Cylinder Head Resurface

This procedure covers removal, machining, and reinstallation of cylinder heads on the 3.5L EcoBoost V6, including turbocharger removal, timing chain work, and head resurfacing to restore proper sealing.

Warnings

Tools required

Parts

• Cylinder head gasket set (left and right) × 1 — Use OEM specification
• Cylinder head bolts (TTY) × 20 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Turbocharger mounting gaskets × 2 — Use OEM specification
• Coolant temperature sensor O-ring × 2 — Use OEM specification
• Oil filter × 1 — FL-910S or equivalent
• Anti-seize compound × 1 — High-temperature rated
• RTV silicone gasket maker × 1 — Motorcraft TA-30 or equivalent

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
3. Remove engine cover and intake air system including air filter housing and intake tubes
4. Drain engine coolant completely into appropriate container by opening radiator petcock and removing lower radiator hose
5. Drain engine oil and remove oil filter
6. Remove front grille and detach charge air cooler (intercooler) from mounting
7. Label and disconnect all vacuum lines, electrical connectors, and fuel lines from intake manifold and cylinder heads
8. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
9. Support engine using support bar across engine bay or attach hoist to engine lift points
10. Remove serpentine belt and accessory drive components as needed for access

Procedure

1. 1

   Remove Valve Covers
   Disconnect ignition coil connectors and remove all six ignition coils. Disconnect PCV hoses and breather tubes from both valve covers. Remove valve cover bolts in reverse of tightening sequence. Carefully lift valve covers away from cylinder heads. Inspect gaskets for damage and discard.
   Torque spec

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

   Remove Intake Manifold
   Disconnect throttle body electrical connector and all fuel injector connectors. Remove fuel rail mounting bolts and carefully lift fuel rail with injectors as an assembly, securing out of the way. Disconnect coolant hoses from intake manifold. Remove intake manifold bolts working from outside toward center. Lift intake manifold from engine and remove old gaskets from cylinder head surfaces.
   ⚠Keep fuel rail assembly clean and protected. Do not allow injectors to hang by wiring or fuel lines.
   Torque spec

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

   Remove Exhaust Manifolds and Turbochargers
   Disconnect oxygen sensors and unbolt turbocharger oil feed and drain lines. Remove turbocharger-to-exhaust downpipe connection bolts. Apply penetrating oil to exhaust manifold nuts and allow to soak. Remove turbocharger mounting nuts and carefully separate turbochargers from exhaust manifolds. Remove exhaust manifold nuts working from hot (center) to cold (outer) positions. Lift manifolds away and discard gaskets.
   ⚠Exhaust studs are prone to breaking. If studs break, drill and extract remaining portion before cylinder head removal.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
4. 4

   Remove Front Engine Cover and Timing Components
   Remove crankshaft pulley using holding tool and appropriate socket. Remove front engine cover bolts and carefully pry cover away from engine block using plastic pry tool at designated pry points. Rotate crankshaft to TDC on cylinder #1 (timing marks aligned). Using paint or marker, mark timing chain positions on camshaft sprockets and crankshaft sprocket. Compress timing chain tensioners and lock in place using tensioner pins or suitable wire. Remove camshaft sprocket bolts while holding camshafts with holding tool.
   ⚠️Verify all timing marks are clearly visible and documented with photos before removing any timing components. Incorrect reassembly will result in catastrophic engine damage.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
5. 5

   Remove Camshafts
   Loosen camshaft bearing cap bolts gradually in multiple passes working from outside toward center to prevent warping. Remove bearing caps and keep in order for reinstallation. Carefully lift camshafts from cylinder heads, keeping intake and exhaust camshafts identified per bank. Store camshafts in protective covering on padded surface.
   ⚠Camshaft bearing caps are directional and position-specific. Mark each cap with cylinder head bank and position before removal.
6. 6

   Remove Cylinder Heads
   Remove all remaining external components from cylinder heads including coolant temperature sensors, coolant crossover pipe, and any remaining brackets. Loosen cylinder head bolts in reverse of tightening sequence in three progressive passes. Remove cylinder head bolts completely and discard (TTY design). Attach lifting fixture or strap to cylinder head and carefully break seal using gentle prying at designated lift points. Lift cylinder head straight up to avoid damage to block surface. Place on padded work surface with combustion chambers facing up. Repeat for second cylinder head.
   ⚠Cylinder heads weigh approximately 40-50 lbs each. Use proper lifting technique and assistance to prevent injury or damage.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
7. 7

   Inspect and Prepare for Machining
   Remove all remaining gasket material from cylinder head mating surfaces using plastic scraper. Clean surfaces thoroughly with brake cleaner. Using straightedge and feeler gauge, check cylinder head flatness at multiple points along length and width. Check both deck surface and manifold mating surfaces. Measure any warpage. Document valve condition and inspect combustion chambers for damage or carbon buildup. If warpage exceeds 0.003 inches or cracks are visible, cylinder head requires resurfacing.
   ℹ️Maximum material removal during resurfacing is typically 0.010 inches. Excessive removal affects compression ratio and requires corresponding block deck machining.
8. 8

