Complete replacement of all rocker arms on the 3.5L EcoBoost V6 engine, requiring removal of valve covers, camshaft components, and proper timing alignment.

Warnings

Tools required

Parts

• Rocker arm set (12 pieces - intake and exhaust) × 1 — Use OEM Ford specification
• Valve cover gasket - left bank × 1 — Use OEM specification
• Valve cover gasket - right bank × 1 — Use OEM specification
• Spark plug tube seals × 6 — Use OEM specification
• Valve cover bolt grommets × 1 — Use OEM specification
• Engine oil × 1 — Motorcraft 0W-20

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt

Preparation

1. Ensure engine is completely cold to the touch
2. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
3. Remove engine cover by pulling upward on front edge
4. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
5. Drain engine oil completely and install drain plug
6. Label and disconnect all ignition coil electrical connectors
7. Remove all six ignition coils from valve covers
8. Mark all vacuum lines, wiring harnesses, and connectors with tape for reinstallation reference

Procedure

1. 1

   Remove engine covers and accessories
   Remove plastic engine cover. Disconnect PCV hoses from both valve covers. Disconnect any electrical connectors mounted to valve covers. Remove the charge air cooler outlet pipe if it obstructs access to the right valve cover.
   Torque spec

   Electrical Connector Bolts8 Nm (6 lb-ft)
2. 2

   Remove left and right valve covers
   Remove valve cover bolts in reverse of tightening sequence (start from outer bolts, work inward). Carefully lift valve covers off cylinder heads. If covers are stuck, gently tap with rubber mallet - do not pry against sealing surfaces. Remove and discard old gaskets and spark plug tube seals.
   Torque spec

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

   Rotate engine to TDC cylinder 1
   Rotate crankshaft clockwise using a socket on the crankshaft pulley bolt until cylinder 1 is at top dead center on compression stroke. Verify timing marks on camshaft sprockets align with cylinder head mating surface. Both intake and exhaust camshaft timing marks should be visible and aligned.
   ⚠Only rotate engine in clockwise direction when viewed from front. Never rotate counterclockwise.
4. 4

   Secure camshafts and remove timing components
   Install camshaft holding tools on both banks to prevent rotation. Remove camshaft position sensor bolts and sensors from both cylinder heads. Mark the position of timing chain to camshaft sprockets with paint pen. Remove camshaft sprocket bolts while holding camshafts with holding tool. Carefully remove sprockets without dropping timing chain into engine.
   ⚠Support timing chain with wire to prevent it from falling into timing cover. Chain position must be maintained.
   Torque spec

   Sensor Bolts12 Nm (9 lb-ft)
5. 5

   Remove camshaft caps and camshafts
   Loosen camshaft bearing cap bolts in multiple passes working from outside to inside in a crisscross pattern. Remove bearing caps and keep them in order - they are numbered and must be reinstalled in original positions. Carefully lift camshafts straight up from cylinder head. Mark intake and exhaust camshafts for each bank to ensure correct reinstallation.
   ⚠Camshaft bearing caps are not interchangeable. Keep them organized by position and bank.
6. 6

   Remove rocker arms and inspect components
   Remove all rocker arms from both cylinder heads, keeping them organized by cylinder and position if reusing lash adjusters. Inspect camshaft lobes for scoring, pitting, or wear. Inspect rocker arm contact surfaces and roller wheels for damage. Check lash adjusters for proper operation by pressing down - they should not collapse easily when full of oil. Inspect valve tips for abnormal wear patterns.
   ℹ️Hydraulic lash adjusters can be reused if in good condition and kept with their original positions.
7. 7

   Clean and prepare cylinder head surfaces
   Thoroughly clean all camshaft bearing surfaces in cylinder head using brake cleaner. Inspect bearing surfaces for scoring or damage. Clean valve cover gasket surfaces with gasket scraper, being careful not to gouge aluminum. Ensure no debris or old gasket material remains. Verify all oil passages are clear.
   Torque spec

