Complete cylinder head removal, inspection, machine shop resurfacing, and reinstallation procedure for the 3.5L EcoBoost V6 engine, including timing component removal and coolant system service.

Warnings

Tools required

Parts

• Cylinder head gasket set (includes head gaskets, valve cover gaskets) × 1 — Use OEM specification
• Cylinder head bolts (TTY - must replace) × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Spark plugs × 6 — Motorcraft SP-546 or equivalent
• Valve cover bolt grommets × 1 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Oil filter × 1 — Motorcraft FL-910S
• Anti-seize compound × 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 2 hours since last operation)
2. Disconnect negative battery cable and wait 2 minutes for airbag system to discharge
3. Remove engine cover and air intake system completely
4. Drain engine coolant completely from radiator petcock and block drain plugs into suitable container
5. Drain engine oil and remove oil filter
6. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
7. Remove intercooler and charge air cooler piping
8. Remove both turbochargers and all associated oil feed/return lines
9. Label and photograph all vacuum lines, electrical connectors, and hose routing before disconnection
10. Position vehicle on level surface with adequate overhead clearance for component removal

Procedure

1. 1

   Remove Valve Covers and Ignition Components
   Disconnect ignition coil electrical connectors and remove all six coil-on-plug ignition coils. Remove valve cover bolts in reverse of tightening sequence (outside-in pattern). Carefully lift valve covers off, breaking RTV seal if necessary. Remove spark plugs and store in order for inspection.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

   Electrical Connector Bolts8 Nm (6 lb-ft)
2. 2

   Remove Intake Manifold Assembly
   Disconnect throttle body electrical connector and all fuel injector connectors. Remove fuel rail mounting bolts and carefully lift fuel rail with injectors attached. Disconnect PCV hoses and brake booster vacuum line. Remove intake manifold bolts in reverse sequence (outside to inside) and lift manifold assembly off engine. Inspect and clean mating surfaces.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
3. 3

   Remove Exhaust Manifolds
   Spray exhaust manifold studs with penetrating oil and allow to soak. Starting from the coldest position (furthest from turbos), remove exhaust manifold nuts working hot-to-cold to prevent stud breakage. Remove heat shields if present. Carefully remove both exhaust manifolds and set aside. Inspect studs for damage.
   ⚠Work exhaust fasteners hot-to-cold (outer to inner) to minimize stud breakage risk. If studs break, extraction will add significant time to repair.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
4. 4

   Remove Accessory Drive and Front Timing Cover
   Remove serpentine belt and tensioner assembly. Remove crankshaft pulley using holding tool to prevent rotation. Remove water pump pulley and alternator mounting bracket. Remove all timing chain cover bolts including lower oil pan interface bolts. Carefully pry timing cover away from engine block, being careful not to damage sealing surfaces. Remove cover gasket completely.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

   Mounting Bolts54 Nm (40 lb-ft)
5. 5

   Lock Timing Chain and Mark Position
   Rotate crankshaft to TDC cylinder #1 (compression stroke). Verify timing marks on camshaft sprockets align with cylinder head surfaces and crankshaft keyway is at 12 o'clock. Use paint marker or scribe to mark chain-to-sprocket relationship on all four camshaft sprockets and both crankshaft sprockets. Install camshaft holding tools to prevent rotation. Photograph timing chain routing and all timing marks.
   ⚠️Accurate timing marks are critical. Take multiple photos and verify all marks before proceeding. Loss of timing position will require complete timing set procedure on reassembly.
6. 6

   Remove Timing Chains and Camshaft Components
   Release timing chain tensioners by compressing and locking with pins or wire. Remove timing chain guides and tensioner arms. Carefully remove primary timing chains from crankshaft sprocket. Remove camshaft sprocket bolts while holding camshafts with holding tool. Remove secondary chains with VCT (Variable Cam Timing) assemblies as a unit. Keep all components organized by cylinder bank (left/right).
7. 7

   Remove Cylinder Head Bolts
   Remove cylinder head bolts in reverse of tightening sequence (outside-in spiral pattern). Loosen each bolt 1/4 turn at a time in sequence to prevent head warpage. Once all bolts are loose, remove completely. These are TTY bolts and must be discarded - do not reuse. Check bolts for stretching or necking as indication of previous overheating.
   ⚠Loosen head bolts gradually in correct sequence to prevent cylinder head cracking or warpage. Never remove head bolts completely in random order.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
8. 8

   Remove Cylinder Heads
   Carefully break cylinder head seal using plastic pry points only - never pry between sealing surfaces. Lift cylinder heads straight up to avoid damaging dowel pins or block surface. Place heads face-up on clean padded surface or head stand. Remove and discard cylinder head gaskets. Cover engine block openings with clean lint-free cloths to prevent debris entry.
9. 9

   Inspect and Prepare Heads for Machining
   Inspect cylinder heads for cracks using dye penetrant or magnetic particle testing if available. Check valve sealing and spring condition. Measure head flatness with precision straight edge and feeler gauges in multiple directions. Transport heads to qualified machine shop for resurfacing. Specify maximum material removal and confirm valve recession will be within specification after surfacing.
   ℹ️Maximum allowable head resurfacing for EcoBoost is typically 0.010 inches total. Exceeding this may require oversized head gaskets or cause piston-to-valve interference.
10. 10

