Complete disassembly, inspection, machining, and reassembly of the 3.5L EcoBoost V6 engine including all internal components, timing system, and turbochargers.

Warnings

Tools required

Parts

• Complete engine gasket set × 1 — Use OEM Ford specification
• Cylinder head gaskets (pair) × 2 — Use OEM Ford MLS gaskets
• Valve cover gaskets (pair) × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing chain kit (includes chains, guides, tensioners) × 1 — Use OEM Ford timing components
• Main bearing set (standard or oversized) × 1 — Measure crank journals before ordering
• Rod bearing set (standard or oversized) × 1 — Measure crank journals before ordering
• Piston ring set × 1 — Use OEM specification, verify bore size
• Oil pump assembly × 1 — Use OEM specification
• Water pump × 1 — Use OEM specification
• Thermostat with housing × 1 — Use OEM specification
• Spark plugs × 6 — Motorcraft SP-546 or equivalent
• Turbocharger gaskets and seals × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Valve stem seals × 24 — Use OEM specification
• Oil filter × 1 — Motorcraft FL-500S
• Oil drain plug crush washer × 1 — Use OEM specification
• RTV silicone sealant (high-temp) × 2 — Motorcraft TA-357 or equivalent
• Engine assembly lube × 1 — Use molybdenum-based assembly lube
• Thread locker (medium strength) × 1 — Loctite 242 or equivalent

Fluids

• Motorcraft 0W-20 Full Synthetic engine oil — 6 qt
• Motorcraft Orange Coolant — 13 qt

Preparation

1. Mount engine securely on engine stand with proper adapter plate rated for engine weight
2. Clean exterior of engine thoroughly before disassembly to prevent contamination
3. Organize workspace with labeled containers for bolts and small parts from each assembly
4. Have digital camera or phone ready to document routing of hoses, wiring, and component positions
5. Prepare measurement log sheet to record all bearing clearances, ring gaps, and cylinder measurements
6. Verify availability of machine shop for cylinder work before beginning disassembly
7. Gather all special tools including camshaft holders, timing tools, and measurement equipment

Procedure

1. 1

   Remove external accessories and ancillaries
   Remove turbochargers, exhaust manifolds, intake manifold, fuel rails, ignition coils, spark plugs, alternator mounting bracket, A/C compressor bracket, power steering pump bracket, and all wiring harnesses. Label and photograph all connections. Remove coolant crossover tubes and thermostat housing. Remove oil filter and drain remaining oil.
2. 2

   Remove valve covers and inspect valvetrain
   Remove valve cover bolts in reverse of tightening sequence. Lift off valve covers and inspect for sludge or varnish buildup. Visually inspect camshafts, followers, and valve springs for wear. Rotate crankshaft and verify smooth operation before further disassembly.
3. 3

   Remove timing cover and set engine to TDC
   Remove crankshaft pulley using impact wrench or by holding crankshaft. Remove all timing cover bolts in reverse sequence and carefully separate timing cover. Rotate crankshaft to bring cylinder #1 to TDC on compression stroke. Verify timing marks on all camshaft sprockets align with cylinder head reference marks. Install camshaft holding tools to lock camshafts in position.
4. 4

   Remove timing chains and components
   Release timing chain tensioners by compressing and installing retaining pins. Remove tensioner bolts and tensioners. Remove timing chain guides. Mark timing chain orientation if reusing (not recommended). Remove camshaft sprocket bolts while camshafts are locked. Remove timing chains, crankshaft sprocket, and all guides. Inspect all components for wear, stretching, or damage.
5. 5

   Remove camshafts and inspect
   Remove camshaft bearing cap bolts in reverse of tightening sequence (outside to center). Loosen caps in multiple passes to prevent distortion. Carefully lift camshafts from cylinder heads. Measure camshaft lobe height, bearing journal diameter, and runout. Inspect cam followers for pitting or wear. Keep all components organized by cylinder bank and position.
6. 6

   Remove cylinder heads
   Remove cylinder head bolts in reverse of tightening sequence using multiple passes. Use proper lifting technique to remove cylinder heads as they are heavy. Place heads on clean workbench with combustion chambers facing up. Inspect head gasket surfaces for warping, cracks, or erosion. Remove and inspect valves using valve spring compressor. Send heads to machine shop for pressure testing, valve job, and surface grinding if needed.
7. 7

   Remove oil pan and oil pickup
   Remove oil pan bolts in reverse sequence. Carefully separate oil pan from block, using plastic scraper if needed. Remove oil pump pickup tube bolts and extract pickup. Inspect pickup screen for debris or restrictions. Clean oil pan thoroughly and inspect for cracks.
8. 8

   Remove oil pump and balance shaft assembly
   Remove oil pump mounting bolts and extract oil pump assembly. On engines equipped with balance shafts, remove balance shaft bolts and carefully extract balance shaft assembly. Inspect oil pump gears for scoring or excessive wear. Measure pump clearances per specifications.
9. 9

