Complete removal and reinstallation of the 3.5L EcoBoost V6 engine from a 2011-2014 Ford F-150 4WD, including separation from transmission, removal of accessories, and extraction from engine bay.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Motorcraft FL-910-S or equivalent
• Engine coolant (if reusing, inspect condition) × 1 — Motorcraft Orange VC-3DIL-B
• Oil drain plug crush washer × 1 — Use OEM specification
• Exhaust manifold gaskets (if reusing engine) × 2 — Use OEM specification
• Intake manifold gaskets (if disturbed) × 1 — Use OEM specification
• Engine mount hardware (inspect and replace as needed) × 1 — Use OEM specification
• Anti-seize compound × 1 — Nickel-based high temp
• Engine assembly lubricant × 1 — Use OEM specification

Fluids

• Motorcraft 5W-20 Synthetic Blend — 6 qt
• Motorcraft Orange Coolant — 13 qt
• Motorcraft MERCON LV ATF — 11 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Chock rear wheels securely.
2. Disconnect negative battery cable, then positive cable. Remove battery from vehicle for access.
3. Remove engine cover and air intake assembly from throttle body to air filter box.
4. Relieve fuel system pressure: remove fuel pump fuse, start engine and let it stall, crank for 5 seconds to ensure complete pressure relief.
5. Raise vehicle on lift or jack stands rated for vehicle weight. Ensure vehicle is stable and secure.
6. Have AC system professionally evacuated by certified technician with recovery equipment.
7. Drain engine oil completely into appropriate container. Remove oil filter.
8. Drain engine coolant from radiator petcock and block drains into appropriate container.
9. Remove front skid plate and lower splash shields for access to engine from below.
10. Label all electrical connectors, vacuum lines, and hoses with tags indicating position and connection point.

Procedure

1. 1

   Remove hood and front accessories
   Mark hood hinge positions with paint pen for reinstallation alignment. With assistant, remove hood bolts and lift hood from vehicle. Remove radiator grille and support. Disconnect headlight connectors and remove headlights for additional working room. Remove radiator cover panel.
2. 2

   Disconnect cooling system components
   Remove radiator hoses (upper and lower) from engine. Disconnect heater hoses at firewall connections. Remove charge air cooler tubes from turbocharger outlets to throttle body - these are plastic and rubber, work carefully to avoid cracking. Disconnect coolant overflow reservoir and remove. Unbolt and remove radiator and cooling fan assembly as single unit by lifting straight up.
3. 3

   Disconnect fuel and EVAP systems
   Disconnect fuel supply line at fuel rail using appropriate fuel line disconnect tool - press release tabs and pull straight off. Cap open fuel line to prevent contamination. Disconnect fuel return line if equipped. Disconnect EVAP purge line and canister vent line from intake manifold and routing clips. Plug all open fuel system ports.
   ⚠Even after pressure relief, residual fuel will spill. Have shop towels ready and avoid ignition sources.
4. 4

   Remove accessory drive components
   Remove serpentine belt by rotating tensioner clockwise and sliding belt off pulleys. Remove power steering pump mounting bolts and secure pump aside with mechanics wire without disconnecting hoses - do not let pump hang by hoses. Remove AC compressor mounting bolts and secure compressor aside without disconnecting AC lines. Remove alternator electrical connections (B+ nut and connector), then remove alternator mounting bolts and alternator.
   Torque spec

   AC Compressor Bolts25 Nm (18 lb-ft)

   Power Steering Pump Bolts25 Nm (18 lb-ft)

   Alternator Mounting Bolts50 Nm (37 lb-ft)
5. 5

   Disconnect exhaust system
   From underneath vehicle, spray exhaust manifold nuts with penetrating oil and allow to soak. Disconnect oxygen sensor connectors (4 sensors total - 2 upstream at manifolds, 2 downstream at catalytic converters). Remove exhaust Y-pipe to manifold nuts on both banks working from hot side (center) to cold side (outer) pattern. Support Y-pipe and lower away from engine. Inspect manifold studs for damage.
   ⚠Exhaust studs are prone to breaking on EcoBoost engines. Use penetrating oil and work carefully. Have replacement studs available.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
6. 6