   Machine Shop Service
   Transport cylinder heads to qualified machine shop for resurfacing. Specify Ford EcoBoost tolerances: maximum warpage after machining is 0.001 inches, surface finish 60-80 RA. Request valve inspection, valve seat reconditioning if needed, and pressure testing. Have shop clean heads thoroughly including all passages and bolt holes. Upon return, verify work meets specifications using dial indicator and straightedge.
   ℹ️Provide machine shop with both cylinder heads for consistent material removal and compression ratio maintenance across both banks.
9. 9

   Clean Block Deck Surface
   Thoroughly clean engine block deck surfaces using plastic scraper to remove all old gasket material. Clean bolt holes using thread chaser or tap to remove debris. Wipe surfaces with brake cleaner and lint-free cloths. Inspect block deck for damage, corrosion, or warpage. Clean coolant and oil passages in block. Verify engine is still at TDC and crankshaft has not moved.
   ⚠Keep all debris out of cylinders. Cover open cylinders with lint-free cloths during cleaning. Any debris entering cylinders will cause damage.
10. 10

    Install Cylinder Heads
    Verify all head bolt holes in block are clean and dry. Position new head gaskets on block deck, ensuring correct orientation using alignment dowels. Carefully lower cylinder heads onto block, aligning with dowel pins. Install new cylinder head bolts finger-tight. Tighten head bolts in proper sequence to 65 Nm (48 lb-ft). Then tighten bolts an additional 90 degrees using torque angle gauge. Finally, tighten bolts an additional 90 degrees (total 180 degrees of angle rotation after initial torque). Verify final torque pattern is uniform.
    ⚠️Follow torque sequence and angle tightening procedure exactly. Incorrect sequence or torque will result in head gasket failure.
    Torque spec

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

    Install Camshafts and Timing Components
    Lubricate camshaft journals and lobes with assembly lube or fresh engine oil. Install camshafts in correct positions (intake/exhaust, left/right bank). Install bearing caps in original positions with arrows pointing toward front of engine. Tighten bearing cap bolts gradually in multiple passes from center outward. Install camshaft sprockets aligned with timing marks made during disassembly. Install timing chains in marked positions. Remove tensioner locking pins to apply tension. Rotate engine two complete revolutions and verify all timing marks align correctly.
    ⚠️Verify timing marks alignment at least three times before proceeding. Incorrect timing will cause piston-to-valve contact upon startup.
12. 12

    Install Front Cover and Accessories
    Clean front cover mating surface and apply thin bead of RTV silicone to designated areas per Ford service manual. Install new gaskets and position front cover onto engine. Install cover bolts and tighten to specification in proper sequence. Install crankshaft pulley and tighten to specification. Reinstall serpentine belt and verify proper routing and tension.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
13. 13

    Install Exhaust Manifolds and Turbochargers
    Install new exhaust manifold gaskets. Apply high-temperature anti-seize to exhaust manifold studs. Position exhaust manifolds and install nuts hand-tight. Tighten exhaust manifold nuts to 30 Nm (22 lb-ft) working from hot (center) positions to cold (outer) positions. Install new turbocharger gaskets and mount turbochargers to manifolds. Reconnect turbocharger oil feed and drain lines. Install new exhaust downpipe gaskets and connect downpipes.
    ℹ️Anti-seize prevents future seizing but must be applied sparingly to avoid contaminating oxygen sensors.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
14. 14

    Install Intake Manifold and Valve Covers
    Install new intake manifold gaskets on cylinder heads. Position intake manifold and install bolts, tightening from center outward to 25 Nm (18 lb-ft). Reinstall fuel rail assembly with injectors and tighten fuel rail bolts. Reconnect all fuel lines, vacuum lines, and electrical connectors. Install new valve cover gaskets ensuring proper seating in grooves. Position valve covers and install bolts, tightening in proper sequence to 10 Nm (7 lb-ft). Install ignition coils and reconnect coil connectors.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

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

    Final Assembly and Fluid Fill
    Reinstall charge air cooler and front grille assembly. Reconnect all remaining electrical connectors, hoses, and cables. Install new oil filter and refill engine with 6 quarts of Motorcraft 0W-20 full synthetic oil. Fill cooling system with 13 quarts of Motorcraft Orange coolant, burping system to remove air pockets. Reconnect battery negative cable. Double-check all connections, fasteners, and fluid levels.
    ℹ️Cooling system may require additional bleeding after initial startup to remove all air pockets.

Reassembly

1. Verify all tools and parts have been removed from engine compartment
2. Confirm all electrical connectors are properly seated and locked
3. Check for any loose fasteners or disconnected hoses
4. Verify oil and coolant levels are at proper marks

Verification

• Perform visual inspection of entire engine bay for leaks, loose connections, or missing components
• Start engine and allow to idle while monitoring for unusual noises, vibrations, or warning lights
• Check for coolant, oil, or exhaust leaks around all serviced areas
• Monitor engine temperature to ensure proper thermostat operation and no overheating
• After engine reaches operating temperature, shut off and allow to cool, then recheck coolant and oil levels
• Perform test drive monitoring for proper power delivery, smooth operation, and no misfires or abnormal sounds
• Clear any stored diagnostic codes and verify no new codes are present
• Recheck all fluid levels after test drive and inspect for any new leaks
• Verify turbocharger boost pressure is within specification using scan tool if available

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