   Remove pistons and connecting rods
   Mark each rod cap and rod with cylinder number and orientation using punch marks. Use ridge reamer to remove any ridge at top of cylinder bores before removing pistons. Remove connecting rod bolts and caps, keeping matched sets together. Push pistons out through top of block. Inspect rod bearings for wear pattern, scoring, or embedded material. Measure rod bearing clearances using Plastigage method before complete disassembly.
10. 10

    Remove crankshaft and main bearings
    Mark all main bearing caps with position and orientation. Remove main bearing cap bolts in sequence from outer caps to center. Carefully lift crankshaft from block using proper lifting technique. Inspect main bearings for wear patterns. Measure crankshaft journals with micrometer at multiple points to check for taper and out-of-round. Measure crankshaft endplay before removal. Send crankshaft to machine shop for grinding if journal wear exceeds specifications.
11. 11

    Inspect and measure cylinder block
    Clean block thoroughly in parts washer or hot tank. Remove all core plugs and clean coolant passages. Inspect cylinder walls for scoring, cracks, or excessive wear. Use dial bore gauge to measure cylinder diameter at top, middle, and bottom in two orientations. Measure cylinder taper and out-of-round. Check deck surface flatness with precision straightedge and feeler gauges. Send block to machine shop for boring, honing, and deck surfacing as needed based on measurements.
12. 12

    Clean and prepare all components for assembly
    After machining is complete, thoroughly clean block, crankshaft, connecting rods, and all components. Wash block with hot soapy water, scrubbing all oil passages with bottle brushes. Dry with compressed air and coat machined surfaces immediately with light oil to prevent rust. Clean pistons and inspect ring grooves. Clean all bolt holes with tap to remove debris and ensure proper torque readings. Blow out all oil galleries and passages with compressed air.
13. 13

    Install main bearings and crankshaft
    Install main bearing shells in block and caps, ensuring bearing tabs are properly seated. Coat bearings with assembly lube. Carefully lower crankshaft into block. Install thrust bearing in correct position (typically center main). Install main bearing caps in correct positions with arrows pointing forward. Install NEW main bearing cap bolts. Tighten main bearing cap bolts to initial torque spec in sequence from center outward, then apply additional torque angle per TTY specification. Verify crankshaft rotates freely. Measure crankshaft endplay with dial indicator (specification: 0.0035-0.0118 inch).
    ⚠️Main bearing cap bolts are TTY and MUST be replaced with new bolts. Tighten in proper sequence plus angle specification.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
14. 14

    Install piston rings and prepare pistons
    If using new pistons, verify piston-to-bore clearance (typically 0.0007-0.0017 inch). Install piston rings using ring expander tool. Install oil control ring first (expander and rails), then lower compression ring, then top compression ring. Verify ring end gap for each ring in its respective cylinder (top ring: 0.010-0.020 inch, second ring: 0.010-0.020 inch). Stagger ring gaps 120 degrees apart. Do not position gaps over piston pin.
15. 15

    Install pistons and connecting rods
    Install connecting rod bearings and coat with assembly lube. Install piston pin if separated (note direction and circlip orientation). Position piston ring gaps as specified. Coat pistons and cylinder walls with assembly lube. Use piston ring compressor to compress rings. Ensure piston orientation mark faces forward. Carefully tap piston into cylinder while guiding connecting rod onto crankshaft journal. Install rod cap in correct orientation. Install NEW connecting rod bolts and torque to specification plus angle. Torque initial spec to 45 Nm (33 lb-ft), then rotate additional 90 degrees. Verify rod side clearance (0.0043-0.0193 inch). Verify crankshaft rotates freely after each piston installation.
    ⚠️Connecting rod bolts are TTY and MUST be replaced with new bolts. Follow torque plus angle specification exactly.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
16. 16

    Install oil pump and pickup tube
    Install new oil pump or thoroughly cleaned and inspected original pump. Ensure oil pump alignment and engagement with crankshaft. Install oil pump bolts to specification. Install oil pump pickup tube with new O-ring. Torque pickup tube mounting bolts to specification. Verify proper pickup tube positioning (clearance from oil pan should be 0.236-0.315 inch).
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)
17. 17

    Install oil pan
    Clean oil pan and block mating surfaces thoroughly. Apply thin bead of RTV silicone to oil pan sealing surface per Ford specification (bead should be 0.12-0.16 inch wide). Install oil pan within 4 minutes of RTV application. Install oil pan bolts and tighten in proper sequence from center outward. Allow RTV to cure for minimum 30 minutes before adding oil.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)
18. 18

