Complete piston replacement procedure requiring full engine disassembly including cylinder head removal, crankshaft access, and connecting rod/piston assembly replacement on the 3.5L EcoBoost V6 twin-turbo engine.

Warnings

Tools required

Parts

• Piston and ring set (complete for 6 cylinders) × 1 — Use OEM specification
• Connecting rod bearing set × 1 — Use OEM specification
• Main bearing set × 1 — Use OEM specification
• Cylinder head gasket set × 1 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Timing chains and guides kit × 1 — Use OEM specification
• Oil pump pickup tube O-ring × 1 — Use OEM specification
• Turbocharger gasket kit × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Water pump gasket × 1 — Use OEM specification
• Thermostat and O-ring × 1 — Use OEM specification
• Oil filter × 1 — FL-910S or equivalent
• Engine oil drain plug washer × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 12 — Use OEM specification
• Cylinder head bolts (TTY) × 2 — Use OEM specification
• Main bearing cap bolts (TTY) × 1 — Use OEM specification
• RTV silicone sealant (Ford specification) × 2 — TA-2-B or equivalent

Fluids

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

Preparation

1. Position vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 10 minutes for capacitor discharge
3. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
4. Drain engine coolant completely into appropriate container
5. Drain engine oil and remove oil filter
6. Remove engine cover and air intake assembly
7. Remove both turbochargers with all connected piping and charge air coolers
8. Support engine with hoist and remove engine mounts
9. Remove engine from vehicle and mount securely on engine stand
10. Clean exterior of engine thoroughly before disassembly
11. Prepare clean workspace with organized parts storage and labeling system

Procedure

1. 1

   Remove Accessory Drive Components
   Remove serpentine belt, alternator, AC compressor (leave hoses connected and secure aside), power steering pump mounting bracket, and all accessory drive pulleys. Remove harmonic balancer using appropriate puller tool. Mark rotational position before removal.
2. 2

   Remove Valve Covers and Timing Components
   Remove both valve covers. Remove timing chain cover by removing all perimeter bolts. Remove timing chains, tensioners, guides, and camshaft sprockets following proper timing mark alignment procedures. Use Ford timing tool kit to lock camshafts in position during removal. Keep all components organized by cylinder bank.
   ⚠Timing chain components must be replaced as a complete set. Do not reuse timing chains, guides, or tensioners.
   Torque spec

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

   Remove Cylinder Heads
   Remove intake manifold assembly completely. Disconnect exhaust manifolds from cylinder heads. Remove cylinder head bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift cylinder heads from block using appropriate lifting points. Place heads on clean surface with combustion chambers facing up. Inspect head surfaces for warpage.
   ⚠Cylinder heads are heavy (approximately 50 lbs each). Use proper lifting technique or assistance.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
4. 4

   Remove Oil Pan and Oil Pump
   Remove oil pan bolts in cross pattern and carefully separate pan from block. Remove oil pump pickup tube and oil pump assembly. Inspect pickup tube screen for debris. Clean all sealing surfaces thoroughly.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
5. 5

   Measure and Remove Ridge from Cylinder Bores
   Rotate crankshaft to bring each piston to bottom dead center. Use ridge reamer to carefully remove any ridge at top of each cylinder bore. Work slowly and avoid removing parent metal from cylinder walls. Clean all cutting debris thoroughly with shop vacuum and lint-free cloths soaked in solvent.
   ⚠Failure to remove cylinder ridge will damage pistons and rings during removal and installation.
6. 6

   Remove Connecting Rod Caps and Pistons
   Mark each connecting rod and cap with cylinder number and orientation using permanent marker or stamps. Remove connecting rod bolts and caps, keeping each set with its respective rod. Push each piston and rod assembly out through top of block. Keep assemblies organized and labeled by cylinder number. Inspect each rod for twisting or bending.
   ℹ️Factory connecting rod orientation marking is on the camshaft side of the engine. Maintain this orientation during reassembly.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
7. 7

   Inspect and Measure Cylinder Bores
   Clean cylinder bores thoroughly. Measure each bore at top, middle, and bottom positions in two perpendicular directions using cylinder bore gauge. Record all measurements. Check for taper (top to bottom difference) not exceeding 0.002 inches and out-of-round not exceeding 0.001 inches. Inspect for scoring or damage. Determine if machining is required.
   ⚠If cylinder bores exceed wear limits, engine block must be bored and honed to next oversize. Use corresponding oversize pistons.
8. 8

   Inspect Crankshaft and Main Bearings
   Remove main bearing caps following proper sequence. Lift crankshaft from block and inspect all journal surfaces for scoring or damage. Measure all main and rod journals with micrometer. Check crankshaft for straightness. Inspect main bearing surfaces in block and caps for damage. Clean all oil passages in crankshaft using rifle brush and compressed air.
   ⚠Crankshaft journals must be within specification. Out-of-spec journals require crankshaft grinding and undersize bearings.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
9. 9

