This procedure covers the removal and replacement of a single cylinder head gasket on the 2021-2024 Ford F-150 3.5L V6 EcoBoost engine, including disassembly of timing components, head removal, and reassembly with proper torque specifications.

Warnings

Tools required

Parts

• Cylinder head gasket (specify left or right bank) × 1 — Use OEM Ford specification
• Cylinder head bolts × 10 — Use OEM Ford specification - must replace
• Valve cover gasket × 1 — Use OEM Ford specification
• Exhaust manifold gasket × 1 — Use OEM Ford specification
• Intake manifold gasket × 1 — Use OEM Ford specification
• Timing cover gasket × 1 — Use OEM Ford specification
• Turbocharger gasket and seals × 1 — Use OEM Ford specification
• Spark plugs × 3 — Motorcraft SP-546 or equivalent
• Oil filter × 1 — Motorcraft FL-500-S or equivalent
• Coolant hose clamps (assorted) × 1 — Replace as needed

Fluids

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

Preparation

1. Disconnect negative battery cable and wait 10 minutes for system capacitors to discharge
2. Drain engine coolant completely into suitable container for proper disposal or reuse
3. Drain engine oil and remove oil filter
4. Remove engine cover and intake air system including air filter housing
5. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
6. Support engine securely with engine support fixture from above or appropriate jack from below
7. Remove intercooler and charge air cooler piping
8. Label all electrical connectors, vacuum lines, and coolant hoses with tape for reinstallation reference
9. Photograph all electrical and vacuum connections before disconnecting

Procedure

1. 1

   Remove intake manifold assembly
   Disconnect all electrical connectors from throttle body, fuel injectors, and sensors. Disconnect fuel lines using proper quick-disconnect tools. Remove PCV hoses and vacuum lines. Remove intake manifold mounting bolts in reverse of tightening sequence and lift manifold assembly away. Cover intake ports with clean shop towels to prevent debris entry.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
2. 2

   Remove valve cover
   Disconnect ignition coil connectors and remove all three ignition coils from the cylinder head being serviced. Remove valve cover bolts in a criss-cross pattern starting from outer bolts working inward. Carefully break valve cover seal and remove. Inspect valve cover for damage or warping.
3. 3

   Remove exhaust manifold and turbocharger assembly
   Disconnect oxygen sensors and turbocharger oil feed and drain lines. Remove heat shields. Disconnect turbocharger coolant lines and exhaust downpipe. Remove exhaust manifold nuts working from center outward. Carefully separate manifold and turbocharger assembly from head, supporting turbo weight to prevent damage. Inspect exhaust studs for damage.
   ⚠Exhaust studs may be seized. Apply penetrating oil 30 minutes before removal and work carefully to avoid breaking studs in head.
   Torque spec

   Exhaust Manifold Nuts25 Nm (18 lb-ft)
4. 4

   Remove timing cover and set engine to TDC
   Remove accessory drive belt and tensioner. Remove crankshaft pulley bolt using appropriate holding tool. Remove timing cover bolts and carefully pry cover away from engine block. Rotate crankshaft to TDC position for cylinder #1 by aligning timing marks on crankshaft and camshafts. Verify both camshaft lobes for cylinder #1 are pointing upward away from valves.
   ⚠Once timing cover is removed, do not rotate crankshaft or camshafts until timing components are properly locked in position.
5. 5

   Lock camshafts and remove timing chain
   Install Ford camshaft locking tools on both intake and exhaust camshafts to prevent rotation. Mark timing chain position relative to cam sprockets with paint marker. Compress timing chain tensioner and lock in compressed position. Remove camshaft sprocket bolts. Carefully remove timing chain from sprockets while supporting chain to prevent it from falling into engine.
   ⚠️Camshafts are under valve spring tension. Ensure locking tools are properly installed before removing sprockets or serious injury may occur.
6. 6

   Remove camshaft caps and camshafts
   Loosen camshaft cap bolts gradually in reverse numerical sequence (start from highest number working to cap #1), turning each bolt 1/4 turn at a time to prevent camshaft distortion. Remove camshaft caps and store in order. Carefully lift camshafts from head, keeping them identified as intake or exhaust. Inspect camshaft journals and lobes for wear or scoring.
   ⚠Camshaft caps are matched to their positions. Mark each cap location clearly and never interchange caps between positions.
7. 7

   Remove cylinder head bolts
   Remove all remaining components connected to cylinder head including coolant temp sensors, knock sensors, and any remaining brackets. Loosen cylinder head bolts in reverse torque sequence (working from outside toward center) in multiple passes. Remove bolts completely and discard - they cannot be reused. Keep bolts in sequence order to verify none are missing during reassembly.
   ℹ️Cylinder head bolts are torque-to-yield design and must be replaced. Count all bolts to ensure none remain in head.
   Torque spec

   Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
8. 8

   Remove cylinder head
   Carefully break cylinder head seal using plastic pry points (never between sealing surfaces). Lift cylinder head straight up evenly to prevent binding on dowel pins. Place head on clean padded surface with combustion chambers facing up. Remove and discard old head gasket. Inspect head gasket failure pattern to determine root cause of failure.
   ⚠Cylinder head weighs approximately 40-50 lbs. Use assistance or proper lifting technique to prevent injury or dropping head.
9. 9

