Valve Job - Complete

Complete valve job including cylinder head removal, valve grinding/lapping, seat refacing, valve guide inspection, and reassembly with new valve stem seals and gaskets for the 3.5L EcoBoost V6 engine.

Warnings

Tools required

Parts

• Cylinder head gaskets (set of 2) × 2 — Use OEM specification
• Valve cover gaskets (set of 2) × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Valve stem seals (set of 24) × 24 — Use OEM specification
• Exhaust manifold gaskets (set of 2) × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Cylinder head bolts (TTY - set of 20) × 20 — Use OEM specification
• Camshaft cap bolts (if reusing shows wear) × 1 — Use OEM specification
• Coolant (Motorcraft Orange) × 1 — VC-7-B
• Engine oil and filter × 1 — 0W-20 Full Synthetic
• Anti-seize compound × 1 — High-temp rated

Fluids

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

Preparation

1. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
2. Drain engine coolant completely from radiator and block drain plugs
3. Drain engine oil and remove oil filter
4. Remove engine cover and air intake system including both turbochargers
5. Relieve fuel system pressure from both high-pressure direct injection and low-pressure port injection rails
6. Remove intercooler system and charge air cooler pipes
7. Support engine from above using engine support fixture
8. Label and photograph all vacuum lines, electrical connectors, and coolant hoses for reassembly reference
9. Remove accessory drive belt and idler pulleys
10. Set up clean workspace with plastic sheeting to protect removed cylinder heads during transport to machine shop

Procedure

1. 1

   Remove Valve Covers and Upper Engine Components
   Disconnect ignition coils and remove all six coils. Remove PCV hoses and breather tubes from valve covers. Remove valve cover bolts in reverse sequence (outside to inside) and carefully lift valve covers. Remove intake manifold assembly including both fuel rails (direct and port injection). Disconnect and remove exhaust manifolds from cylinder heads.
2. 2

   Remove Timing Chain Components
   Remove front timing cover after removing all bolts in reverse sequence. Mark timing chain position on all sprockets using paint pen - mark camshaft sprockets, crankshaft sprocket, and chain links at TDC position for cylinder 1. Remove timing chain tensioners by inserting retaining pin or clip to compress tensioner. Remove timing chain guides. Remove camshaft sprockets while holding camshaft hex with wrench. Lift timing chains off crankshaft sprocket.
   ⚠Do not rotate crankshaft or camshafts independently once timing chains are removed to prevent valve-to-piston contact.
3. 3

   Remove Camshafts
   Loosen camshaft cap bolts in reverse sequence (outward to center) in multiple passes, no more than 1/4 turn per pass to prevent camshaft or bearing damage. Remove camshaft caps keeping them in order and marked for position. Carefully lift camshafts out and place on clean towels. Inspect camshaft journals and lobes for scoring or wear.
4. 4

   Remove Cylinder Heads
   Loosen cylinder head bolts in reverse torque sequence in multiple passes. Remove cylinder head bolts completely - these are TTY bolts and must be discarded. Carefully break cylinder head gasket seal using plastic wedge tools, never pry between machined surfaces. Lift cylinder heads straight up using assistance due to weight (approximately 40 lbs each). Place heads on wooden blocks with combustion chambers facing up.
   ⚠Never lay cylinder heads on their machined mating surface. Always support on wooden blocks to prevent warping.
5. 5

   Disassemble Valvetrain and Remove Valves
   Using valve spring compressor, compress each valve spring and remove valve keepers using magnetic tool. Release spring tension and remove valve spring retainer, spring, and valve stem seal. Remove valve from combustion chamber side. Keep all components organized by cylinder and intake/exhaust position. Clean each valve thoroughly with wire brush and solvent. Inspect valve stems for wear, scoring, or bending.
6. 6

   Measure Valve Guides and Stems
   Using telescoping gauge, measure inside diameter of each valve guide at top, middle, and bottom positions. Record measurements. Using micrometer, measure valve stem diameter at multiple points. Calculate stem-to-guide clearance. Intake valve clearance should be 0.0008-0.0027 inches, exhaust 0.0017-0.0037 inches. If clearance exceeds 0.004 inches, guides must be replaced or knurled at machine shop.
   ℹ️Excessive valve guide wear will cause oil consumption and premature valve seal failure even with new seals.
7. 7

   Inspect and Measure Valve Seats
   Clean valve seats thoroughly with wire brush. Inspect for cracks, pitting, or burning especially on exhaust valves. Using Prussian blue dye, coat valve face and rotate valve against seat to check contact pattern. Contact band should be centered on valve face, 1.5-2.0mm wide. Measure valve seat concentricity using dial indicator - runout should not exceed 0.002 inches. Mark seats requiring refacing.
8. 8

   Machine Shop Preparation and Services
   Transport cylinder heads to qualified machine shop for the following services: valve seat refacing using three-angle cut (typically 30-45-60 degrees), valve face grinding to match seat angle, valve guide replacement if clearances are excessive, cylinder head deck surface milling if warpage exceeds 0.003 inches (check with straightedge), pressure testing for cracks, and valve lapping after seat work. Specify intake seat width 1.5-2.0mm and exhaust seat width 1.75-2.25mm.
   ℹ️Maximum cylinder head deck surface removal is 0.010 inches. Exceeding this requires piston height verification to prevent interference.
9. 9

