Lifters/Tappets - All

This procedure involves removing both cylinder heads to replace all hydraulic lash adjusters (lifters/tappets) on the 3.5L EcoBoost twin-turbo V6 engine, a complex job requiring precise timing component alignment and torque procedures.

Warnings

Tools required

Parts

• Hydraulic lash adjusters (lifters) × 24 — Motorcraft MM-1131 or equivalent, set of 24
• Valve cover gaskets (left and right) × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Coolant thermostat housing gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Camshaft position sensor O-rings × 4 — Use OEM specification
• Engine oil and filter × 1 — Motorcraft FL-910S filter
• RTV silicone sealant × 1 — Motorcraft TA-357 or equivalent
• Assembly lubricant (molybdenum disulfide) × 1 — Use OEM specification

Fluids

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

Preparation

1. Ensure engine is completely cold (minimum 3 hours after last operation)
2. Disconnect negative battery cable and wait 10 minutes for airbag system capacitor discharge
3. Remove engine cover and air intake system completely
4. Drain engine coolant 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 fuse, starting engine, and allowing it to stall
7. Remove front grille and radiator support components for access
8. Remove drive belts (serpentine and accessories)
9. Position vehicle on level surface with wheel chocks applied
10. Set up engine support fixture or attach hoist to engine lifting eyes
11. Clear generous workspace around engine bay and organize containers for fasteners by assembly location

Procedure

1. 1

   Remove intake manifold and fuel system components
   Disconnect all electrical connectors from throttle body, fuel injectors, and intake manifold sensors. Mark each connector location. Disconnect fuel supply line using appropriate disconnect tool. Remove all vacuum lines from intake manifold. Remove throttle body mounting bolts. Unbolt intake manifold in reverse of tightening sequence (work from outside toward center) and lift away carefully. Stuff shop towels into intake ports to prevent debris entry.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
2. 2

   Remove valve covers
   Disconnect ignition coil electrical connectors and remove all six coils from both banks. Remove PCV hoses and breather tubes from valve covers. Remove valve cover bolts in reverse sequence (outside to inside pattern). Carefully break seal with plastic pry tool if stuck. Lift valve covers away and inspect gasket sealing surfaces for damage. Clean all gasket residue from mating surfaces using plastic scraper only (do not use metal tools on aluminum).
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
3. 3

   Remove accessory drive components and front timing cover
   Remove power steering pump (if equipped) and A/C compressor, securing them aside without disconnecting refrigerant lines. Remove water pump and thermostat housing assembly. Remove crankshaft pulley using appropriate puller tool (do not hammer). Remove all timing chain front cover bolts and carefully pry cover away from block. Clean all RTV sealant residue from block and cover mating surfaces. Inspect timing chain tensioners and guides for wear.
   ⚠Do not disconnect A/C lines unless properly certified for refrigerant handling. Secure compressor to frame with wire or strap to avoid hose strain.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
4. 4

   Lock timing components and verify alignment
   Rotate crankshaft clockwise using breaker bar on crankshaft bolt until cylinder #1 is at TDC compression stroke. Install camshaft timing holding tool (Ford 303-1530) into both camshafts on each bank to lock them in position. Verify all timing marks align with indicators on chain guides. Install timing chain tensioner locking pins to prevent tensioner movement. Take multiple photographs of timing mark positions from different angles for reference during reassembly.
   ⚠️Absolute precision is required. If timing marks do not align perfectly, DO NOT proceed. Consult factory service manual for troubleshooting procedures.
5. 5

   Remove camshaft position sensors and camshaft bearing caps
   Remove all four camshaft position sensors (intake and exhaust, both banks). Using permanent marker, clearly mark each camshaft bearing cap with its position number and orientation arrow. Loosen camshaft bearing cap bolts in multiple passes working from outside toward center, loosening each bolt 1/4 turn at a time to prevent camshaft distortion. Remove bolts completely and lift caps straight up. Store caps in order on clean workspace. Carefully lift camshafts out, keeping intake and exhaust separate and marked for bank identification.
   ⚠Camshaft bearing caps MUST be reinstalled in exact original positions. Cap interchange will cause immediate bearing seizure and engine destruction.
   Torque spec

   Camshaft Position Sensor10 Nm (7 lb-ft)

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
6. 6

   Remove rocker arms and hydraulic lash adjusters
   Remove rocker arm bolts and carefully lift each rocker arm assembly. Keep rocker arms organized by cylinder and position (intake/exhaust). Using magnetic pickup tool, remove each hydraulic lash adjuster from its bore in the cylinder head. Each cylinder head has 12 lash adjusters. Place old adjusters in numbered compartmentalized container matching cylinder position for inspection. Inspect cylinder head bores for scoring or damage. Clean each bore thoroughly with clean lint-free cloth and brake cleaner.
   ℹ️The 3.5L EcoBoost has 24 total lash adjusters (12 per bank). Each rocker arm operates one valve with one lash adjuster underneath.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)
7. 7

   Inspect and prepare new hydraulic lash adjusters
   Inspect all old lash adjusters for wear, scoring, or collapse. Compare new adjusters to old ones to verify correct parts. Submerge each new lash adjuster in clean engine oil for minimum 10 minutes. Remove one adjuster at a time from oil bath and repeatedly compress plunger while submerged to purge air and prime internal mechanism. Adjuster should compress with moderate resistance when fully primed. Apply assembly lubricant to exterior of each adjuster.
   ⚠Lash adjusters MUST be oil-primed before installation. Air-locked adjusters will cause severe valvetrain noise and potential valve float damage at high RPM.
8. 8

