This procedure covers the removal and reinstallation of the cylinder head on a 2021-2024 Ford F-150 3.5L V6 EcoBoost engine, including turbocharger removal, timing component access, and head bolt torque-to-yield replacement.

Warnings

Tools required

Parts

• Cylinder head gasket (specify left or right bank) × 1 — Use OEM specification
• Cylinder head bolts (torque-to-yield, must replace) × 10 — Use OEM specification
• Valve cover gasket × 1 — Use OEM specification
• Turbocharger to exhaust manifold gasket × 1 — Use OEM specification
• Exhaust manifold gaskets × 1 — Use OEM specification
• Turbocharger oil feed line gaskets/seals × 2 — Use OEM specification
• Coolant hose clamps (replacement recommended) × 6 — Various sizes
• Timing chain tensioner gasket × 1 — Use OEM specification
• VVT solenoid O-rings × 2 — Use OEM specification

Fluids

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

Preparation

1. Verify engine is completely cold. Position 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 all four corners.
4. Place drain pan under radiator and drain cooling system completely using petcock and block drain plugs.
5. Drain engine oil and remove oil filter.
6. Relieve fuel system pressure: Remove fuel pump fuse, start engine and allow to stall, crank for 5 seconds.
7. Remove front wheels if accessing right bank for better working clearance.
8. Remove air intake system from throttle body to air filter box completely.
9. Photograph all hose routing, connector positions, and bracket locations for reassembly reference.

Procedure

1. 1

   Remove valve cover and ignition components
   Disconnect ignition coil electrical connectors and remove all six coils from the cylinder head being serviced. Label coils by cylinder number. Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully pry valve cover loose using plastic pry tool only at designated pry points. Remove and discard valve cover gasket.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
2. 2

   Disconnect turbocharger and exhaust components
   For right bank: Remove charge air cooler outlet tube. For both banks: Disconnect turbocharger oil feed line at turbo inlet. Disconnect turbo coolant lines and cap openings immediately. Remove turbocharger to exhaust manifold nuts and separate turbocharger. Support turbo with mechanics wire, do not allow to hang on oil drain line. Remove exhaust manifold heat shields.
   ⚠Turbocharger components may have carbon buildup. Avoid breathing dust and wear respiratory protection.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
3. 3

   Remove timing chain front cover access components
   Remove accessory drive belt by rotating tensioner clockwise and sliding belt off pulleys. Remove power steering pump mounting bolts and secure pump aside without disconnecting lines. Remove A/C compressor mounting bolts and secure aside without disconnecting refrigerant lines. Remove crankshaft pulley bolt using holder tool (requires high torque - approximately 300 lb-ft removal torque). Remove crankshaft pulley and front timing chain cover bolts. Carefully remove timing cover, noting RTV locations.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
4. 4

   Set engine to TDC and lock timing components
   Rotate crankshaft clockwise using 22mm socket on crankshaft bolt until cylinder #1 is at TDC on compression stroke (both camshaft lobes pointing outward). Verify timing marks on camshaft sprockets align with cylinder head markings. Install camshaft holding tools to prevent rotation. Mark timing chain to camshaft and crankshaft sprocket positions using paint marker at three points minimum for reference.
   ⚠️Verify valve timing marks are correctly aligned before proceeding. Incorrect timing will cause immediate engine damage on startup.
5. 5

   Remove timing chain tensioner and timing components
   Remove primary timing chain tensioner by compressing and installing retaining pin, then removing mounting bolts. Remove timing chain tensioner arm. Remove camshaft sprocket bolts while holding camshaft with holding tool. Remove camshaft sprockets and timing chain as assembly. Remove VVT solenoids from front of camshafts if necessary for additional clearance.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
6. 6

   Disconnect fuel system and sensors
   Disconnect fuel rail from cylinder head being serviced. Use proper fuel line disconnect tools and have shop towels ready for residual fuel. Remove fuel injector electrical connectors and secure harness aside. Disconnect camshaft position sensor connectors and knock sensor connector. Remove temperature sensors from cylinder head. Remove engine wiring harness brackets from cylinder head.
   ⚠Fuel will spill when disconnecting fuel lines. Have fire extinguisher accessible and ensure adequate ventilation.
   Torque spec

   Electrical Connector Bolts8 Nm (6 lb-ft)

   Sensor Bolts12 Nm (9 lb-ft)
7. 7

   Remove coolant passages and remaining accessories
   Disconnect all coolant hoses attached to cylinder head including heater hoses and bypass tubes. Remove coolant crossover tube if present. Remove thermostat housing from cylinder head. Disconnect any remaining vacuum lines, breather hoses, and PCV connections. Remove engine ground straps from cylinder head.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
8. 8

   Remove exhaust manifold from cylinder head
   Remove all exhaust manifold to cylinder head mounting nuts/bolts working from center outward to prevent warping. Carefully remove manifold and discard gaskets. Inspect manifold for cracks, particularly around ports 3 and 4 which are common failure points on EcoBoost engines. Clean all exhaust studs with wire brush.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
9. 9

   Remove cylinder head bolts and head
   Loosen cylinder head bolts in reverse of tightening sequence: start from outside bolts working toward center in specified pattern. Remove all 10 head bolts and discard (torque-to-yield, must not be reused). Carefully lift cylinder head straight up, using plastic pry points only if necessary. Do not pry between head and block gasket surfaces. Place head on clean padded work surface with combustion chambers facing up. Remove and discard head gasket.
   ⚠️Cylinder head weighs approximately 50-60 lbs. Use proper lifting technique or get assistance to avoid personal injury.
   Torque spec

