Complete disassembly, inspection, machining, and rebuild of the 3.5L EcoBoost V6 engine including cylinder head removal, crankshaft and piston service, and timing system replacement.

Warnings

Tools required

Parts

• Complete engine gasket set × 1 — Use OEM specification
• Cylinder head gaskets × 2 — Use OEM specification
• Piston ring sets × 6 — Use OEM specification
• Main bearing set × 1 — Use OEM specification
• Rod bearing set × 1 — Use OEM specification
• Timing chain kit with guides and tensioners × 1 — Use OEM specification
• Camshaft position sensors × 4 — Use OEM specification
• Crankshaft position sensor × 1 — Use OEM specification
• Oil pump assembly × 1 — Use OEM specification
• Water pump × 1 — Use OEM specification
• Thermostat housing assembly × 1 — Use OEM specification
• Turbocharger gasket kit × 1 — Use OEM specification
• Oil filter × 1 — FL-500S or equivalent
• Spark plugs × 6 — SP-546 or OEM
• Valve stem seals × 24 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine assembly lube × 1 — Use OEM specification
• RTV silicone sealant × 2 — TA-25 or OEM

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge.
2. Drain engine oil and coolant completely into appropriate containers. Remove engine oil filter.
3. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls.
4. Remove hood assembly and tag for reinstallation. Cover fenders with protective blankets.
5. Label and photograph all electrical connectors, vacuum lines, and hose routing before disconnection.
6. Remove intake air system, intercooler pipes, and both turbochargers as complete assemblies.
7. Disconnect all engine wiring harnesses, fuel lines, coolant hoses, and transmission cooler lines.
8. Remove radiator, cooling fans, and AC condenser assembly for clearance.
9. Support transmission with jack and remove bellhousing bolts. Disconnect exhaust system at manifolds.
10. Attach engine hoist with load leveler to factory lifting points. Remove engine mount bolts and carefully extract engine from vehicle.
11. Mount engine securely on engine stand. Clean exterior surfaces before disassembly begins.

Procedure

1. 1

   Remove valve covers and timing components
   Remove both valve covers and set aside with gaskets. Remove crankshaft pulley using holding tool and impact wrench or breaker bar. Remove timing cover bolts in reverse sequence and carefully pry cover off. Note RTV sealant locations for reassembly. Remove timing chain tensioners by compressing and locking with pins, then remove both timing chains, guides, and sprockets. Mark camshaft position before removal.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)
2. 2

   Remove cylinder heads
   Remove intake manifolds and exhaust manifolds from both cylinder heads. Loosen cylinder head bolts in reverse of tightening sequence (outside to inside) in multiple passes. Carefully lift cylinder heads off block and place on clean padded surface. Do not pry between head and block surfaces. Remove and discard head gaskets. Inspect head bolt holes for coolant or oil contamination.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
3. 3

   Remove pistons and connecting rods
   Rotate crankshaft to position each piston at bottom dead center. Use ridge reamer to remove any ridge at top of cylinder bores before removing pistons. Mark each connecting rod and cap with cylinder number and orientation using number stamps. Remove connecting rod bolts and caps, keeping them with their respective rods. Push piston and rod assemblies out through top of block. Install rod caps back on rods immediately to prevent mixing. Inspect rod bolts for stretching or damage - these are TTY and must be replaced.
   ⚠Connecting rod caps and bolts are matched sets. Never interchange caps between rods or mix hardware.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
4. 4

   Remove crankshaft and main bearings
   Remove oil pan and oil pump assembly. Mark main bearing caps with position and orientation before removal. Loosen main bearing cap bolts in multiple passes working from outside to center. Carefully remove main caps and set aside in order. Lift crankshaft straight up out of block and place on padded surface. Remove main bearings from block and caps, keeping upper and lower halves paired by position. Inspect crankshaft journals for scoring, discoloration, or out-of-round condition.
   ⚠Main bearing cap bolts are torque-to-yield. Order new bolts before reassembly begins.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)
5. 5

