Complete replacement of both cylinder head gaskets on the 3.5L EcoBoost V6, including removal of turbochargers, timing chains, camshafts, and cylinder heads.

Warnings

Tools required

Parts

• Cylinder head gasket - Left × 1 — Ford DG1Z-6051-B or equivalent
• Cylinder head gasket - Right × 1 — Ford DG1Z-6051-B or equivalent
• Cylinder head bolts (set of 20) × 1 — Use OEM - TTY bolts must be replaced
• Valve cover gasket - Left × 1 — Use OEM specification
• Valve cover gasket - Right × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets - Left × 1 — Use OEM specification
• Exhaust manifold gaskets - Right × 1 — Use OEM specification
• Turbocharger mounting gaskets × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Water pump O-rings × 1 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Coolant crossover gasket × 1 — Use OEM specification
• Oil filter × 1 — Motorcraft FL-910S
• Camshaft cap bolts (if needed) × 1 — Inspect during disassembly

Fluids

• Motorcraft 0W-20 Full Synthetic engine oil — 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 by pulling upward on front clips
4. Drain engine coolant completely by opening radiator drain and removing lower radiator hose
5. Drain engine oil and remove oil filter
6. Remove air intake system from air box to turbo inlet pipes on both sides
7. Label and photograph all vacuum lines, electrical connectors, and coolant hoses before disconnection
8. Support engine weight using engine support bar across fender aprons or engine hoist from above
9. Remove front wheels and engine splash shields for access to lower components

Procedure

1. 1

   Remove intercooler and charge air piping
   Disconnect charge air cooler outlet pipes from both turbochargers. Remove intercooler mounting bolts and carefully extract intercooler assembly from behind front bumper. Remove all charge air piping between turbos and throttle body. Cap all openings to prevent debris entry.
2. 2

   Remove intake manifold assembly
   Disconnect fuel rail electrical connectors and fuel lines (relieve fuel pressure first by removing fuel pump fuse and running engine until it stalls). Remove throttle body and PCV connections. Remove 10 intake manifold bolts in reverse of tightening sequence (outside to inside). Carefully lift intake manifold straight up to avoid damaging port seal surfaces.
   ⚠️Fuel system is under high pressure. Relieve pressure before disconnecting any fuel lines. Have fire extinguisher accessible.
   Torque spec

   Intake Manifold Bolts28 Nm (21 lb-ft)
3. 3

   Remove valve covers
   Disconnect ignition coil electrical connectors and remove all six coils. Disconnect PCV hoses and any remaining electrical connections to valve covers. Remove valve cover bolts in sequence and carefully pry covers loose. Inspect valve train for abnormal wear patterns while exposed.
   Torque spec

   Valve Cover Bolts16 Nm (12 lb-ft)
4. 4

   Remove exhaust manifolds and turbochargers
   Disconnect oxygen sensor connectors on both banks. Remove heat shields from exhaust manifolds. Unbolt turbo oil feed and drain lines (capture residual oil). Disconnect exhaust downpipes from turbo outlets. Remove turbocharger mounting nuts and extract turbos. Remove exhaust manifold nuts and remove manifolds from both banks. Keep left and right components separated.
   ⚠Turbocharger oil drain tubes are fragile. Support turbos during removal to prevent bending drain tubes.
   Torque spec

   Exhaust Manifold Nuts39 Nm (29 lb-ft)
5. 5

   Remove accessory drive and front covers
   Remove serpentine belt and tensioner. Remove power steering pump and bracket (position aside without disconnecting lines). Remove alternator. Remove crankshaft pulley bolt using holding tool and remove pulley. Remove all timing cover bolts and carefully separate front cover from engine. Remove coolant crossover tube from front of heads.
6. 6

   Lock timing and remove timing chains
   Rotate crankshaft to TDC cylinder #1 (timing marks aligned). Install crankshaft holding tool. Verify all timing marks on camshaft sprockets align with marks on cylinder heads. Take multiple detailed photographs. Mark chain-to-sprocket relationship with paint pen. Compress primary chain tensioners and lock with retaining pins. Remove primary chain guides. Remove camshaft sprocket bolts while holding camshafts with holding tool. Remove timing chains, keeping left and right bank components separated.
   ⚠️Do NOT rotate crankshaft or camshafts once timing chains are removed. This will cause valve-to-piston contact and severe engine damage.
7. 7

   Remove camshafts
   Using camshaft holding tool to prevent rotation, loosen camshaft cap bolts evenly in reverse of tightening sequence (from center outward, 1/4 turn at a time) on each bank. This prevents camshaft binding. Once all bolts are loose, remove caps keeping them in order with their respective positions. Carefully lift out intake and exhaust camshafts from each head. Store upright to prevent lobe damage. Keep left and right bank components completely separated.
   ⚠Camshaft caps must be loosened gradually and evenly. Rapid loosening can cause camshaft or cap damage due to valve spring pressure.
   Torque spec

   Camshaft Cap Bolts19 Nm (14 lb-ft)
8. 8

   Remove cylinder heads
   Remove remaining coolant hoses and temperature sensor connectors from cylinder heads. Loosen cylinder head bolts in reverse of tightening sequence (outside working inward in spiral pattern) on both heads. Remove all 10 head bolts from each cylinder head and discard (TTY bolts cannot be reused). Carefully break heads loose from block using plastic pry points only - never metal tools between sealing surfaces. Lift heads straight up and place on padded surface with combustion chambers facing up.
   ⚠Cylinder heads weigh approximately 40 lbs each. Use proper lifting technique or get assistance.
   Torque spec

