This procedure covers the removal and replacement of ignition coil packs on the 3.5L EcoBoost V6 engine, including accessing coils under the engine cover and replacing spark plugs if needed.

Warnings

Tools required

Parts

• Ignition coil pack(s) × 1 — Motorcraft DG-511 or equivalent
• Spark plug(s) × 1 — Motorcraft SP-546 (iridium)

Preparation

1. Ensure engine is cool to the touch
2. Disconnect negative battery cable to prevent accidental ignition system activation
3. Identify which coil pack(s) need replacement - cylinders 1-2-3 are passenger side (right bank), 4-5-6 are driver side (left bank)
4. Remove engine cover by lifting upward - it is retained by grommets on ball studs

Procedure

1. 1

   Remove engine cover
   Grasp the engine cover firmly and pull straight upward to disengage the rubber grommets from the ball studs. The cover may require moderate force to release. Set cover aside in a clean area.
2. 2

   Disconnect electrical connector
   Locate the ignition coil for the cylinder being serviced. Press the locking tab on the electrical connector and pull straight up to disconnect from the coil pack. Do not pull on the wires themselves.
3. 3

   Remove coil pack mounting bolt
   Using a 7mm socket, remove the single bolt securing the ignition coil to the valve cover. Keep the bolt in a safe location for reinstallation.
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
4. 4

   Extract ignition coil
   Grasp the coil pack firmly and pull straight upward with a twisting motion to break the seal. The coil may be tight in the spark plug tube. Avoid excessive side-to-side movement that could damage the boot.
5. 5

   Clean spark plug area
   Use compressed air to blow out any debris from around the spark plug well before proceeding. Debris falling into the cylinder can cause engine damage. Inspect the coil boot for oil contamination which may indicate valve cover gasket leakage.
   ⚠Do not allow dirt or debris to fall into the spark plug well or cylinder
6. 6

   Remove spark plug (if replacing)
   If replacing spark plugs, use a 5/8 inch spark plug socket with extension to remove the spark plug. Turn counterclockwise until the plug is free. Inspect the old plug condition for signs of misfiring, oil fouling, or incorrect heat range.
7. 7

   Install new spark plug (if replacing)
   Apply a small amount of anti-seize compound to the spark plug threads (avoid getting any on the electrode). Thread the new spark plug by hand to prevent cross-threading, then tighten to specification using a torque wrench. The aluminum cylinder heads require precise torque to avoid damage.
   ⚠️CRITICAL: Do not exceed 20 Nm (15 lb-ft) torque specification - aluminum threads strip easily
   Torque spec

   Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
8. 8

   Prepare new coil pack
   Apply a thin coat of dielectric grease to the inside of the new coil boot. This prevents moisture intrusion and makes future removal easier. Do not use excessive grease.
9. 9

   Install new coil pack
   Align the coil pack with the spark plug well and push down firmly until it is fully seated on the spark plug. The coil should sit flush with the valve cover mounting surface. Ensure the mounting bolt hole is properly aligned.
10. 10

    Install coil mounting bolt
    Install the 7mm mounting bolt and tighten to specification using a torque wrench. Do not over-tighten as this can crack the coil housing or damage valve cover threads.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect electrical connector
    Press the electrical connector onto the coil pack until you hear and feel a positive click. Gently tug on the connector to verify it is locked in place.
12. 12

    Reinstall engine cover
    Align the engine cover grommets with the ball studs on the engine and press down firmly until all grommets are fully seated. The cover should sit evenly without gaps.
13. 13

    Reconnect battery
    Reconnect the negative battery cable. The PCM may need to relearn idle characteristics after coil replacement.

Reassembly

1. Ensure all electrical connectors are fully locked in place with audible clicks
2. Verify engine cover is properly seated on all mounting grommets
3. Double-check that all tools have been removed from engine compartment

Verification

• Start the engine and verify it runs smoothly without misfires or rough idle
• Check for diagnostic trouble codes using an OBD-II scanner - clear any codes that were present before the repair
• Listen for any unusual sounds or detect any vibrations that would indicate improper installation
• Verify no check engine light after several minutes of operation
• Test drive the vehicle under light and moderate acceleration to confirm proper operation under load

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