Complete replacement of all six pistons and rings in the 3.5L EcoBoost V6 engine, requiring engine removal, disassembly, cylinder honing, and precision reassembly with torque-to-yield fasteners.

Warnings

Tools required

Parts

• Piston and ring set (complete set of 6) × 1 — Use OEM specification
• Connecting rod bearing set (6 pairs) × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 12 — Use OEM specification
• Cylinder head gasket set × 2 — Use OEM specification
• Cylinder head bolts (TTY) × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Turbocharger gasket kit × 2 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil filter × 1 — Use OEM specification
• RTV silicone gasket maker (OEM spec) × 2 — TA-357 or equivalent

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt
• Motorcraft Orange Coolant — 13 qt
• Motorcraft MERCON LV ATF — 2 qt

Preparation

1. Park 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 and both turbocharger intercooler tubes
4. Drain engine oil completely and remove oil filter
5. Drain cooling system at radiator petcock and block drain plugs
6. Remove front bumper cover, grille, and radiator support to access engine mounting points
7. Label and disconnect all electrical connectors, vacuum lines, and fuel lines with digital photos for reference
8. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
9. Remove both turbochargers with oil feed and drain lines
10. Remove intake manifold assembly completely
11. Remove both exhaust manifolds
12. Disconnect transmission cooler lines and mark orientation
13. Support transmission with jack and remove bellhousing bolts
14. Disconnect wiring harness from engine block and position aside
15. Remove accessory drive belt and all accessories (alternator, A/C compressor, power steering pump)
16. Attach engine hoist with load leveler to factory lifting points
17. Remove engine mount bolts and carefully lift engine from vehicle
18. Mount engine securely on engine stand using bellhousing bolt holes
19. Position engine stand for easy access to oil pan and cylinder heads

Procedure

1. 1

   Remove cylinder heads
   Remove valve covers by loosening bolts in reverse of tightening pattern. Remove cylinder head bolts in reverse of factory tightening sequence (start from outside, work inward in three passes). Carefully lift both cylinder heads from block and place on clean padded surface. Inspect head gasket mating surfaces for damage or warpage.
2. 2

   Remove oil pan and pickup tube
   Remove all oil pan bolts in crisscross pattern. Carefully separate oil pan from block using plastic wedge (do not pry against gasket surfaces). Remove oil pump pickup tube mounting bolts and remove tube assembly. Inspect oil pickup screen for debris.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)
3. 3

   Remove timing chain cover and components
   Remove crankshaft pulley center bolt using holding tool. Remove all timing chain cover bolts and carefully separate cover from block. Remove timing chains, guides, and tensioners as assembly. Mark chain orientation to camshafts before removal. Rotate crankshaft to access each piston at bottom dead center during disassembly.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
4. 4

   Remove cylinder ridge and mark components
   Using cylinder ridge reamer, carefully remove ridge from top of each cylinder bore (approximately 0.5mm below deck surface). This prevents piston ring damage during removal. Mark each connecting rod and cap with cylinder number using metal stamps (1-6, front to rear). Mark orientation (toward front or rear of engine) on rod and cap to ensure correct reassembly. Verify marks are on same side of rod and cap.
   ⚠Do not remove material below the ridge wear area. Only remove the ridge itself to prevent piston damage during extraction.
5. 5

   Remove pistons and connecting rods
   Rotate crankshaft to bring cylinder #1 to bottom dead center. Remove connecting rod cap bolts and carefully separate cap from rod. Push piston and rod assembly up and out through top of cylinder bore. Install rod cap back onto rod immediately to prevent mixing. Repeat for all six cylinders. Place each assembly in order in clean containers to maintain cylinder identification.
6. 6

   Disassemble and inspect pistons
   Using piston ring removal tool, carefully expand and remove top compression ring, second compression ring, and oil control ring assembly from each piston. Remove piston pin retaining clips and press out wrist pins (may require heat to 150°F if tight). Separate pistons from connecting rods. Inspect each piston for cracks, scoring, or wear. Inspect cylinder walls for scoring, taper, and out-of-round using bore gauge. Maximum taper specification is 0.05mm; beyond this requires machining.
   ⚠Piston rings are brittle and sharp. Use proper ring removal tools to prevent breakage and injury.
7. 7

   Clean and measure components
   Thoroughly clean all connecting rods, old pistons (for reference), and cylinder bores with parts cleaner and lint-free cloths. Use shop vacuum to remove all debris from cylinders. Measure each cylinder bore at three heights (top, middle, bottom) and in two perpendicular directions. Record all measurements. Measure connecting rod big end bore diameter and side clearance. Compare all measurements to Ford specifications.
8. 8

   Hone cylinders and prepare surfaces
   Using rigid hone with 280-320 grit stones, hone each cylinder to create proper crosshatch pattern (45-55 degree angle). Hone only enough to establish fresh surface for ring seating. Clean cylinders thoroughly with hot soapy water and brush, then dry and immediately coat with engine assembly lube. Clean all gasket surfaces on block deck, oil pan rail, and timing cover mating surfaces. Use plastic scraper only; do not gouge aluminum surfaces.
   ℹ️Proper crosshatch pattern is critical for ring seating. Pattern should be visible but not deep. Over-honing will require machining.
   Torque spec

   Gasket Surface Bolts23 Nm (17 lb-ft)
9. 9

   Install new piston rings and check gaps
   For each new piston, install rings using ring installation tool. Place top compression ring in cylinder bore and push down 1 inch with inverted piston to square it. Measure ring end gap with feeler gauge (specification 0.20-0.40mm for top ring, 0.25-0.45mm for second ring). File ring ends if gap is too tight. Install oil control ring expander first, then rails, then second compression ring, then top compression ring. Stagger ring gaps 120 degrees apart, with no gap aligned with wrist pin.
   ⚠Ring gaps must be within specification. Insufficient gap can cause ring breakage; excessive gap reduces compression and increases oil consumption.
10. 10

