This procedure covers the replacement of a single ignition coil on a 2011-2014 Ford F-150 with the 3.5L EcoBoost V6 engine, including removal of the engine cover and disconnect of the electrical connector.

Warnings

Tools required

Parts

• Ignition coil × 1 — Motorcraft DG-511 or equivalent

Preparation

1. Ensure engine is cool to the touch
2. Open hood and secure with prop rod
3. Identify which cylinder requires coil replacement (cylinders numbered 1-3 passenger side front to rear, 4-6 driver side front to rear)
4. Gather all tools and new ignition coil

Procedure

1. 1

   Remove engine cover
   Locate and remove the plastic engine cover by removing the screws or lifting the cover upward if it uses grommet-style fasteners. The 3.5L EcoBoost typically has a cover secured with screws at the front. Set the cover aside in a clean area.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
2. 2

   Disconnect ignition coil electrical connector
   Locate the electrical connector on top of the ignition coil for the affected cylinder. Press the release tab on the connector and pull straight up to disconnect. Do not pull on the wiring harness itself.
   ℹ️The connector may be stiff if this is the first time it has been removed; wiggle gently while pulling if needed
3. 3

   Remove ignition coil mounting bolt
   Using a 7mm socket with a short extension, remove the single bolt securing the ignition coil to the valve cover. The bolt is located at the top of the coil. Keep the bolt in a safe place for reinstallation.
   Torque spec

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

   Extract ignition coil from cylinder head
   Grasp the ignition coil body firmly and pull straight upward with a twisting motion to break the seal with the spark plug boot. The coil should slide out of the valve cover opening. If resistance is felt, continue twisting gently while pulling - do not force it.
   ⚠If the boot separates from the coil and remains on the spark plug, use needle-nose pliers to carefully remove it from the spark plug well
5. 5

   Inspect spark plug well and spark plug
   Using a flashlight, inspect the spark plug well for any oil, debris, or moisture. If oil is present, the valve cover gasket may be leaking and should be addressed. Visually inspect the visible portion of the spark plug for damage or excessive wear. If replacing the spark plug, remove it using a spark plug socket.
   ℹ️Oil in the spark plug well can cause misfires and should be cleaned out with compressed air and shop towels before installing the new coil
   Torque spec

   Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
6. 6

   Prepare new ignition coil
   Remove the new ignition coil from its packaging. Inspect the coil boot for any damage. Apply a thin coating of dielectric grease to the inside of the spark plug boot to ensure a good seal and ease future removal.
   ℹ️Dielectric grease is recommended but not required; it helps prevent moisture intrusion and boot sticking
7. 7

   Install new ignition coil
   Align the new ignition coil with the spark plug well and carefully insert it straight down. Push firmly until the coil boot is fully seated on the spark plug and the mounting hole aligns with the valve cover threaded hole. You should feel the boot click onto the spark plug terminal.
   ⚠Ensure the coil is fully seated before installing the bolt to prevent damage to the spark plug or coil boot
8. 8

   Install and torque ignition coil bolt
   Insert the ignition coil mounting bolt and hand-tighten it. Using a torque wrench with a 7mm socket, torque the bolt to the specified value. Do not over-tighten as this can crack the coil housing.
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
9. 9

   Reconnect electrical connector
   Push the electrical connector onto the top of the ignition coil until you hear and feel it click into place. Gently tug on the connector to verify it is fully seated and locked.
   ℹ️Ensure the connector is fully engaged; a partially connected coil will cause a misfire code
10. 10

    Reinstall engine cover
    Position the engine cover back onto the engine, aligning any grommets or screw holes. If equipped with screws, torque them to the specified value. If using grommet fasteners, press down firmly until all grommets are fully seated.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)

Reassembly

1. Double-check that the electrical connector is fully engaged and locked
2. Verify the engine cover is properly secured and all fasteners are tight
3. Ensure no tools or parts are left in the engine compartment

Verification

• Start the engine and listen for smooth idle with no misfires
• Check for any diagnostic trouble codes using an OBD-II scanner - there should be no active misfire codes
• Allow the engine to idle for 2-3 minutes and verify the check engine light does not illuminate
• Test drive the vehicle to confirm normal acceleration and no hesitation under load
• Recheck after 50-100 miles of driving to ensure no codes have returned

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