Replace a single hydraulic valve lifter on a 2015-2020 Ford F-150 3.5L EcoBoost V6 engine, requiring removal of valve covers, timing components, and camshaft to access the lifter bore.

Warnings

Tools required

Parts

• Hydraulic valve lifter × 1 — Use OEM Ford specification
• Valve cover gaskets (both banks) × 2 — BR3Z-6584-B (LH), BR3Z-6584-A (RH)
• Valve cover bolt grommets × 20 — Use OEM specification
• Camshaft cap bolts (if reuse not recommended) × 6 — Use OEM specification
• Engine oil × 1 — Motorcraft 0W-20 Full Synthetic
• Engine coolant (if draining system) × 1 — Motorcraft Orange Coolant
• RTV silicone sealant × 1 — Motorcraft TA-31 or equivalent

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt
• Motorcraft Orange Coolant — 2 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 wait at least 2 minutes
4. Remove engine cover by pulling upward on cover clips
5. Drain engine coolant from radiator drain cock into appropriate container
6. Drain engine oil completely and replace oil filter
7. Document all electrical connector positions with photos before disconnection
8. Relieve fuel system pressure by removing fuel pump fuse and attempting to start engine until it fails to run
9. Identify which cylinder bank (left or right) contains the failed lifter

Procedure

1. 1

   Remove intake manifold and affected valve cover
   Disconnect all vacuum lines, PCV hoses, and electrical connectors from intake manifold. Remove charge air cooler outlet pipe. Remove intake manifold bolts in reverse of tightening sequence and lift manifold away. Disconnect ignition coils and remove from affected cylinder bank. Remove valve cover bolts and carefully pry cover loose using plastic wedge at designated pry points only. Clean all gasket surfaces thoroughly.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Cover Bolts19 Nm (14 lb-ft)
2. 2

   Rotate engine to TDC for cylinder #1
   Using a 22mm socket on the crankshaft pulley bolt, rotate engine clockwise (viewed from front) until timing marks on camshaft sprockets align with cylinder head deck surface. Verify that crankshaft keyway is at 12 o'clock position. This ensures #1 cylinder is at top dead center compression stroke. Mark timing chain-to-sprocket relationship with paint marker on both intake and exhaust cam sprockets.
   ⚠Only rotate engine in normal direction of rotation (clockwise from front). Reverse rotation can damage timing components.
3. 3

   Remove timing chain tensioner and lock chain
   Locate timing chain tensioner on the affected bank. Using timing chain tensioner release tool, compress and lock tensioner in retracted position. Remove tensioner mounting bolts and extract tensioner assembly. Verify timing chain is still properly positioned on sprockets. Install camshaft holding tool to prevent cam rotation during disassembly.
   ⚠️Chain must remain engaged on both cam sprockets at all times. If chain falls off, engine timing will be lost and must be completely re-timed.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Remove camshaft bearing caps
   Identify the camshaft (intake or exhaust) that operates the failed lifter. Each camshaft cap is numbered and directional - photograph positions before removal. Loosen camshaft bearing cap bolts in reverse numerical sequence (outside to inside) in multiple passes, no more than 1/4 turn per pass. Remove caps and store in order. Keep bolts with their respective caps.
   ⚠Uneven cap removal will bend the camshaft. Always loosen gradually and in proper sequence.
5. 5

   Remove camshaft and timing chain
   With bearing caps removed, carefully lift camshaft straight up and away from cylinder head. Note position of timing chain on sprocket. If removing intake camshaft, chain can remain on exhaust cam sprocket. If removing exhaust cam, secure chain with wire to prevent it from falling into timing cover. Mark chain position relative to remaining sprocket teeth for reassembly.
   ⚠️Support timing chain to prevent it from dropping into engine. A dropped chain requires complete front cover removal for retrieval.
6. 6

   Remove rocker arms from affected cylinder
   Identify which cylinder corresponds to the failed lifter. Remove rocker arm shaft bolts for that cylinder position only if using shaft-type rockers, or individual rocker arm bolts if applicable. Lift rocker arms away and keep in order. Note orientation of each rocker arm for reinstallation.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)

   Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
7. 7

   Extract failed lifter
   Using magnetic lifter removal tool, carefully extract the failed lifter from its bore. If lifter is stuck, apply gentle twisting motion while pulling. Do NOT use excessive force or pry tools that could damage the lifter bore. Inspect lifter bore for scoring, wear, or debris. Clean bore thoroughly with lint-free cloth. Inspect camshaft lobe corresponding to this lifter for wear, scoring, or discoloration.
   ⚠If lifter bore shows scoring or damage, cylinder head may require machine shop service. A damaged bore will cause premature failure of the new lifter.
   ℹ️Examine old lifter for signs of oil starvation, debris contamination, or mechanical collapse. This may indicate additional issues requiring attention.
8. 8

