This procedure covers the replacement of all six ignition coils on the 3.5L EcoBoost V6 engine, including removal of the engine cover and spark plug replacement.

Warnings

Tools required

Parts

• Ignition coil × 6 — Motorcraft DG-511 or equivalent
• Spark plug × 6 — Motorcraft SP-546 or equivalent

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow engine to cool completely (minimum 2 hours after running)
3. Disconnect negative battery terminal to prevent accidental starts
4. Have a clean workspace prepared for removed components to keep track of all six coils

Procedure

1. 1

   Remove engine cover
   Remove the plastic engine cover by pulling upward on the cover to disengage the grommets. The cover is held by multiple grommets and does not require tools for removal. Set aside in a clean area.
2. 2

   Locate and access all ignition coils
   Identify all six ignition coils on top of the engine. Three coils are on the driver side cylinder bank and three on the passenger side. Note that some components may need to be moved aside for better access, particularly the air intake duct on the passenger side.
3. 3

   Disconnect electrical connectors
   Press the locking tab on each ignition coil electrical connector and pull straight up to disconnect. Start with the driver side coils (cylinders 1, 2, 3) then move to passenger side (cylinders 4, 5, 6). Use a pick tool if connectors are tight.
4. 4

   Remove ignition coil mounting bolts
   Remove the single bolt securing each ignition coil using a socket wrench. Keep bolts organized by cylinder position. If bolts are difficult to access, use an extension and universal joint.
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
5. 5

   Extract ignition coils
   Grasp each ignition coil firmly and pull straight up with a twisting motion to break the seal. Work slowly to avoid breaking the coil boot. If a coil is stuck, gently twist back and forth while pulling upward. Remove all six coils and inspect boots for damage or oil contamination.
6. 6

   Clean spark plug wells
   Use compressed air or a vacuum to remove any debris from the spark plug wells before removing plugs. This prevents debris from falling into the cylinders. Inspect wells for oil or coolant contamination which would indicate a larger problem.
7. 7

   Remove spark plugs
   Using a 5/8 inch spark plug socket with extension, carefully remove all six spark plugs. Turn counterclockwise and remove slowly to prevent cross-threading. Keep plugs in order to inspect for unusual wear patterns that might indicate engine issues.
8. 8

   Prepare and gap new spark plugs
   Verify the gap on all new spark plugs using a gap gauge (should be 0.051-0.057 inches for this engine). Apply a thin coat of anti-seize compound to the spark plug threads, being careful not to get any on the electrodes or insulator.
9. 9

   Install new spark plugs
   Thread each spark plug by hand first to ensure proper seating and prevent cross-threading. Once hand-tight, use the torque wrench and spark plug socket to tighten to specification. Work in a pattern across the engine rather than one bank at a time.
   Torque spec

   Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
10. 10

    Prepare new ignition coils
    Apply a thin layer of dielectric grease to the inside of each new ignition coil boot where it contacts the spark plug. This prevents moisture intrusion and makes future removal easier. Inspect each coil for shipping damage before installation.
11. 11

    Install new ignition coils
    Push each ignition coil straight down into the spark plug well until it fully seats on the spark plug. Apply firm downward pressure while twisting slightly to ensure proper connection. The coil should sit flush with the valve cover surface.
12. 12

    Secure ignition coils and reconnect electrical
    Install and torque the mounting bolt on each ignition coil to specification. Reconnect each electrical connector, ensuring the locking tab clicks into place. Verify each connection is secure by gently pulling on the connector.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)
13. 13

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

Reassembly

1. Reconnect the negative battery terminal
2. Ensure all tools and parts packaging are removed from the engine bay
3. Double-check that all electrical connectors are properly seated and locked

Verification

• Start the engine and listen for smooth idle with no misfires or rough running
• Allow engine to reach operating temperature and verify no check engine light appears
• Perform a test drive and confirm normal acceleration and power delivery
• Use a scan tool to verify no misfire codes are present in the ECM (P0300-P0306)
• Visually inspect engine bay for any disconnected connectors or loose components

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