   Disassemble cylinder heads and inspect valvetrain
   Remove camshaft bearing caps in reverse of tightening sequence, working from outside to center in multiple passes. Lift camshafts out and mark intake/exhaust and bank position. Using valve spring compressor, compress each valve spring and remove keepers, retainers, and springs. Remove valves from heads and keep organized by cylinder. Remove valve stem seals. Inspect camshaft lobes, journals, and bearing surfaces for wear. Check valve stems for wear and faces for burning or pitting.
   Torque spec

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
6. 6

   Clean and measure all components
   Thoroughly clean block, heads, crankshaft, pistons, and rods using parts washer. Remove all carbon, gasket material, and sealant. Clean all oil passages with rifle brush and compressed air. Measure cylinder bores for taper and out-of-round with dial bore gauge at top, middle, and bottom in two directions. Measure crankshaft main and rod journals with micrometer in multiple positions. Check deck surface flatness with precision straightedge and feeler gauges. Measure piston-to-bore clearance and ring end gaps.
   ℹ️Record all measurements and compare to Ford service specifications. Any component outside specification must be machined or replaced.
7. 7

   Machine shop services and parts acquisition
   Deliver block and heads to qualified machine shop for inspection and machining. Typical services include: cylinder boring/honing to next oversize if needed, deck resurfacing, crankshaft grinding if journals are worn, connecting rod reconditioning, valve job with seat cutting, and head resurfacing. Order all required oversized pistons/rings and bearings based on machine shop measurements. Have machine shop hot tank clean all components. Obtain new oil pump, timing components, and all gaskets while machining is being performed.
   ℹ️Allow 3-5 business days for machine shop work. Verify all machining is within Ford specifications before proceeding.
8. 8

   Reassemble cylinder heads
   Install new valve stem seals on valve guides using proper installation tool. Lubricate valve stems with assembly lube and install valves in original positions. Install valve springs, retainers, and keepers using spring compressor. Verify keepers are fully seated. Install camshafts with assembly lube on all journals and lobes. Install camshaft bearing caps in sequence from center outward, tightening in three passes to final specification. Verify camshafts rotate freely with no binding.
   Torque spec

   Camshaft Cap Bolts14 Nm (10 lb-ft)
9. 9

   Install crankshaft and main bearings
   Install upper main bearings in block, ensuring bearing tabs engage notches. Lubricate bearings thoroughly with engine assembly lube. Carefully lower crankshaft into block. Install lower bearings in main caps with assembly lube. Install main caps in correct positions and orientation. Install new main bearing cap bolts and tighten in sequence from center outward to initial torque specification, then apply additional angle per Ford specification. Verify crankshaft rotates freely with smooth resistance. Check bearing clearances using Plastigage method.
   ⚠Use only new main bearing cap bolts. TTY bolts cannot be reused. Follow torque-plus-angle sequence exactly.
   Torque spec

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

    Install pistons and connecting rods
    Install piston rings on pistons with ring expander tool, ensuring ring gaps are positioned 120 degrees apart and not aligned with piston pin. Oil rings install first, then compression rings with markings facing up. Lubricate cylinder bores, pistons, and rings with engine oil. Install rod bearings with assembly lube. Compress piston rings with ring compressor and carefully tap piston into bore, ensuring orientation mark faces front. Install connecting rod cap with new bolts, tightening to specification plus angle. Repeat for all six cylinders. Verify crankshaft still rotates smoothly.
    ⚠New connecting rod bolts must be used. Verify ring gaps meet specification and rings are not damaged during installation.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
11. 11

    Install oil pump and pan
    Install new oil pump with assembly lube on gears. Torque oil pump bolts to specification. Install oil pump pickup tube with new O-ring and torque fastener. Clean oil pan and block mating surfaces thoroughly. Apply thin bead of RTV silicone to oil pan rail where corners meet timing cover. Install oil pan with new gasket and tighten bolts in sequence from center outward.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
12. 12