   Clean Engine Block and Inspect
   Thoroughly clean cylinder head mating surfaces on block using plastic scraper - never use metal tools on aluminum surfaces. Clean out all bolt holes using bottoming tap and compressed air. Inspect block deck surface with straightedge for warpage. Verify cylinder bore condition and crosshatch pattern. Clean timing chain area and oil passages with solvent and compressed air. Cover cylinders with clean towels to prevent debris entry.
10. 10

    Install New Valve Stem Seals and Reassemble Valves
    Once cylinder heads return from machine shop, lightly oil valve stems with assembly lube. Install new valve stem seals using seal installation tool - tap gently until seated. Insert valves into guides from combustion chamber side. Install valve springs with closely wound coils toward cylinder head. Compress spring and install valve keepers using magnetic tool. After keepers are installed, tap valve tip lightly with plastic mallet to seat keepers, then release spring compressor. Verify keepers are properly seated.
    ⚠Valve stem seals must be installed using proper driver tool. Improper installation will cause oil consumption.
11. 11

    Install Cylinder Heads
    Position new cylinder head gaskets on block with all alignment dowels properly seated and 'TOP' or 'FRONT' markings visible. Carefully lower cylinder heads onto block using assistance. Install new TTY cylinder head bolts finger tight in all positions. Torque cylinder head bolts in proper sequence to 65 Nm (48 lb-ft), then tighten an additional 90 degrees, then final 90 degrees for total of 180 degrees additional rotation. Verify all bolts have turned equal amounts.
    ⚠️Cylinder head bolts are TTY three-step torque procedure: 48 lb-ft plus 90 degrees plus 90 degrees. Missing angle torque steps will cause head gasket failure.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
12. 12

    Install Camshafts and Timing Components
    Lubricate camshaft journals and lobes with assembly lube. Position camshafts in their original banks with timing marks accessible. Install camshaft caps in original positions with alignment marks facing forward. Torque camshaft cap bolts in sequence from center outward in multiple passes to final torque of 14 Nm (10 lb-ft). Install camshaft sprockets while holding cam on hex, torque sprocket bolts to 80 Nm (59 lb-ft). Install timing chains with all painted timing marks aligned. Install chain guides and tensioners with tensioner pins installed.
    ⚠Verify all timing marks align exactly as marked during disassembly before releasing tensioners.
    Torque spec

    Camshaft Cap Bolts14 Nm (7 lb-ft)

    Camshaft Sprocket Bolt80 Nm (89 lb-ft)
13. 13

    Install Timing Cover and Remove Tensioner Pins
    Install new timing cover gasket and position timing cover. Install and torque 8mm timing cover bolts in sequence to 25 Nm (18 lb-ft). Remove timing chain tensioner retaining pins or clips to apply tension to chains. Rotate engine by hand two complete revolutions clockwise (viewed from front) and verify all timing marks realign at TDC. Check for any unusual resistance indicating valve-to-piston contact.
    ⚠️If engine does not rotate smoothly or timing marks do not realign, STOP. Disassemble and verify timing chain installation before proceeding.
    Torque spec

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

    Install Exhaust Manifolds and Intake System
    Apply anti-seize compound to exhaust manifold studs. Install new exhaust manifold gaskets and position manifolds. Torque exhaust manifold nuts working from center outward (hot to cold) to 30 Nm (22 lb-ft). Install intake manifold with new gaskets and torque bolts to 25 Nm (18 lb-ft) in proper sequence. Reconnect both fuel rail systems and all vacuum lines per photographs taken during disassembly.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

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

    Install Valve Covers and Complete Assembly
    Install new valve cover gaskets ensuring proper seating in gasket grooves. Position valve covers and install bolts finger tight. Torque valve cover bolts in sequence from center outward to 10 Nm (7 lb-ft). Install ignition coils and reconnect all electrical connectors. Reinstall turbochargers, intercooler system, and air intake. Install new oil filter and fill with 6 quarts of Motorcraft 0W-20 synthetic oil. Refill cooling system with 13 quarts Motorcraft Orange coolant and bleed air from system.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

Reassembly

1. Reconnect negative battery cable
2. Prime oil system by cranking engine for 10 seconds without starting (disable fuel or ignition)
3. Double-check all electrical connectors, vacuum lines, and coolant hoses are reconnected
4. Verify no tools or parts are left in engine compartment

Verification

• Start engine and verify immediate oil pressure on gauge within 5 seconds
• Listen for any unusual valvetrain noise such as ticking or tapping that would indicate valve lash issues
• Allow engine to reach operating temperature and check for coolant, oil, or exhaust leaks at all gasket surfaces
• Monitor for coolant loss or white smoke from exhaust indicating head gasket failure
• Verify smooth idle quality and throttle response with no misfires
• Road test vehicle under varying loads and check for proper boost pressure from turbochargers
• Recheck all fluid levels after test drive and inspect for leaks
• Clear any stored diagnostic codes and verify no new codes set during test

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