   Disconnect engine electrical and sensors
   Disconnect main engine wiring harness connector at firewall (large multi-pin connector). Disconnect PCM connectors if engine harness is being removed with engine. Disconnect throttle body connector, MAF sensor, intake air temperature sensor. Disconnect all ignition coil connectors (6 total). Disconnect camshaft position sensors, crankshaft position sensor, knock sensors, oil pressure sensor, coolant temperature sensors. Disconnect turbocharger wastegate actuator connectors. Release harness from all routing clips and position harness on top of engine.
7. 7

   Remove intake manifold and turbocharger components
   Remove throttle body bolts and separate throttle body. Disconnect PCV hose and brake booster vacuum line from intake manifold. Remove intake manifold bolts in reverse of tightening sequence (outside to inside pattern) and lift intake manifold from engine. Disconnect turbocharger oil feed lines at block (banjo bolts) and oil return tubes at turbo drain connections - oil will drain out, have pan ready. Disconnect wastegate vacuum lines and boost pressure control solenoid hoses.
   ℹ️Intake manifold gaskets are reusable if not damaged. Inspect carefully and replace if torn or compressed excessively.
   Torque spec

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

   Separate transmission from engine
   From underneath, install transmission jack or engine support bar to hold transmission weight. Remove starter motor wiring, then remove starter mounting bolts and starter. Disconnect transmission cooler lines at transmission and cap openings. Disconnect transmission wiring harness and shift linkage. Remove torque converter access cover. Mark torque converter to flexplate position, then remove torque converter to flexplate bolts by rotating crankshaft with breaker bar on front crank bolt. Remove all transmission to engine bellhousing bolts - there are multiple lengths, note positions. Carefully pull transmission straight back approximately 2 inches to clear dowel pins, then support transmission securely on jack.
   ⚠️Transmission must be adequately supported before removing final bellhousing bolts. Transmission falling can cause severe injury or death.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)

   Flywheel Bolts95 Nm (70 lb-ft)
9. 9

   Disconnect transfer case and driveline (4WD)
   Mark front and rear driveshaft positions at flanges for reinstallation. Remove front driveshaft bolts at transfer case and front differential, then remove driveshaft. Remove rear driveshaft bolts and remove rear driveshaft. Disconnect transfer case wiring connector and vent hose. Support transfer case on transmission jack if removing with transmission, or leave supported on transmission if engine-only removal.
10. 10

    Remove engine mounts and final connections
    Support engine securely with hoist. Attach lifting chains to factory lifting eyes on engine (located at front and rear of cylinder heads). Tension hoist slightly to take engine weight. Remove left and right engine mount to frame bracket bolts. Remove engine mount to block bolts on both sides. Check entire engine perimeter for any remaining electrical connectors, hoses, or brackets still attached - remove any found. Verify transmission is fully separated and supported.
    ⚠️Verify engine is balanced on hoist before removing mounts. Engine center of gravity is toward front due to turbochargers - adjust chain positions as needed.
    Torque spec

    Engine Mount-to-Block Bolts65 Nm (48 lb-ft)

    Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)
11. 11

    Extract engine from vehicle
    Slowly raise engine with hoist while watching clearances at firewall, frame rails, and radiator support. Tilt engine slightly nose-up (approximately 15 degrees) as it clears the engine bay to clear oil pan and accessories. Angle engine toward driver side slightly as you lift to clear AC lines and master cylinder. Continue raising until engine fully clears radiator support, then carefully pull forward and lower to engine stand height. Guide engine onto engine stand and secure with bolts through bellhousing pattern.
    ⚠EcoBoost engine is front-heavy with turbos and accessories. Move slowly and watch for contact with body, frame, or remaining components.
12. 12

    Install replacement or rebuilt engine
    Mount replacement engine on hoist using lifting eyes. Position engine above engine bay at same angle used for removal (nose-up, slightly toward driver side). Slowly lower engine into bay while guiding past radiator support, frame rails, and firewall. Watch turbocharger clearance at frame and steering components. Continue lowering until engine is at approximately correct height for transmission mating. Align engine with transmission bellhousing and move rearward to engage dowel pins - engine should slide easily onto pins, do not force.
    ⚠If engine does not easily align with transmission, raise slightly and reposition. Forcing engine can damage transmission input shaft or bellhousing dowels.
13. 13