    Assemble pistons to connecting rods
    Heat new pistons to approximately 150°F using heat gun. Lubricate wrist pins with assembly lube. Orient piston to rod according to factory markings (piston arrow toward front of engine, rod markings toward same side). Install wrist pin through rod small end and piston. Install new retaining clips on both sides, ensuring clips are fully seated in piston grooves. Verify piston moves freely on pin without binding.
11. 11

    Install new rod bearings and check clearances
    Install new connecting rod bearings into rod and cap (do not lubricate yet for clearance check). Ensure bearing tangs are properly seated in rod notches. Place strip of Plastigage across bearing journal on crankshaft. Install rod cap with new TTY bolts and torque to 45 Nm (33 lb-ft) only - do not perform angle torque yet. Remove cap and measure Plastigage width to verify bearing clearance is within 0.025-0.055mm specification. Repeat for all six rods.
    ⚠Do not rotate crankshaft with Plastigage installed. This will give false readings and may damage bearings.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
12. 12

    Install piston and rod assemblies
    Coat cylinder walls, piston rings, and pistons generously with engine assembly lube. Position piston ring compressor on piston, compress all rings fully. Orient piston with arrow marking toward front of engine. Guide connecting rod big end onto crankshaft journal while gently tapping piston through ring compressor into cylinder bore using wooden hammer handle. Ensure rod does not strike crankshaft journal during installation. Install rod bearing cap in correct orientation matching previous marks.
13. 13

    Torque connecting rod bolts
    Lubricate threads and underside of new TTY connecting rod bolt heads with engine oil. Install new connecting rod cap bolts and torque in two steps: First torque all bolts to 45 Nm (33 lb-ft). Then rotate each bolt an additional 90 degrees using torque angle gauge. Verify rod side clearance on crankshaft journal is 0.10-0.25mm using feeler gauge. Repeat for all six connecting rod assemblies.
    ⚠️Rod bolts are torque-to-yield and must be replaced. Do not reuse old bolts under any circumstances.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
14. 14

    Install oil pump pickup and pan
    Clean oil pan and block mating surfaces thoroughly. Install new oil pump pickup tube with new O-ring and torque mounting bolts to 12 Nm. Apply thin bead of RTV silicone to oil pan rail corners and front/rear main seal areas per Ford specifications. Install new oil pan gasket and position oil pan. Install all oil pan bolts hand-tight, then torque in crisscross pattern from center outward to 12 Nm.
    Torque spec

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
15. 15

    Reinstall timing components and cylinder heads
    Apply RTV silicone to timing cover sealing areas per factory specifications. Install timing chains, guides, and tensioners according to timing marks. Rotate crankshaft two complete revolutions and verify all timing marks align correctly. Install new timing cover gasket and cover, torquing cover bolts to 19 Nm. Clean cylinder head mating surfaces and block deck thoroughly. Install new head gaskets with TOP marking facing up. Position cylinder heads and install new TTY head bolts. Torque head bolts in factory sequence: torque all bolts to 65 Nm, then rotate each bolt 90 degrees, then an additional 90 degrees (total 180 degrees rotation after initial torque).
    ⚠️Cylinder head bolts are torque-to-yield. Use only new bolts and follow exact torque sequence and angle specifications to prevent head gasket failure.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Cylinder Head Bolts65 Nm (48 lb-ft)

Reassembly

1. Reinstall all remaining engine components in reverse order of removal
2. Install new valve cover gaskets and torque valve cover bolts to specification in crisscross pattern
3. Reinstall intake manifold with new gaskets, torquing bolts to 23 Nm in proper sequence
4. Install exhaust manifolds with new gaskets and torque bolts to specification
5. Reinstall both turbochargers with new gaskets and torque mounting bolts to 54 Nm
6. Reconnect all turbocharger oil feed and drain lines with new crush washers
7. Carefully lower engine into vehicle using hoist and align with transmission bellhousing
8. Install engine mount bolts and torque to 55 Nm before removing hoist
9. Reconnect transmission and torque bellhousing bolts to specification
10. Reinstall all accessories, drive belt, and verify proper belt alignment
11. Reconnect all electrical connectors, vacuum lines, and fuel lines using reference photos
12. Install new oil filter and drain plug with new crush washer, torquing drain plug to 35 Nm
13. Fill engine with 6 quarts Motorcraft 0W-20 synthetic oil
14. Refill cooling system with 13 quarts Motorcraft Orange coolant and bleed air from system
15. Top off transmission fluid if needed (approximately 2 quarts lost during separation)
16. Reinstall radiator support, grille, and front bumper cover
17. Reconnect battery negative cable

Verification

• Perform initial start procedure: crank engine for 10 seconds without starting to build oil pressure, then start engine
• Verify oil pressure reaches normal range (40-70 psi) within 5 seconds of startup
• Listen for abnormal noises including knocking, ticking, or rattling during initial run period
• Allow engine to idle for 20 minutes while monitoring for leaks at oil pan, timing cover, valve covers, and all gasket surfaces
• Check coolant level after engine reaches operating temperature and top off as needed
• Perform test drive under light load conditions for first 50 miles, avoiding wide-open throttle or high RPM
• Monitor oil consumption and check level after 100 miles of varied driving
• Perform compression test on all cylinders to verify proper ring seating (should be within 10% across all cylinders)
• Change engine oil and filter at 500 miles to remove assembly lube and break-in debris
• Scan for diagnostic trouble codes and verify no misfires or sensor issues are present
• Follow Ford recommended break-in procedure: vary engine speed and load for first 1000 miles, avoid sustained high RPM operation

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