   Cylinder Head Bolts40 Nm (30 lb-ft) + 180°
9. 9

   Clean and inspect sealing surfaces
   Remove all old gasket material from cylinder head and engine block surfaces using plastic gasket scraper only - never use metal scrapers that can gouge aluminum. Clean surfaces with degreaser and lint-free cloths. Inspect cylinder head surfaces with straight edge and feeler gauges - check lengthwise, crosswise, and diagonally. Maximum warpage is 0.003 inches. If warpage exceeds spec, heads must be resurfaced or replaced. Inspect block deck surface similarly. Check head bolt holes in block for debris or thread damage - clean with tap if necessary.
   ⚠Even minor scratches in head or block surfaces can cause gasket failure. Work carefully and inspect thoroughly.
10. 10

    Install new head gaskets and cylinder heads
    Ensure block deck and head surfaces are completely clean and dry. Install new head gaskets on block with orientation marks facing up (gaskets are marked TOP or THIS SIDE UP). Verify gaskets are positioned correctly over dowel pins and align with all coolant and oil passages. Carefully lower cylinder heads onto block, aligning over dowel pins. Install NEW cylinder head bolts finger-tight. Apply light oil to bolt threads and underside of bolt heads per Ford specifications.
    ⚠️Head gaskets must be installed in correct orientation. Installing upside-down will block critical oil or coolant passages causing engine failure.
11. 11

    Torque cylinder head bolts
    Torque cylinder head bolts following the proper sequence (start at center, spiral outward) in multiple steps: Step 1 - Torque all bolts to 30 lb-ft. Step 2 - Rotate all bolts an additional 90 degrees in sequence. Step 3 - Rotate all bolts a final 90 degrees in sequence (total 180 degrees beyond initial torque). Verify each bolt receives proper torque and angle. Do NOT reuse old bolts.
    ⚠️Use only a calibrated torque-angle gauge or electronic torque wrench. Improper torque will result in gasket failure or bolt breakage.
    Torque spec

    Cylinder Head Bolts40 Nm (30 lb-ft) + 180°
12. 12

    Install camshafts and timing components
    Lubricate camshaft lobes and journals with assembly lube or clean engine oil. Install camshafts into their original positions (intake and exhaust are different - verify markings). Install camshaft caps in their original positions and orientation (caps are numbered). Torque camshaft cap bolts in sequence from center outward to specification evenly. Install timing chains over crankshaft and camshaft sprockets with all timing marks aligned exactly as photographed during disassembly. Install chain guides and tensioners. Remove locking pins from tensioners to apply tension. Verify all timing marks still align. Rotate engine two complete revolutions by hand and recheck timing mark alignment.
    ⚠️Timing marks MUST align perfectly. One tooth off on any sprocket will cause catastrophic engine damage when started.
    Torque spec

    Camshaft Cap Bolts19 Nm (14 lb-ft)
13. 13

    Install front covers and accessory components
    Install new timing cover gasket and water pump O-rings. Install front timing cover with all bolts torqued to specification. Install crankshaft pulley and torque pulley bolt to specification. Reinstall alternator, power steering pump bracket, and belt tensioner. Install new serpentine belt.
14. 14

    Install exhaust manifolds and turbochargers
    Install new exhaust manifold gaskets on cylinder heads. Install exhaust manifolds and torque nuts in sequence from center outward to specification. Install new turbocharger gaskets. Install turbochargers with new oil feed and drain line gaskets/seals. Torque all turbo mounting hardware. Reconnect exhaust downpipes. Install heat shields and oxygen sensors.
    Torque spec

    Exhaust Manifold Nuts39 Nm (29 lb-ft)
15. 15

    Complete reassembly
    Install valve covers with new gaskets, torquing bolts in sequence to specification. Install ignition coils. Install intake manifold with new gaskets, torquing bolts in sequence from center outward to specification. Reconnect fuel rail and all fuel lines. Install throttle body. Reinstall intercooler and all charge air piping. Reconnect all vacuum lines, electrical connectors, and coolant hoses per labels and photos. Install new oil filter. Fill engine with 6 quarts of Motorcraft 0W-20 synthetic oil. Fill cooling system with 13 quarts of Motorcraft Orange coolant - burp system per Ford procedure. Reinstall air intake system, splash shields, and wheels.
    Torque spec

    Valve Cover Bolts16 Nm (12 lb-ft)

    Intake Manifold Bolts28 Nm (21 lb-ft)

Reassembly

1. Double-check that all electrical connectors, vacuum lines, and coolant hoses are reconnected per photographs
2. Verify all ground connections are tight and clean
3. Ensure charge air system has no loose connections that could cause boost leaks
4. Verify oil drain plug is tight and oil filter is properly seated
5. Check that coolant system is properly filled and burped of air
6. Confirm serpentine belt is properly routed and tensioned

Verification

• Reconnect battery and turn key to ON position (do not start). Check for warning lights or fault codes using scan tool
• Visually inspect entire work area for forgotten tools, loose fasteners, or disconnected components
• Prime fuel system by cycling key ON for 5 seconds, OFF for 10 seconds, repeat 3 times
• Start engine and immediately check for oil pressure indication. If no pressure within 5 seconds, shut down and investigate
• Allow engine to idle and warm up while monitoring for coolant, oil, fuel, or boost leaks
• Check for abnormal noises, particularly valve train noise or timing chain rattle
• Once at operating temperature, verify cooling fans cycle and temperature gauge reads normal
• Perform test drive monitoring for normal boost pressure (15-18 psi under acceleration), smooth operation, and no check engine light
• After test drive, allow to cool and recheck all fluid levels. Top off coolant if needed after burping
• Check for any new leaks around gasket surfaces after first heat cycle
• Clear any stored diagnostic codes and verify no active faults remain

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