Complete replacement of all hydraulic valve lifters/tappets on the 3.5L EcoBoost V6 engine, requiring removal of valve covers, camshafts, and timing components.

Warnings

Tools required

Parts

• Hydraulic valve lifters × 24 — Use OEM specification - 24 required
• Valve cover gaskets (left and right) × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• VVT solenoid O-rings × 4 — Use OEM specification
• Camshaft position sensor O-rings × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Spark plug tube seals × 6 — Use OEM specification
• Timing chain tensioner seals × 2 — Use OEM specification

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt
• Motorcraft Orange Coolant — 2 qt

Preparation

1. Ensure engine is completely cold (minimum 4 hours after shutdown)
2. Disconnect negative battery cable and wait 10 minutes for system discharge
3. Drain engine coolant into approved container - capture approximately 2 quarts
4. Remove engine cover and air intake system completely
5. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it will not start
6. Remove both ignition coils and spark plugs from all cylinders
7. Support engine from above using engine support fixture or hoist - engine will need to be raised slightly
8. Label and photograph all electrical connectors, vacuum lines, and hose routing before removal
9. Have clean, organized workspace prepared for storing 24 lifters in order

Procedure

1. 1

   Remove intake manifold assembly
   Disconnect all electrical connectors from intake manifold including throttle body, fuel injectors, and sensors. Remove PCV hoses and vacuum lines. Unbolt and remove intake manifold, keeping all bolts organized. Clean gasket surfaces on cylinder heads.
   Torque spec

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

   Remove valve covers
   Disconnect ignition coil harness connectors. Remove valve cover bolts in reverse of tightening sequence. Carefully lift valve covers, breaking gasket seal with plastic pry tool if necessary. Remove and discard valve cover gaskets and spark plug tube seals.
   ⚠Do not pry against gasket surfaces. Damage to sealing surfaces will cause oil leaks.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
3. 3

   Position crankshaft to TDC cylinder #1
   Rotate crankshaft clockwise (viewed from front) using appropriate socket on crankshaft bolt until cylinder #1 is at Top Dead Center on compression stroke. Verify timing marks on camshaft sprockets align with cylinder head reference marks. Install crankshaft holding tool to prevent rotation.
   ⚠️Never rotate engine counterclockwise. Always rotate clockwise only. Verify both intake and exhaust valves for cylinder #1 are closed before proceeding.
4. 4

   Remove front timing cover
   Remove accessory drive belt and crankshaft pulley. Disconnect coolant hoses from timing cover. Remove all timing cover bolts following proper sequence. Carefully remove timing cover and gasket. Inspect timing chain, guides, and tensioners for wear.
   ⚠Coolant will drain from cover - have drain pan ready. Timing cover houses coolant passages.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

   Gasket Surface Bolts23 Nm (17 lb-ft)
5. 5

   Lock timing chain tensioners and mark timing
   Insert tensioner holding pins into both primary and secondary timing chain tensioners to lock them in compressed position. Use paint marker or similar to mark exact position of timing chains on all sprockets. Photograph timing chain alignment from multiple angles for reference.
   ⚠️Do not proceed without proper tensioner locking tools. Timing chain under tension can cause serious injury and engine damage.
6. 6

   Remove camshaft sprockets and timing chains
   Install camshaft holding tools on both banks to prevent camshaft rotation. Remove camshaft sprocket bolts. Carefully remove camshaft sprockets and timing chains together, keeping them organized by bank. Support chains to prevent falling into engine.
   ⚠Camshafts are under spring pressure from valves. Holding tools must be secure before loosening sprocket bolts.
7. 7

   Remove camshaft bearing caps
   Loosen camshaft bearing cap bolts in reverse order of tightening sequence (outside to center), loosening each bolt 1/4 turn at a time in multiple passes to prevent camshaft distortion. Remove bearing caps and keep them in order - they are not interchangeable. Carefully lift camshafts from cylinder heads.
   ⚠Bearing caps must be reinstalled in exact original positions. Mark or photograph positions before removal. Uneven loosening will bend camshafts.
   Torque spec

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)

   Camshaft Cap Bolts14 Nm (10 lb-ft)
8. 8

   Remove rocker arms
   Remove rocker arm shaft bolts evenly in sequence. Lift rocker arm assemblies from cylinder heads. Keep rocker arms organized by cylinder and position if reusing. Inspect rocker arm contact surfaces for wear or scoring.
   ℹ️Rocker arms may be stuck to valve stems. Use gentle rocking motion to free them - do not pry against aluminum cylinder head.
   Torque spec

   Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
9. 9

   Extract all hydraulic lifters
   Use magnetic lifter removal tool to extract all 24 lifters (12 per bank). Place lifters in numbered tray or container maintaining exact order of removal. Inspect each lifter bore in cylinder head for scoring, debris, or wear. Clean each bore thoroughly with lint-free cloth and solvent.
   ⚠Never mix lifter positions. Each lifter wears to its specific cam lobe and bore. If reusing any lifters, they must return to exact original positions.
   ⚠Inspect lifter bores with flashlight. Any debris left in bore will cause immediate new lifter failure.
10. 10

    Prepare and install new lifters
    Remove new lifters from packaging. Prime each lifter by submerging in clean engine oil and pumping plunger 10-15 times until resistance is felt. Coat exterior of each lifter with assembly lubricant. Install lifters into their respective bores, ensuring they move freely and seat completely in bore.
    ⚠Lifters must be primed with oil before installation. Un-primed lifters will cause valve train noise and potential damage on first startup.
    ℹ️Each lifter should drop into bore by its own weight when oiled. Tight or binding fit indicates bore damage or wrong part.
11. 11

    Reinstall rocker arms
    Coat rocker arm contact surfaces with assembly lubricant. Install rocker arm assemblies onto cylinder heads. Install rocker arm shaft bolts and tighten evenly in proper sequence to specification. Verify each rocker arm moves freely on its shaft.
    ℹ️Ensure rocker arms are properly located on valve stem tips before tightening. Misalignment will bend pushrods or damage valves.
    Torque spec

    Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
12. 12

    Reinstall camshafts
    Liberally coat all camshaft journals and lobes with assembly lubricant. Carefully lower camshafts into cylinder heads, ensuring they seat fully in journals. Install camshaft bearing caps in correct positions and orientation. Tighten bearing cap bolts in sequence from center outward in 3 passes (1/3 torque, 2/3 torque, final torque) to specification.
    ⚠️Bearing caps have specific positions marked. Installing caps incorrectly will destroy camshafts and engine. Verify markings before tightening.
    Torque spec

    Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)

    Camshaft Cap Bolts14 Nm (10 lb-ft)
13. 13

    Install timing chains and set timing
    Install camshaft holding tools. Position timing chains on sprockets following marked positions from disassembly. Install camshaft sprockets ensuring timing marks align exactly with cylinder head references. Verify crankshaft is still at TDC. Install and tighten camshaft sprocket bolts to specification. Remove camshaft holding tools.
    ⚠️Verify timing mark alignment three times before proceeding. Incorrect timing will cause immediate catastrophic engine failure when started. Use dial indicator to verify piston position if any doubt exists.
14. 14

    Install timing cover and tensioners
    Clean all gasket surfaces thoroughly with gasket remover and razor blade. Install new timing cover gasket and timing cover. Install cover bolts and tighten to specification in proper sequence. Release timing chain tensioners by removing locking pins - verify tensioners extend properly. Install camshaft position sensors with new O-rings.
    ⚠Gasket surfaces must be completely clean and dry. Any old gasket material will cause coolant or oil leaks.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Gasket Surface Bolts23 Nm (17 lb-ft)

    Camshaft Position Sensor10 Nm (7 lb-ft)
15. 15

    Install valve covers and intake manifold
    Install new valve cover gaskets and spark plug tube seals. Clean valve cover bolt threads and apply light coat of clean engine oil. Install valve covers and tighten bolts in sequence to specification. Install intake manifold with new gaskets and tighten bolts to specification in sequence. Reconnect all electrical connectors, vacuum lines, and hoses per earlier documentation.
    ℹ️Do not use sealant on valve cover gaskets unless specifically called for by gasket manufacturer. Excess sealant can block oil return passages.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)

Reassembly

1. Reinstall crankshaft pulley and accessory drive belt with proper tension
2. Reconnect all coolant hoses and refill cooling system with Motorcraft Orange Coolant to proper level
3. Install spark plugs with anti-seize and tighten to specification (not provided - use torque wrench and OEM spec)
4. Install ignition coils and reconnect electrical connectors
5. Refill engine oil with full 6 quarts of Motorcraft 0W-20 synthetic oil
6. Reinstall air intake system and engine cover
7. Reconnect battery negative cable

Verification

• Rotate engine by hand two complete revolutions clockwise and verify smooth rotation with no binding or unusual resistance
• Verify timing marks return to proper alignment after two crankshaft rotations - confirms timing is correct
• Check for any coolant or oil leaks around valve covers, timing cover, and intake manifold gaskets
• Start engine and listen for abnormal valve train noise - some ticking is normal for first 30 seconds while lifters prime
• Allow engine to reach operating temperature and verify no warning lights illuminate
• After 20 minutes of run time, shut off engine and recheck all fluid levels - top off as necessary
• Check for oil leaks around valve covers and timing cover after engine reaches operating temperature
• Test drive vehicle and verify normal operation under various load conditions
• Recheck valve cover and intake manifold bolt torque after engine cools completely (recommended after first heat cycle)

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