    Install cylinder heads and timing components
    Clean block deck surfaces and cylinder head mating surfaces with solvent. Install new head gaskets ensuring orientation marks and coolant passages align correctly. Carefully position cylinder heads on block. Install new cylinder head bolts and tighten in sequence from center outward in multiple passes to final torque, then apply additional angle per specification. Install new timing chains, guides, and tensioners. Set camshaft timing using Ford timing tool set to ensure correct valve timing. Install timing cover with new gasket and RTV at block-to-head joints. Install crankshaft pulley with new bolt.
    ⚠️Incorrect camshaft timing will result in valve-to-piston contact and catastrophic engine damage. Use proper timing tools and verify timing marks multiple times.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Cover Bolts19 Nm (14 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
13. 13

    Install intake and exhaust manifolds
    Install exhaust manifolds with new gaskets, applying anti-seize to stud threads. Tighten nuts in sequence from center outward working hot-to-cold. Install intake manifolds with new gaskets and tighten bolts in sequence. Install all sensors including camshaft position sensors, crankshaft position sensor, and knock sensors to specification. Connect all coolant passages and install thermostat housing with new gasket.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Sensor Bolts12 Nm (9 lb-ft)

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

    Install valve covers and accessories
    Install new valve cover gaskets and tighten valve cover bolts in sequence from center outward. Install water pump with new gasket. Reinstall turbochargers with new gaskets and oil feed/return lines. Install new spark plugs with anti-seize on threads. Connect all electrical connectors, vacuum lines, and breather hoses. Install new oil filter and oil drain plug with new crush washer.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Oil Drain Plug35 Nm (26 lb-ft)
15. 15

    Install engine and initial startup
    Remove engine from stand and attach to hoist with load leveler. Carefully lower engine into vehicle, aligning with transmission and motor mounts. Install engine mount bolts and transmission bellhousing bolts. Reconnect exhaust system, all wiring harnesses, fuel lines, coolant hoses, and accessory drive components. Install radiator and cooling system components. Fill engine with correct quantity of 0W-20 synthetic oil. Fill cooling system with Motorcraft Orange coolant and bleed air from system. Reconnect battery and perform initial start. Allow engine to idle and monitor for leaks, unusual noises, or warning lights. Verify oil pressure reaches normal range within 10 seconds.
    ⚠️Do not rev engine during initial startup. Allow oil pressure to build and components to receive lubrication before increasing RPM.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)

Reassembly

1. After initial startup and leak check, allow engine to reach operating temperature while monitoring coolant level and temperature gauge
2. Perform complete visual inspection for any fluid leaks, especially around oil pan, valve covers, and head gaskets
3. Check and adjust accessory drive belt tension after engine has cooled
4. Road test vehicle under light load and monitor engine performance, oil pressure, and coolant temperature
5. After 50-100 miles of light driving, drain engine oil and replace filter to remove assembly lube and break-in contaminants
6. Retorque cylinder head bolts after 500 miles if required by machining performed (consult machine shop recommendation)

Verification

• Verify no oil, coolant, or fuel leaks after initial startup and after reaching operating temperature
• Confirm oil pressure reads within normal range (25-75 PSI at operating temperature)
• Check that engine idles smoothly with no misfires or abnormal noises (knocking, ticking, rattling)
• Verify coolant temperature reaches and maintains normal operating range (195-220°F)
• Scan for diagnostic trouble codes - there should be no engine-related codes stored
• Perform compression test across all cylinders - readings should be within 10% of each other and meet specification (typically 150-180 PSI)
• Test drive vehicle and verify normal power delivery, no smoke from exhaust, and smooth acceleration through RPM range
• After 500-mile break-in period, perform oil analysis to verify no abnormal wear metals are present

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