   Prepare and install new lifter
   Remove new lifter from packaging. Prime hydraulic lifter by submerging in fresh engine oil and manually compressing plunger 10-15 times to purge air. Coat lifter exterior thoroughly with fresh engine oil. Verify lifter bore is completely clean and dry. Install new lifter into bore with gentle downward pressure - it should slide in smoothly. Lifter should sit fully seated in bore with top surface approximately flush with or slightly below machined deck.
   ⚠New lifter MUST be primed with oil before installation. Installing a dry lifter can cause valve train noise and premature failure.
9. 9

   Reinstall rocker arms
   Coat rocker arm pivot points and valve stem tips with fresh engine oil. Position rocker arms in their original locations and orientations. If applicable, ensure cam lobe is pointing away from lifter (base circle position) before tightening rocker arm fasteners. Install and tighten rocker arm bolts or shaft bolts to specification in proper sequence.
   ⚠Rocker arm bolts must be tightened with cam lobe on base circle to prevent valve bending.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)

   Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
10. 10

    Reinstall camshaft
    Liberally coat all camshaft bearing journals and lobes with fresh engine oil or assembly lube. Carefully position camshaft back into cylinder head, ensuring timing chain engages sprocket at previously marked position. Verify timing marks still align. Install camshaft bearing caps in their exact original positions with directional arrows pointing toward front of engine.
    ⚠️Camshaft caps installed in wrong positions will cause immediate engine damage. Verify numbering and orientation before tightening.
11. 11

    Torque camshaft bearing caps
    Install camshaft cap bolts finger-tight. Tighten bearing cap bolts in numerical sequence (inside to outside) in multiple passes. First pass: 5 Nm, second pass: 12 Nm, final pass: to specification per torque data. Ensure camshaft rotates freely by hand after torquing. Remove camshaft holding tool.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
12. 12

    Reinstall timing chain tensioner
    Verify timing chain is properly seated on both sprockets and timing marks are still aligned. Install timing chain tensioner with new gasket if equipped. Tighten tensioner mounting bolts to specification. Release tensioner locking mechanism to allow tensioner to apply proper chain tension. Manually rotate engine two complete revolutions clockwise and recheck timing mark alignment.
    ⚠️After rotating engine two full turns, timing marks MUST realign perfectly. If marks do not align, timing is incorrect and engine must not be started.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Reinstall valve cover
    Install new valve cover gasket and bolt grommets. Apply small bead of RTV silicone to cylinder head at front and rear corners where head meets timing cover. Position valve cover and install bolts finger-tight. Tighten valve cover bolts in proper sequence (center outward) to specification. Allow RTV to cure for minimum 30 minutes before adding oil.
    ℹ️Do not overtighten valve cover bolts. Excessive torque will distort cover and cause oil leaks.
    Torque spec

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

    Reinstall intake manifold and accessories
    Install new intake manifold gaskets. Position intake manifold and install bolts finger-tight. Torque intake manifold bolts in proper sequence (center outward) to specification. Reconnect all vacuum lines, PCV hoses, and electrical connectors. Install charge air cooler outlet pipe. Reinstall ignition coils and connect all related wiring.
    Torque spec

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

    Refill fluids and final checks
    Install new oil filter and refill engine with 6 quarts of Motorcraft 0W-20 synthetic oil. Refill cooling system with Motorcraft Orange coolant to proper level. Reconnect negative battery cable. Double-check that all fasteners are tight, all electrical connections are secured, and no tools remain in engine bay. Install engine cover.
    ⚠Do not start engine until all fluid levels are verified correct and all connections are secure.

Reassembly

1. Reassembly is covered in the main procedure steps. Ensure all torque specifications are followed precisely.
2. All timing marks must align perfectly before attempting to start engine.
3. Allow RTV sealant to cure for 30 minutes minimum before starting engine.

Verification

• Before starting: Verify all timing marks align correctly and engine rotates smoothly by hand through two complete revolutions
• Check that all electrical connectors are fully seated and locked
• Verify engine oil level is correct on dipstick (should read between MIN and MAX marks)
• Verify coolant level is correct in overflow tank
• Start engine and listen for abnormal noises - there should be no valve train ticking or knocking
• Allow engine to reach operating temperature and check for oil or coolant leaks around valve cover and intake manifold
• Verify no diagnostic trouble codes are present using scan tool
• Road test vehicle under normal driving conditions and verify smooth operation with no unusual noises
• Recheck oil and coolant levels after test drive and top off if necessary
• Monitor engine for first 100 miles for any signs of oil consumption or recurring lifter noise

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