   Cylinder Head Bolts40 Nm (30 lb-ft) + 180°
10. 10

    Clean and inspect mating surfaces
    Using plastic gasket scraper only, carefully remove all old gasket material from engine block deck surface and cylinder head mating surface. Do not use metal scrapers which can gouge aluminum surfaces. Clean surfaces with brake cleaner and lint-free cloths. Inspect block deck and cylinder head surface with straightedge and feeler gauge. Maximum warpage tolerance is 0.003 inches. If beyond specification, cylinder head must be resurfaced by machine shop. Inspect head bolt holes in block for damage, debris, or coolant. Clean threads with thread chaser and blow out with compressed air.
    ⚠Any debris or coolant in head bolt holes will cause incorrect torque readings and potential head gasket failure. Holes must be completely clean and dry.
    Torque spec

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

    Install new head gasket and position cylinder head
    Verify new head gasket matches old gasket exactly in configuration and bore size. Install new head gasket on block with 'TOP' or 'OBEN' marking facing up. Align all coolant and oil passages. Do not use any sealant on MLS (multi-layer steel) head gasket. Carefully lower cylinder head onto block, aligning dowel pins. Ensure head seats completely flat on gasket. Install new cylinder head bolts finger-tight in numerical sequence.
    ℹ️Head gasket is NOT directional front-to-back but IS directional top-to-bottom. Verify 'TOP' marking is visible after installation.
12. 12

    Torque cylinder head bolts in sequence
    Using torque wrench and angle gauge, tighten head bolts following this exact sequence: Step 1 - Torque all bolts to 30 lb-ft in numerical order (front to rear, alternating sides). Step 2 - Rotate each bolt an additional 90 degrees in same numerical order. Step 3 - Rotate each bolt another 90 degrees (total 180 degrees from Step 1) in same numerical order. Verify all bolts have been torqued by checking sequence again. Total rotation after initial torque is 180 degrees.
    ⚠️Head bolt torque sequence and angle rotation MUST be followed exactly. Improper torque will cause head gasket failure, coolant leaks, or engine damage. Verify your service manual year-specific procedure as some years use different specifications.
    Torque spec

    Cylinder Head Bolts40 Nm (30 lb-ft) + 180°
13. 13

    Reinstall exhaust manifold and turbocharger
    Install new exhaust manifold gaskets. Position exhaust manifold and install all bolts/nuts finger-tight. Torque manifold fasteners from center outward to specification. Install new turbocharger to manifold gasket. Position turbocharger and install mounting nuts to specification. Reconnect turbo oil feed line with new gaskets/seals. Reconnect turbo coolant lines with new O-rings.
    Torque spec

    Mounting Bolts55 Nm (40 lb-ft)

    Gasket Bolts23 Nm (17 lb-ft)
14. 14

    Reinstall timing components
    Install timing chain over crankshaft and camshaft sprockets, aligning all paint marks made during disassembly. Install camshaft sprockets onto camshafts with timing marks aligned to cylinder head reference marks. Install and torque camshaft sprocket bolts while holding camshafts with holding tool. Install timing chain tensioner arm. Compress new timing chain tensioner, install retaining pin, and mount tensioner to engine. Remove tensioner retaining pin to apply tension. Remove camshaft holding tools. Manually rotate crankshaft two complete revolutions clockwise and verify timing marks realign perfectly.
    ⚠️After rotating engine two revolutions, timing marks MUST align exactly. If not aligned, remove timing components and reinstall correctly before proceeding.
    Torque spec

    Mounting Bolts55 Nm (40 lb-ft)
15. 15

    Reinstall front cover, accessories, and valve cover
    Clean timing cover mating surfaces and apply new RTV sealant at specified locations per service manual. Install timing cover and torque bolts to specification. Install crankshaft pulley and torque center bolt to specification. Reinstall A/C compressor and power steering pump to mounting brackets. Install accessory drive belt. Install new valve cover gasket on valve cover. Apply small dab of RTV at camshaft cap corners. Install valve cover and torque bolts in sequence from center outward. Reinstall ignition coils and reconnect all electrical connectors. Reinstall fuel rail and reconnect fuel lines. Reconnect all coolant hoses, sensors, and ground straps.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Mounting Bolts55 Nm (40 lb-ft)

    Sensor Bolts12 Nm (9 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)

Reassembly

1. Install new oil filter and refill engine with 6 quarts Motorcraft 0W-20 full synthetic oil.
2. Refill cooling system with 13 quarts Motorcraft Orange coolant mixture. Burp cooling system by running engine to operating temperature with radiator cap off, adding coolant as level drops.
3. Reinstall air intake system from throttle body to air filter box.
4. Reinstall engine cover.
5. Reconnect negative battery cable.
6. If wheels were removed, reinstall and torque lug nuts to specification.

Verification

• Before starting engine, rotate crankshaft by hand two complete revolutions to verify no interference or binding.
• Prime oil system by cranking engine with fuel pump fuse removed for 10-15 seconds.
• Start engine and verify immediate oil pressure on gauge. If no pressure within 5 seconds, shut down immediately.
• Allow engine to idle and inspect for coolant, oil, or exhaust leaks at all disturbed connections.
• Monitor coolant temperature and verify thermostat opens properly and cooling fans cycle normally.
• After engine reaches operating temperature, shut off and allow to cool. Recheck all fluid levels and top off as necessary.
• Check for diagnostic trouble codes using scan tool. Clear any codes related to battery disconnect.
• Test drive vehicle and verify normal operation, smooth idle, proper power delivery, and no abnormal noises.
• After 50-100 miles of operation, recheck valve cover bolts, exhaust connections, and all fluid levels as final verification.

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