   Install New Main Bearings and Crankshaft
   Install new main bearing shells in block and caps, ensuring locating tabs are properly seated. Lubricate bearings with assembly lube or engine oil. Carefully lower crankshaft into block. Install upper thrust bearing halves. Place Plastigage on each journal and install caps finger-tight to check bearing clearances. Remove caps and measure Plastigage. Clearance should be 0.0008-0.0015 inches. Once verified, apply final lubricant and install caps.
   ⚠Follow exact torque sequence from center main bearing outward. Tighten to 75 Nm (55 lb-ft) then rotate additional angle per Ford specification (typically 90 degrees).
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
10. 10

    Prepare and Install New Pistons on Connecting Rods
    If reusing connecting rods, install new rod bearings in rods and caps. Remove old pistons from rods by removing piston pin retaining clips and pressing out pins. Install new pistons on rods ensuring directional markings align correctly (piston arrow faces front of engine, rod markings face camshaft side). Install new piston pin retaining clips ensuring they are fully seated in grooves. Install piston rings using ring installer tool in correct order: oil control ring (expander first, then rails), then lower compression ring, then top compression ring. Verify all ring end gaps are properly positioned (120 degrees apart).
    ⚠Piston rings are fragile and can break if over-expanded. Use proper ring installation tool and work carefully.
11. 11

    Install Piston and Rod Assemblies
    Install new connecting rod bearings and lubricate thoroughly. Lubricate cylinder bores with engine oil. Install piston ring compressor on first piston assembly, ensuring all rings are fully compressed. Install guide sleeves over rod bolts to protect crankshaft journals. Insert assembly into correct cylinder with piston arrow facing front of engine. Tap piston gently through ring compressor using wooden hammer handle. Guide connecting rod onto crankshaft journal. Install rod cap in correct orientation with new TTY bolts. Repeat for all six cylinders.
    ⚠Tighten connecting rod bolts to 45 Nm (33 lb-ft), then rotate additional angle per Ford specification (typically 90 degrees). Use new TTY bolts only.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
12. 12

    Install Oil Pump and Oil Pan
    Install oil pump assembly with new O-ring and tighten mounting bolts. Install oil pump pickup tube with new O-ring. Apply thin bead of RTV silicone to oil pan rail where specified in service manual. Install new oil pan gasket and position oil pan. Install oil pan bolts in criss-cross pattern.
    Torque spec

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)

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

    Install Cylinder Heads
    Ensure block deck surfaces are perfectly clean and dry. Install new cylinder head gaskets with alignment dowels. Carefully position cylinder heads onto block. Install new TTY cylinder head bolts with light oil on threads. Tighten bolts in proper sequence (center outward pattern) to initial torque of 65 Nm (48 lb-ft), then follow Ford's multi-stage angle tightening procedure (typically 90 degrees, then additional 90 degrees).
    ⚠️Cylinder head bolt tightening sequence and procedure must be followed exactly. Improper procedure will result in head gasket failure.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
14. 14

    Install Timing Components
    Install new timing chains, guides, tensioners, and sprockets following exact timing mark alignment procedures. Use Ford timing tool kit to lock camshafts and crankshaft in proper position. Verify timing alignment three times before proceeding. Apply RTV silicone to timing cover at specified locations. Install timing cover with new gasket. Install harmonic balancer to original position using installer tool (never hammer onto crankshaft).
    ⚠️Incorrect timing chain installation will result in valve-to-piston contact and catastrophic engine damage.
    Torque spec

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

    Complete Engine Reassembly
    Install valve covers with new gaskets. Install intake manifold with new gaskets. Reconnect exhaust manifolds with new gaskets. Install all accessory components including alternator, AC compressor, and brackets. Install turbochargers with new gaskets and all associated piping. Install new oil filter and drain plug with new crush washer. Install engine into vehicle and reconnect all mounts, electrical connections, coolant hoses, and fuel lines. Refill with specified coolant and engine oil.
    Torque spec

    Gasket Bolts23 Nm (17 lb-ft)

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Double-check all fastener torque values and sequences before initial startup
2. Verify all electrical connectors are fully seated and locked
3. Confirm all vacuum lines and boost piping are properly connected with no leaks
4. Install fresh engine air filter
5. Prime oil system by cranking engine with fuel pump fuse removed until oil pressure builds
6. Reconnect battery and clear any diagnostic codes

Verification

• Perform initial startup and listen for abnormal noises (ticking, knocking, rattling)
• Monitor oil pressure gauge - should reach normal pressure within 5 seconds
• Check for oil, coolant, and boost leaks while engine idles
• Allow engine to reach operating temperature and verify cooling system operation
• Perform idle relearn procedure using Ford IDS or equivalent scan tool
• Road test vehicle and monitor for proper operation under various loads
• Recheck all fluid levels after test drive
• Perform first oil change at 500 miles, then follow normal service intervals
• Monitor for any oil consumption or performance issues during break-in period (first 1000 miles)

More procedures for this vehicle