   Install hydraulic lash adjusters
   Coat each cylinder head lash adjuster bore with clean engine oil. Install each primed lash adjuster into its bore, ensuring it seats fully at bottom of bore. Adjuster should slide in smoothly without forcing. Verify each adjuster moves freely by pressing down with clean finger (should compress slightly with moderate pressure). Install all 24 adjusters (12 per bank) before proceeding.
   ℹ️Work on one bank at a time to prevent confusion. Keep workspace clean to prevent debris from entering engine.
9. 9

   Reinstall rocker arms
   Lubricate each rocker arm contact surface (adjuster pad, valve stem contact, and camshaft contact) with assembly lubricant. Position each rocker arm over its valve stem and lash adjuster, ensuring alignment. Verify corresponding camshaft lobe is pointing away from rocker arm (base circle position) before installing bolt. Install rocker arm bolts finger-tight initially. Once all rocker arms are positioned, torque bolts to specification in two passes: first to 15 Nm, then final to specification. Work across cylinder head in alternating pattern (1-6-2-5-3-4 for example).
   ⚠Never torque rocker arm bolts with camshaft lobe at peak lift position. This will damage valve, rocker arm, and lash adjuster. Ensure cam lobe points away from rocker before tightening.
   Torque spec

   Rocker Arm Bolts30 Nm (22 lb-ft)
10. 10

    Reinstall camshafts and bearing caps
    Liberally lubricate all camshaft bearing journals and lobes with assembly lubricant. Carefully position each camshaft into its corresponding location (intake and exhaust per bank), ensuring timing marks are visible and accessible. Install camshaft bearing caps in their exact original positions following marked orientation arrows. Install cap bolts finger-tight initially. Torque bearing cap bolts in three progressive passes (5 Nm, 10 Nm, then final 14 Nm) working from center caps outward toward ends in sequence. Install camshaft timing holding tool to verify camshafts remain locked in correct position.
    ⚠️Bearing cap position errors will cause immediate catastrophic failure. Triple-check cap markings before torquing.
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
11. 11

    Verify valve timing and reinstall timing components
    With camshaft holding tools still installed, verify all timing chain marks align perfectly with indicators. Use dial indicator on cylinder #1 intake valve to verify TDC position matches crankshaft position. Remove timing chain tensioner locking pins and verify tensioners apply proper tension. Carefully remove camshaft holding tools while observing that camshafts do not rotate. Install new camshaft position sensor O-rings lubricated with clean engine oil, then install all four sensors to specification.
    ⚠️This is final verification before sealing engine. Any timing discrepancy must be corrected before proceeding.
    Torque spec

    Camshaft Position Sensor10 Nm (7 lb-ft)
12. 12

    Install front timing cover
    Apply thin bead of RTV sealant to timing cover mating surface following factory pattern (continuous bead around perimeter, small dabs at block-to-pan joints). Install new cover gasket where applicable. Position timing cover carefully onto block, ensuring all alignment dowels engage properly. Install cover bolts and torque to specification in crisscross pattern from center outward. Allow RTV to cure for minimum 30 minutes before adding fluids.
    Torque spec

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

    Reinstall valve covers and intake manifold
    Install new valve cover gaskets onto covers, ensuring gasket alignment tabs engage properly. Apply small dabs of RTV at camshaft cap-to-cylinder head junctions (front and rear only). Position valve covers carefully and install bolts. Torque valve cover bolts to specification in sequence from center outward in two passes. Remove shop towels from intake ports. Install new intake manifold gaskets. Position intake manifold and install bolts finger-tight. Torque intake manifold bolts to specification in sequence from center outward.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
14. 14

    Reinstall remaining components and refill fluids
    Reinstall all remaining components in reverse order of removal: ignition coils, fuel system components, throttle body, cooling system components, accessory drives, belts, and front grille assembly. Refill cooling system with Motorcraft Orange coolant to proper level. Install new oil filter and refill with 6 quarts Motorcraft 0W-20 synthetic oil. Reconnect battery negative cable.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)

    Mounting Bolts31 Nm (23 lb-ft)

    Gasket Bolts23 Nm (17 lb-ft)
15. 15

    Initial startup and break-in procedure
    Prime oil system by cranking engine for 10 seconds with fuel pump fuse removed and throttle wide open (this prevents firing while building oil pressure). Reinstall fuel pump fuse. Start engine and immediately verify oil pressure light extinguishes. Allow engine to idle for 5 minutes while monitoring for leaks, unusual noises, or warning lights. Check for coolant, oil, and fuel leaks. Rev engine slowly to 2000 RPM several times to seat components. After initial run, shut down and recheck all fluid levels. Avoid high RPM or heavy loads for first 50 miles of operation.
    ⚠️If any unusual noises occur during startup (knocking, rattling, grinding), immediately shut down engine and investigate. Do not continue operation.
    ⚠Lash adjusters require several minutes of operation to fully pump up and eliminate valvetrain noise. Some light ticking for first 1-2 minutes is normal.

Reassembly

1. All components must be reinstalled in reverse order of removal with new gaskets and seals
2. Verify all electrical connectors are fully seated and locked
3. Double-check all hose clamps and connections are properly tightened
4. Ensure no tools or rags remain in engine bay before startup
5. Torque specifications must be followed precisely in specified sequences

Verification

• Verify oil pressure within normal range (gauge or light) within 2 seconds of startup
• Check for any coolant, oil, or fuel leaks around all disturbed components
• Listen for abnormal valvetrain noise beyond initial 2-minute pump-up period
• Verify smooth idle with no misfires or rough running (check for diagnostic codes)
• Test drive vehicle under light load to verify normal operation and power delivery
• After 50-mile break-in, recheck all fluid levels and inspect for leaks
• Monitor oil consumption over next 500 miles to verify proper lash adjuster sealing
• Consider professional scan tool verification of camshaft position sensor correlation after repair

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