   Inspect and clean surfaces
   Thoroughly clean cylinder head and engine block mating surfaces using non-metallic gasket scraper. Remove all traces of old gasket material, carbon, and sealant. Clean bolt holes in block using thread chaser or tap. Inspect block surface for warping using precision straightedge and feeler gauge - maximum allowable warpage is 0.003 inches. Check head surface in same manner. If head or block exceeds specification, machining or replacement is required. Clean all oil and coolant passages.
   ⚠Do not use abrasive pads or power tools on aluminum head or block surfaces. Hand scraping with proper tools only.
10. 10

    Install new head gasket and position cylinder head
    Verify block surface is completely clean and dry. Install new head gasket on block with orientation marks (TOP, FRONT, or part number) facing upward and toward front of engine. Align gasket over dowel pins. Do not use any sealant on head gasket. Carefully lower cylinder head onto block, aligning with dowel pins. Ensure head seats fully on gasket.
    ⚠Head gasket is directional and bank-specific. Verify correct gasket orientation before installation or catastrophic failure will occur.
11. 11

    Install and torque cylinder head bolts
    Install new cylinder head bolts finger-tight in their correct positions. Follow six-step torque procedure precisely: Step 1 - Torque all bolts to 26 lb-ft in sequence. Step 2 - Torque all bolts to 44 lb-ft in sequence. Step 3 - Loosen all bolts 1 complete turn in reverse sequence. Step 4 - Torque all bolts to 26 lb-ft in sequence. Step 5 - Rotate all bolts 90 degrees in sequence using angle gauge. Step 6 - Rotate all bolts additional 90 degrees in sequence. Torque sequence starts at center bolts and works outward in spiral pattern.
    ⚠️Head bolt torque sequence and procedure must be followed exactly as specified. Any deviation can cause head gasket failure or head warping.
    Torque spec

    Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
12. 12

    Install camshafts and camshaft caps
    Lubricate camshaft journals and lobes with clean engine oil. Install camshafts in correct positions (intake and exhaust) with timing marks visible. Position camshaft caps in their original numbered locations with arrows pointing toward front of engine. Install cap bolts and torque in numerical sequence (cap #1 first) gradually in multiple passes to final specification of 14 lb-ft. Rotate camshafts to verify smooth rotation without binding.
    ⚠Tighten camshaft cap bolts gradually and evenly. Uneven tightening can distort camshafts or crack caps.
13. 13

    Install timing chain and verify timing alignment
    Verify camshafts and crankshaft are still at TDC position with locking tools installed. Align timing chain with marks made during disassembly on cam sprockets. Install chain onto sprockets and install sprocket bolts. Release timing chain tensioner. Remove camshaft locking tools. Manually rotate crankshaft two complete revolutions and verify timing marks realign at TDC. Reinstall locking tools to confirm proper timing.
    ⚠️Incorrect timing will cause piston-to-valve contact and catastrophic engine damage. Triple-check timing alignment before proceeding.
14. 14

    Install timing cover and reassemble engine
    Install new timing cover gasket and position timing cover onto engine. Torque cover bolts to specification. Install crankshaft pulley and torque to specification. Install accessory drive belt tensioner and belt. Install exhaust manifold with new gasket and torque nuts to specification from center outward. Install turbocharger oil and coolant lines. Install valve cover with new gasket and torque bolts in criss-cross pattern to specification. Install intake manifold with new gasket and torque bolts in sequence to specification. Reconnect all electrical connectors, vacuum lines, fuel lines, and coolant hoses.
    Torque spec

    Exhaust Manifold Nuts25 Nm (18 lb-ft)

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

    Refill fluids and final preparation
    Install new oil filter and refill engine with 6 quarts of Motorcraft 0W-20 synthetic oil. Refill cooling system with 13 quarts of Motorcraft Orange coolant using proper bleeding procedure to remove air pockets. Bleed cooling system at bleed screws on thermostat housing and heater hoses. Reconnect battery negative cable. Prime fuel system by cycling ignition on for 5 seconds, off for 10 seconds, repeat 3 times before attempting to start.
    ℹ️Do not start engine until cooling system is completely filled and bled of air to prevent overheating damage.

Reassembly

1. Torque all fasteners to proper specifications in correct sequence - refer to torque reference list
2. Use only new gaskets and seals - do not reuse any gaskets
3. Apply light coat of clean engine oil to all rubber seals before installation
4. Ensure all electrical connectors are fully seated and locked
5. Verify all coolant hose clamps are properly positioned and tightened
6. Double-check that no tools or shop towels remain in engine compartment

Verification

• Start engine and immediately verify oil pressure light extinguishes within 2-3 seconds
• Monitor coolant temperature and verify thermostat opens normally (around 195-210°F)
• Check for any coolant, oil, or exhaust leaks around head gasket area, timing cover, valve cover, and exhaust manifold
• Listen for unusual noises that might indicate timing issues or improperly torqued components
• Allow engine to reach full operating temperature and verify cooling fans cycle properly
• Check for any fault codes using OBD-II scanner and address any issues
• After initial warm-up and cool-down cycle, recheck coolant level and top off as needed
• Perform test drive and monitor for proper boost pressure from turbocharger
• After 500 miles, recheck valve cover and intake manifold bolt torque as these may require retightening

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