    Install cylinder heads with new gaskets
    Verify cylinder head surfaces are clean and flat (maximum warpage: 0.003 inch). Install new head locating dowels if removed. Position new MLS head gaskets on block with orientation marks facing up (do not reuse head gaskets). Carefully lower cylinder heads onto block. Install NEW cylinder head bolts lightly lubricated with engine oil. Tighten head bolts in proper sequence in multiple stages: first pass to 65 Nm (48 lb-ft), then rotate all bolts 90 degrees, then rotate all bolts an additional 90 degrees (total 180 degrees). Do not exceed maximum angle specification.
    ⚠️Cylinder head bolts are TTY and MUST be replaced with new bolts. Follow exact torque sequence and angle specifications.
    ⚠MLS head gaskets must not be reused. Verify head surface finish meets specification for MLS gaskets.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
19. 19

    Install camshafts and bearing caps
    Lubricate camshaft journals and cam lobes with assembly lube. Position camshafts in cylinder heads with timing marks in correct orientation. Install bearing caps in correct positions (caps are numbered and directional). Install camshaft bearing cap bolts and tighten in sequence from center outward in 3 passes: first pass 3-4 Nm, second pass 8 Nm, final pass to 14 Nm (10 lb-ft). Verify camshafts rotate freely.
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
20. 20

    Install timing chains and components
    Install crankshaft sprocket ensuring alignment key is engaged. Install lower timing chain guides and tighten bolts to specification. Route timing chains over crankshaft sprocket and up to camshaft positions. Install camshaft sprockets with timing marks aligned to cylinder head reference marks. Compress timing chain tensioners and install retaining pins. Install tensioners and tighten bolts to specification. Install upper chain guides. Remove tensioner pins to activate tensioners. Rotate crankshaft two complete revolutions and verify all timing marks realign correctly.
    ⚠️Timing chain alignment is critical. Verify all timing marks align exactly before and after rotation test. Incorrect timing will cause immediate engine damage.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
21. 21

    Install timing cover and front accessories
    Clean timing cover and block mating surfaces. Install new timing cover gasket or apply RTV per Ford specification. Position timing cover and install bolts in proper sequence, tightening 8mm bolts to 25 Nm (18 lb-ft). Install crankshaft front seal if not integrated with cover. Install crankshaft pulley and torque bolt to 180 Nm (133 lb-ft). This bolt may require impact wrench or holding tool to achieve proper torque.
    ⚠Crankshaft pulley bolt requires high torque. Use impact wrench or proper holding tool to prevent crankshaft rotation.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
22. 22

    Install valve covers and external components
    Install new valve cover gaskets ensuring proper seating in covers. Position valve covers and install bolts in sequence from center outward. Tighten valve cover bolts to 10 Nm (7 lb-ft) in multiple passes to ensure even compression. Install intake manifold with new gaskets and torque bolts to specification. Install exhaust manifolds with new gaskets, applying anti-seize to studs, and torque nuts to 30 Nm (22 lb-ft) working from center outward.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
23. 23

    Install turbochargers and remaining accessories
    Install turbochargers with new gaskets and seals. Install all mounting brackets, alternator, A/C compressor, and remaining accessories. Install all wiring harnesses and sensors using new seals where applicable. Install ignition coils and new spark plugs. Install new oil filter. Install oil drain plug with new crush washer and torque to 35 Nm (26 lb-ft).
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)
24. 24

    Prime oil system and perform initial startup
    Fill engine with 6 quarts of Motorcraft 0W-20 full synthetic oil. Remove fuel pump fuse or disable fuel system. Crank engine with starter for 10-15 seconds at a time (allowing starter to cool between attempts) until oil pressure registers on gauge. This may take several attempts. Once oil pressure is confirmed, re-enable fuel system. Start engine and immediately verify oil pressure. Listen for any abnormal noises. Allow engine to idle for 5 minutes monitoring for leaks, unusual noises, or warning lights.
    ⚠Do not run engine without verified oil pressure. Shut down immediately if oil pressure warning activates or unusual noises occur.

Reassembly

1. After initial startup and verification of no leaks, perform break-in procedure: vary engine speed between 1500-3000 RPM for first 30 minutes, avoiding sustained high load
2. Change oil and filter after first 500 miles of operation to remove break-in debris
3. Retorque cylinder head bolts after first heat cycle if using aftermarket gaskets (not typically required with OEM MLS gaskets)
4. Monitor oil consumption and check for leaks regularly during first 1000 miles
5. Avoid full throttle or sustained high RPM operation for first 1000 miles to allow proper ring seating

Verification

• Verify oil pressure reads normal at idle (minimum 10 PSI) and increases with RPM
• Check for any external oil, coolant, or fuel leaks around all gasket surfaces
• Verify no unusual engine noises including knocking, ticking, or grinding sounds
• Confirm all warning lights extinguish after startup
• Monitor engine temperature to verify proper thermostat operation and cooling system function
• Verify proper turbocharger operation with no unusual boost-related noises or smoke
• Perform compression test after break-in period to verify proper ring sealing (specification typically 150-200 PSI with less than 10% variation between cylinders)
• Road test vehicle under varying load conditions and verify smooth operation throughout RPM range
• Scan for diagnostic trouble codes and verify no misfire or sensor codes are present

More procedures for this vehicle