouble codes - there should be none related to valvetrain or timing
• Road test vehicle under load and verify proper boost pressure from turbochargers
• Recheck all torque specifications after engine reaches operating temperature
• Monitor coolant level for 2-3 days after repair and top off as air purges from system
• Perform oil and filter change after 500 miles to remove assembly lubricants and break-in debris

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