   Gasket Surface Bolts23 Nm (17 lb-ft)
8. 8

   Install new rocker arms
   If reusing hydraulic lash adjusters, install them in their original positions. If installing new adjusters, soak them in clean engine oil for at least 30 minutes before installation. Install new rocker arms onto lash adjusters, ensuring rollers move freely. Apply clean engine oil to all rocker arm contact surfaces and valve stem tips.
   ℹ️New hydraulic lash adjusters must be primed with oil to prevent valve train noise on startup.
9. 9

   Reinstall camshafts
   Lubricate all camshaft journals and lobes with clean engine oil. Carefully set camshafts into cylinder head, ensuring they are positioned in their original banks (intake vs exhaust). Verify camshaft timing marks are still aligned for TDC cylinder 1. Install camshaft bearing caps in their original positions with arrows pointing toward front of engine.
   ⚠Ensure no rocker arms are positioned on camshaft lobe peaks during initial installation to prevent valve binding.
10. 10

    Torque camshaft bearing caps
    Install camshaft bearing cap bolts finger tight. Tighten bearing cap bolts in multiple passes (30%, 60%, 100% of final torque) working from inside to outside. Follow factory tightening sequence. Verify camshafts rotate smoothly by hand after torquing - if binding occurs, remove caps and check for misalignment or debris.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
11. 11

    Reinstall timing components
    Align timing chain marks with marks made during disassembly on camshaft sprockets. Install sprockets onto camshafts ensuring timing marks align properly. Install camshaft sprocket bolts and torque while holding camshafts with holding tool. Remove camshaft holding tools. Rotate engine two complete revolutions clockwise and verify timing marks realign perfectly at TDC.
    ⚠️If timing marks do not realign after two rotations, DO NOT start engine. Timing is incorrect and must be corrected.
12. 12

    Reinstall camshaft position sensors
    Clean camshaft position sensor mounting areas. Install new O-rings on sensors if equipped. Install sensors and torque bolts to specification. Ensure sensors are fully seated before tightening.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Install new valve cover gaskets and reinstall covers
    Install new spark plug tube seals into valve covers. Install new valve cover gaskets with integrated bolt grommets. Ensure gaskets are properly seated in valve cover grooves. Place valve covers onto cylinder heads, being careful not to dislodge gaskets. Install valve cover bolts and torque in sequence from center outward.
    Torque spec

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

    Reinstall remaining components
    Reconnect all PCV hoses and vacuum lines per reference marks. Reinstall charge air cooler outlet pipe if removed. Reconnect all electrical connectors to valve covers. Install ignition coils and torque electrical connector bolts to specification. Reinstall engine covers.
    Torque spec

    Electrical Connector Bolts8 Nm (6 lb-ft)
15. 15

    Refill engine oil and perform startup procedure
    Install new oil filter and refill engine with 6 quarts of Motorcraft 0W-20 synthetic oil. Reconnect battery. Turn ignition to ON position without starting to prime fuel system (repeat 3 times). Start engine and verify no unusual noises. Check for oil leaks around valve covers. Allow engine to idle for 5 minutes, monitoring oil pressure and listening for valve train noise which should disappear within 30 seconds as lash adjusters pump up.
    ⚠Some valve train noise on initial startup is normal with new rocker arms or lash adjusters. Noise should cease within 30 seconds.

Reassembly

1. Torque all fasteners to exact specifications in proper sequence
2. Verify timing alignment multiple times before final assembly
3. Use new gaskets and seals - never reuse old valve cover gaskets
4. Apply clean engine oil to all moving components during assembly

Verification

• Engine starts smoothly without hesitation
• No valve train noise after 30 seconds of operation
• No oil leaks from valve covers after 10 minutes of running
• Engine runs smoothly at idle and under acceleration with no misfires
• Oil pressure reads normal on instrument cluster
• Scan for diagnostic trouble codes - none should be present related to camshaft position
• Perform test drive and verify normal engine performance and power delivery

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