    Clean Engine Block Deck Surfaces
    Using plastic scrapers only, carefully remove all gasket material from block deck surfaces. Rotate crankshaft to position pistons mid-stroke to prevent debris falling into cylinders. Clean surfaces with brake cleaner and lint-free cloths. Inspect deck surface for damage, corrosion, or warpage. Clean cylinder bores with light oil and verify piston ring condition while accessible.
    ⚠Never use metal scrapers on aluminum block surfaces. Keep all debris out of cylinders, oil passages, and coolant jackets.
    Torque spec

    Gasket Surface Bolts23 Nm (17 lb-ft)
11. 11

    Install Resurfaced Cylinder Heads
    Verify cylinder heads return from machine shop within specification and valve job is complete. Install new head gaskets on block with all alignment dowels properly seated - ensure correct orientation (TOP mark facing up). Carefully lower cylinder heads onto block, aligning with dowel pins. Install NEW cylinder head bolts finger-tight in all positions. Do not apply any lubricant to head bolt threads or washers unless specifically required by gasket manufacturer.
    ⚠Head gaskets have specific front/rear and top/bottom orientation. Verify correct positioning before installing heads.
    Torque spec

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

    Torque Cylinder Head Bolts to Specification
    Following Ford tightening sequence (consult service manual for exact pattern, typically inside-out spiral), torque all head bolts to 65 Nm (48 lb-ft) using calibrated torque wrench. Then tighten each bolt in sequence an additional 90 degrees using angle gauge. Follow with final tightening of 90 degrees in sequence. Verify final angle total matches specification (typically 180 degrees total additional rotation after initial torque).
    ⚠️TTY bolt tightening procedure must be followed exactly. Incorrect torque sequence or angle will result in head gasket failure and possible head warpage.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
13. 13

    Reinstall Timing Components
    Install camshaft position sensors and verify sensor air gaps. Install VCT assemblies onto camshafts with secondary timing chains, aligning marks made during disassembly. Install primary timing chains onto crankshaft sprocket with alignment marks positioned correctly. Route chains over camshaft sprockets verifying all timing marks align with marks made during removal. Install chain guides, tensioner arms, and release tensioners. Rotate engine two complete revolutions by hand and recheck all timing marks for proper alignment.
    ⚠️Verify timing mark alignment after rotating engine two full revolutions. Misaligned timing will cause immediate engine damage on startup.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)
14. 14

    Install Front Timing Cover and Accessories
    Clean timing cover mating surfaces thoroughly. Apply continuous bead of specified RTV sealant to timing cover where indicated in service manual (typically at engine block-to-oil pan joints). Install new timing cover gasket and position cover onto engine, aligning dowels. Install all cover bolts finger-tight, then torque to specification in sequence. Install water pump pulley, crankshaft pulley, and accessory brackets to specification.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

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

    Install Exhaust and Intake Manifolds
    Apply anti-seize compound to exhaust manifold studs as specified. Install new exhaust manifold gaskets and position manifolds on cylinder heads. Install exhaust nuts working from hot-to-cold (center outward) and torque to 30 Nm (22 lb-ft). Install new intake manifold gaskets ensuring proper orientation. Position intake manifold and install bolts, tightening in sequence from center outward to 25 Nm (18 lb-ft). Reconnect fuel rail, injectors, and all associated wiring.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
16. 16

    Install Valve Covers and Ignition System
    Clean valve cover mating surfaces on cylinder heads. Install new valve cover gaskets and grommets. Apply small bead of RTV at camshaft cap-to-head joints as specified. Position valve covers and install bolts with new grommets. Torque valve cover bolts to 10 Nm (7 lb-ft) in proper sequence (typically center outward). Install spark plugs to specification. Install ignition coils and connect all electrical connectors.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

Reassembly

1. Reinstall turbochargers with new gaskets and oil lines, ensuring proper oil feed/drain routing
2. Install intercooler system and charge air cooler piping with new clamps
3. Reconnect all coolant hoses, vacuum lines, and electrical connectors per photos taken during disassembly
4. Install new oil filter and fill engine with 6 quarts of Motorcraft 0W-20 synthetic oil
5. Fill cooling system with 13 quarts of Motorcraft Orange coolant, bleeding air from system per Ford procedure
6. Reinstall air intake system and engine cover
7. Reconnect battery negative cable

Verification

• Perform cooling system pressure test to verify head gasket seal - hold 16 psi for 2 minutes with no pressure loss
• Start engine and verify no coolant, oil, or vacuum leaks at all reinstalled components
• Monitor for abnormal noises during initial startup indicating timing or valvetrain issues
• Allow engine to reach normal operating temperature and verify cooling fans cycle properly
• Check for combustion gases in coolant using block tester or exhaust gas analyzer
• Perform test drive monitoring for proper engine performance, boost pressure, and temperature stability
• Recheck all fluid levels after test drive and inspect for any leaks
• Scan for diagnostic trouble codes and verify no misfires or timing-related faults are present
• Retorque cylinder head bolts after 500 miles if specified by gasket manufacturer (verify requirement)

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