Complete replacement of the long block assembly on a 2011-2014 Ford F-150 3.5L EcoBoost engine, including removal of all external components, transmission separation, engine extraction, and installation of new long block with reassembly of all systems.

Warnings

Tools required

Parts

• Long block assembly (remanufactured or new) × 1 — Use OEM specification for 3.5L EcoBoost
• Exhaust manifold gaskets × 2 — Use OEM specification
• Turbocharger mounting gaskets × 2 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Valve cover gaskets with spark plug tube seals × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil filter × 1 — Motorcraft FL-910S or equivalent
• Oil drain plug crush washer × 1 — Use OEM specification
• Thermostat housing gasket/O-ring × 1 — Use OEM specification
• Water pump gasket/O-ring × 1 — Use OEM specification
• Engine coolant × 13 — Motorcraft Orange Coolant
• Spark plugs × 6 — Motorcraft SP-520 or equivalent
• Engine oil × 6 — Motorcraft 5W-20 Synthetic Blend
• Transmission fluid × 2 — Motorcraft MERCON LV
• Anti-seize compound × 1 — Nickel-based high temperature

Fluids

• Motorcraft 5W-20 Synthetic Blend — 6 qt
• Motorcraft Orange Coolant — 13 qt
• Motorcraft MERCON LV ATF — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Disconnect negative battery cable, then positive battery cable. Remove battery and battery tray for access.
3. Raise front of vehicle and secure on jack stands rated for vehicle weight. Remove front skid plate if equipped.
4. Drain engine coolant completely from radiator and engine block drain plugs into appropriate container.
5. Drain engine oil completely and remove oil filter.
6. Remove engine cover and air intake system including both air filter housings and intake tubes to turbochargers.
7. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls, then crank for 5 seconds.
8. Have AC system professionally evacuated and refrigerant recovered by certified technician.
9. Mark and photograph all vacuum lines, electrical connectors, coolant hoses, and fuel lines for reinstallation reference.
10. Place transmission jack or engine support fixture under transmission to support weight when engine is removed.
11. Attach engine hoist to factory lift points on engine using appropriate lifting brackets or chains. Take up slack but do not lift yet.

Procedure

1. 1

   Remove front accessories and cooling system components
   Remove radiator hoses (upper and lower), heater hoses, and coolant reservoir. Disconnect transmission cooler lines from radiator. Remove radiator support brackets and lift radiator and cooling fan assembly out of vehicle. Remove AC condenser mounting bolts and carefully position condenser aside without disconnecting lines (if not already disconnected). Remove serpentine belt by rotating tensioner clockwise. Remove alternator, power steering pump (position aside with lines attached), and AC compressor (position aside with lines attached unless already evacuated and disconnected).
2. 2

   Disconnect fuel system and engine wiring
   Disconnect fuel supply and return lines at engine using appropriate disconnect tools. Cap open lines to prevent contamination. Disconnect main engine wiring harness connectors at bulkhead (typically 2-3 large multi-pin connectors on passenger side firewall). Disconnect throttle body electrical connector, mass airflow sensors, oxygen sensors (all 4), turbocharger wastegate actuators, turbo speed sensors, knock sensors, camshaft position sensors, crankshaft position sensor, oil pressure sender, and coolant temperature sensors. Label each connector location.
3. 3

   Remove turbocharger and exhaust system connections
   Remove heat shields from both turbochargers. Disconnect intercooler charge air tubes from both turbochargers to intercooler (4 connections total). Remove oil feed lines to both turbochargers from top of engine. From underneath vehicle, disconnect exhaust downpipes from both turbocharger outlets (4 bolts or studs per side). Remove oil return lines from bottom of turbochargers. The turbochargers can remain attached to exhaust manifolds during engine removal.
4. 4

   Remove intake manifold and valve covers
   Disconnect all vacuum lines from intake manifold including brake booster, PCV system, and purge valve. Remove throttle body and any remaining sensors or actuators. Remove intake manifold bolts in reverse of tightening sequence and lift intake manifold off engine. Remove ignition coils (6 total) and set aside. Disconnect PCV hoses from valve covers. Remove valve cover bolts in reverse sequence and carefully remove both valve covers. Inspect valve cover gaskets and spark plug tube seals for condition.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Cover Bolts19 Nm (14 lb-ft)
5. 5