    Install transmission and torque converter
    With engine and transmission aligned on dowel pins, install all transmission to engine bellhousing bolts hand-tight, then torque to specification in star pattern. Rotate crankshaft to align torque converter with flexplate bolt holes. Install torque converter bolts through access hole and torque to specification in star pattern - this may require rotating crankshaft multiple times to access all bolts. Install torque converter cover. Install starter motor and torque mounting bolts to specification. Connect starter wiring.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)

    Mounting Bolts55 Nm (40 lb-ft)
14. 14

    Install engine mounts
    Position engine at correct installed height using hoist. Install engine mount to block bolts on both sides and torque to specification. Install engine mount to frame bolts and torque to specification. Rock engine gently to verify mounts are properly seated and secure. Reduce tension on hoist but leave attached until final verification.
    Torque spec

    Engine Mount-to-Block Bolts65 Nm (48 lb-ft)

    Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)
15. 15

    Reconnect driveline, exhaust, and accessories
    Reconnect front and rear driveshafts at marked positions and torque bolts to specification. Connect transfer case wiring and vent hose. Position exhaust Y-pipe to manifolds using new gaskets. Apply anti-seize to manifold studs and install nuts hand-tight, then torque to specification working from hot to cold (center outward). Connect oxygen sensor connectors. Install alternator and torque mounting bolts to specification, connect electrical. Install AC compressor with new O-rings on lines if disconnected, torque mounting bolts to specification. Install power steering pump and torque mounting bolts to specification. Install serpentine belt.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Alternator Mounting Bolts50 Nm (37 lb-ft)

    AC Compressor Bolts25 Nm (18 lb-ft)

    Power Steering Pump Bolts25 Nm (18 lb-ft)

Reassembly

1. Reinstall intake manifold with new or inspected gaskets, torque bolts in sequence from center outward to gasket bolt specification.
2. Reconnect turbocharger oil feed lines with new crush washers and oil return tubes - ensure proper seating to prevent oil leaks.
3. Install throttle body with new gasket if needed. Reconnect all intake tubing, charge air cooler tubes, and PCV system.
4. Reconnect all engine electrical connectors in reverse of removal using labels. Verify each connection is fully seated and locked.
5. Reconnect fuel lines - listen for audible click indicating proper connection. Reconnect EVAP system lines.
6. Install radiator and fan assembly. Connect all coolant hoses ensuring clamps are positioned correctly. Reinstall charge air cooler tubes.
7. Reconnect transmission cooler lines and torque fittings to specification. Connect transmission wiring harness and shift linkage.
8. Install new engine oil filter. Install oil drain plug with new crush washer and torque to specification.
9. Reinstall battery, connect positive cable first, then negative cable. Install engine cover.
10. Fill engine with 6 quarts Motorcraft 5W-20 synthetic blend oil. Fill cooling system with 13 quarts Motorcraft Orange coolant - bleed air from system at bleeder screws.
11. Check and fill transmission fluid to proper level with engine running in Park - may require up to 11 quarts depending on how much was lost.
12. If AC system was opened, have system evacuated, leak tested, and recharged by certified technician.
13. Reinstall front skid plates, splash shields, headlights, grille, and hood at marked positions.

Verification

• With engine cold, verify all electrical connectors are fully seated. Check that no tools or hardware are left in engine bay.
• Check all fluid levels: engine oil (dipstick to FULL mark), coolant (reservoir to COLD FILL line), transmission (in Park, running, warm), power steering, brake fluid.
• Inspect underneath vehicle for any fluid leaks at oil pan, transmission, cooler lines, and power steering connections.
• Start engine and verify oil pressure builds immediately (gauge or warning light). Listen for unusual noises indicating problems.
• Allow engine to reach operating temperature while monitoring coolant level. Bleed cooling system again if necessary after initial warm-up.
• Check for coolant, oil, fuel, and exhaust leaks while engine is running. Pay special attention to turbo oil feed/return connections.
• Verify all warning lights extinguish after startup. Check for stored diagnostic trouble codes with scan tool.
• Test drive vehicle at varying speeds. Verify smooth acceleration, boost operation (manifold pressure should build under load), and transmission shifting.
• After test drive, recheck all fluid levels and inspect for leaks. Retorque exhaust manifold nuts after first heat cycle if accessible.
• Monitor oil consumption and coolant level over first 100 miles. Some minor seepage at new gaskets may occur initially but should stop.

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