This procedure covers removal and replacement of a single cylinder head gasket on the 2015-2020 Ford F-150 3.5L EcoBoost V6 engine, including turbocharger removal, timing chain service, and head reinstallation.

Warnings

Tools required

Parts

• Cylinder head gasket (single bank) × 1 — Use OEM specification
• Cylinder head bolts (set of 10) × 1 — Use OEM specification - MUST replace
• Valve cover gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Turbocharger to exhaust manifold gasket × 1 — Use OEM specification
• Spark plugs (6) × 6 — Motorcraft SP-546 or equivalent
• Oil filter × 1 — Motorcraft FL-910-S
• Timing chain tensioner gasket × 1 — Use OEM specification
• Coolant temperature sensor O-ring × 1 — Use OEM specification

Fluids

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

Preparation

1. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
2. Raise vehicle on lift or support safely on jack stands with front elevated
3. Remove engine cover (twist and pull retaining grommets)
4. Drain engine coolant completely into appropriate container by opening radiator petcock and lower radiator hose
5. Drain engine oil and remove oil filter
6. Relieve fuel system pressure by removing fuel pump relay and cranking engine until it stalls
7. Document or photograph all electrical connector positions and vacuum line routing with camera
8. Position a suitable engine support fixture or hoist to support engine weight during mount removal

Procedure

1. 1

   Remove air intake system and charge air cooler
   Remove air filter housing and intake duct assembly. Disconnect mass airflow sensor electrical connector. Remove charge air cooler inlet and outlet tubes. Remove charge air cooler mounting bolts and remove cooler assembly. On the affected bank, disconnect all boost pressure hoses and PCV hoses from turbocharger and intake manifold.
2. 2

   Remove turbocharger assembly
   Disconnect oxygen sensor connectors for the affected bank. Remove heat shields from turbocharger. Disconnect oil supply line from top of turbocharger (14mm banjo bolt). Disconnect oil return line from bottom of turbo. Support turbocharger and remove mounting nuts securing turbo to exhaust manifold. Remove turbocharger assembly and set aside. Plug all oil passages to prevent contamination.
3. 3

   Remove intake manifold
   Disconnect throttle body electrical connector and all fuel injector connectors. Disconnect fuel supply line using appropriate fuel line disconnect tool. Remove brake booster vacuum line. Disconnect all vacuum lines from intake manifold and mark for reinstallation. Remove intake manifold mounting bolts in reverse of tightening sequence (outside to center). Carefully lift intake manifold away from engine and cover intake ports with clean shop towels to prevent debris entry.
4. 4

   Remove valve cover and ignition components
   Disconnect ignition coil electrical connectors on affected bank. Remove all six ignition coils (10mm bolts). Remove spark plugs and store in order. Remove valve cover bolts in crisscross pattern. Carefully break valve cover seal using plastic pry tool if necessary. Remove valve cover and gasket. Inspect valve train for wear or damage while exposed.
5. 5

   Remove exhaust manifold
   Working from underneath vehicle if needed, remove exhaust manifold heat shield. Disconnect exhaust pipe from manifold at flange (may require penetrating oil on studs). Remove exhaust manifold mounting nuts working from outside to inside. Remove exhaust manifold and gasket. Inspect manifold for cracks or warping.
6. 6

   Set engine to TDC and lock timing
   Rotate crankshaft clockwise (viewed from front) using 22mm socket on crankshaft bolt until number 1 cylinder is at top dead center on compression stroke. Both camshafts on the affected bank should have lobes pointing upward and outward. Install Ford camshaft holding tool 303-1046 on rear of both camshafts to lock position. Install crankshaft TDC timing pin tool 303-1248 through cylinder block to lock crankshaft position. Verify both tools are fully seated.
7. 7

   Remove timing chain components
   Remove timing chain cover bolts for affected bank (multiple bolt sizes and lengths - note positions). Carefully remove timing chain cover. Remove timing chain tensioner mounting bolts and remove tensioner. Remove timing chain guide bolts and guides. Mark timing chain position on camshaft sprockets with paint marker. Remove camshaft sprocket bolts while holding camshafts with holding tool. Remove timing chain and both camshaft sprockets as assembly. Do not allow camshafts to rotate.
8. 8

   Remove camshaft caps and camshafts
   Loosen camshaft cap bolts in reverse order of tightening sequence (outside to center) in multiple passes to gradually release valve spring pressure. Remove all camshaft caps and mark position and orientation. Carefully lift both camshafts from cylinder head and place on clean work surface. Inspect camshaft lobes and journals for wear or scoring. Keep all components in order for reinstallation.
9. 9

   Remove cylinder head bolts and head
   Disconnect any remaining coolant hoses, sensor connectors, or brackets attached to cylinder head. Loosen cylinder head bolts in reverse of tightening sequence (outside to center pattern) in several passes. Remove all 10 cylinder head bolts and discard - these must be replaced. Using lifting hooks or carefully positioned pry bars, break cylinder head gasket seal. Lift cylinder head straight up and off engine block. Place cylinder head on clean wooden blocks with combustion chambers facing up.
   ⚠Cylinder head weighs approximately 40-50 pounds. Use proper lifting technique or get assistance to avoid injury or dropping head.
   Torque spec

   Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
10. 10

    Clean and inspect mating surfaces
    Carefully remove all gasket material from cylinder head and engine block surfaces using plastic gasket scraper. Do not gouge or scratch aluminum surfaces. Clean surfaces with brake cleaner and lint-free cloths. Use a precision straight edge and feeler gauge to check cylinder head deck flatness - maximum allowable warpage is 0.003 inches (0.076mm). Check engine block deck surface similarly. If beyond specification, cylinder head must be resurfaced by machine shop. Inspect head for cracks, especially between valve seats and around coolant passages.
11. 11

    Install new head gasket and cylinder head
    Ensure engine block and cylinder head surfaces are completely clean and dry. Install new cylinder head gasket on engine block with 'TOP' or 'OBEN' marking facing up. Align gasket over dowel pins. Carefully lower cylinder head onto engine block, aligning with dowel pins. Install NEW cylinder head bolts finger-tight in sequence. Using torque wrench and angle gauge, follow multi-step torque sequence: Step 1 - Torque all bolts to 26 lb-ft in sequence. Step 2 - Torque all bolts to 44 lb-ft in sequence. Step 3 - Loosen all bolts 1 complete turn. Step 4 - Torque all bolts to 26 lb-ft in sequence. Step 5 - Rotate all bolts an additional 90 degrees in sequence. Step 6 - Rotate all bolts an additional 90 degrees in sequence.
    ⚠Use only NEW cylinder head bolts. Follow the exact torque sequence and procedure. Deviating from this procedure will result in gasket failure.
    Torque spec

    Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
12. 12

    Reinstall camshafts and caps
    Lubricate camshaft journals and lobes with clean engine oil. Position both camshafts in cylinder head with lobes pointing upward and outward (TDC position). Install camshaft caps in original positions, noting position markings. Install camshaft cap bolts finger-tight. Torque camshaft cap bolts to 14 lb-ft (19 Nm) in sequence from center outward in multiple passes. Install camshaft holding tool 303-1046 to verify proper positioning.
13. 13

    Reinstall timing chain assembly
    Verify crankshaft is still locked at TDC with timing pin installed. Position camshaft sprockets on timing chain with timing marks aligned per Ford specification. Install timing chain and sprocket assembly onto camshafts, ensuring chain is properly seated in crankshaft sprocket. Install camshaft sprocket bolts and torque to specification while holding camshafts with holding tool. Install timing chain guides and tensioner. Install new tensioner gasket and timing chain tensioner, torque bolts to specification. Remove camshaft holding tool and crankshaft timing pin. Rotate engine two complete revolutions by hand and verify timing marks align again.
14. 14

    Install timing cover, exhaust manifold, and valve cover
    Install new timing cover gasket and reinstall timing cover with all bolts in original positions, torque to specification. Install new exhaust manifold gasket on cylinder head. Position exhaust manifold and install mounting nuts, torquing to 29 lb-ft (39 Nm) working from center outward. Install new valve cover gasket on valve cover. Position valve cover on cylinder head and install bolts, torquing to 12 lb-ft (16 Nm) in crisscross pattern. Install spark plugs (torque to specification) and ignition coils.
    Torque spec

    Exhaust Manifold Nuts25 Nm (18 lb-ft)
15. 15

    Reinstall intake manifold and turbocharger
    Remove shop towels from intake ports. Install new intake manifold gaskets on cylinder heads. Position intake manifold and install mounting bolts finger-tight. Torque intake manifold bolts to 21 lb-ft (28 Nm) in sequence from center outward. Reconnect all fuel lines, vacuum lines, and electrical connectors. Install new turbocharger to exhaust manifold gasket. Position turbocharger on exhaust manifold studs and install mounting nuts. Torque turbo mounting nuts to specification. Reconnect turbocharger oil supply and return lines with new crush washers. Install all heat shields.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

Reassembly

1. Reinstall charge air cooler and all boost pressure hoses, ensuring all clamps are tight
2. Reinstall air intake system and reconnect mass airflow sensor
3. Reconnect all oxygen sensor electrical connectors
4. Fill engine with 6 quarts of Motorcraft 0W-20 full synthetic oil and install new oil filter
5. Refill cooling system with 13 quarts of Motorcraft Orange Coolant using vacuum fill procedure if available
6. Reconnect negative battery cable
7. Reinstall engine cover

Verification

• Start engine and allow to idle - verify no coolant, oil, or exhaust leaks at all gasket surfaces
• Monitor engine temperature gauge and verify cooling system reaches normal operating temperature without overheating
• Check for proper oil pressure indication on instrument cluster
• Listen for unusual valve train noise or timing chain noise - should be smooth and quiet
• Perform a test drive and verify normal engine operation, power delivery, and boost pressure
• After test drive, recheck all fluid levels and inspect for any new leaks
• Allow engine to cool and retorque cylinder head bolts if required by service manual (not typically required with torque-to-yield bolts)
• Verify no diagnostic trouble codes are present using OBD-II scanner

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