   Separate transmission from engine
   From underneath vehicle, remove transmission-to-engine bolts (typically 6-8 bolts). Mark flexplate-to-torque converter position with paint marker. Remove torque converter-to-flexplate bolts (4 bolts) by rotating crankshaft to access each bolt through starter opening. Ensure transmission is properly supported on transmission jack or support fixture. Carefully separate transmission from engine by pulling transmission straight back approximately 2 inches to clear dowel pins and torque converter. Slowly lower transmission support to angle transmission away from engine compartment.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
6. 6

   Disconnect final engine connections and mounts
   Remove starter motor (2-3 bolts). Disconnect remaining ground straps from engine to chassis (typically 2-3 locations). Remove engine mount through-bolts on both left and right motor mounts. Remove rear engine support bracket or transmission mount bracket if it interferes with engine removal. Verify all electrical connectors, hoses, lines, and cables are disconnected from engine.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
7. 7

   Extract engine from vehicle
   Double-check that all connections are disconnected and transmission is properly supported. Slowly raise engine hoist while guiding engine upward and forward out of engine compartment. The engine will need to tilt and angle during removal - have an assistant guide from below. Watch carefully for any remaining connections that may snag. Once engine is clear of vehicle, lower onto appropriate engine stand or work surface. Inspect engine bay for any remaining components, bolts, or tools before installing new long block.
8. 8

   Transfer components to new long block - external sensors and fittings
   Verify what components are included with new long block assembly. Typically, you will need to transfer: turbochargers with exhaust manifolds, oil cooler, water pump, thermostat housing, oil filter adapter, all sensors (oxygen sensors, knock sensors, cam/crank position sensors, temperature sensors, oil pressure sender), motor mounts, flexplate, front engine accessories (alternator, AC compressor, power steering pump), and all brackets. Clean all mounting surfaces thoroughly. Install rear main seal into new long block if not pre-installed. Install flexplate onto crankshaft using new bolts if required. Apply anti-seize to exhaust manifold studs.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
9. 9

   Transfer components to new long block - turbochargers and oil system
   Install new exhaust manifold gaskets and mount exhaust manifolds with turbochargers to cylinder heads. Apply anti-seize to nuts and tighten from center outward. Install turbocharger oil feed lines and oil return lines with new gaskets/O-rings. Install oil pan with new gasket using proper sealant if required. Install oil pump pickup tube. Install front timing cover with new gasket. Install water pump with new gasket/O-ring. Install crankshaft pulley and harmonic balancer. Install valve covers with new gaskets, ensuring spark plug tube seals are properly seated.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)

   Oil Pan Bolts12 Nm (9 lb-ft)

   Cover Bolts19 Nm (14 lb-ft)
10. 10

    Install new long block into vehicle
    Attach engine hoist to new long block at factory lift points. Carefully raise and position engine into engine compartment, reversing removal procedure. Angle engine as needed to clear firewall, frame rails, and AC lines. Align engine with transmission bellhousing while lowering into position. Guide engine onto motor mount brackets. Install motor mount through-bolts hand-tight initially. Connect starter motor and ground straps.
    Torque spec

    Mounting Bolts55 Nm (40 lb-ft)
11. 11

    Mate engine to transmission
    Ensure torque converter is fully seated in transmission (should be recessed approximately 1/2 inch from bellhousing face). Align transmission with engine, ensuring dowel pins engage properly. Carefully slide transmission forward until bellhousing contacts engine block completely - do not use bolts to draw transmission to engine. Install transmission-to-engine bolts and tighten to specification. Rotate crankshaft to align flexplate with torque converter following marks made during disassembly. Install torque converter-to-flexplate bolts through starter opening and tighten in star pattern.
    Torque spec

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

    Flywheel Bolts95 Nm (70 lb-ft)
12. 12

    Install intake manifold and accessories
    Install new intake manifold gaskets. Position intake manifold onto engine and install bolts hand-tight. Tighten intake manifold bolts to specification in proper sequence (center to ends). Install throttle body with new gasket. Reconnect all vacuum lines, PCV hoses, and purge valve. Install alternator, power steering pump, and AC compressor to mounting brackets. Install serpentine belt following routing diagram on fan shroud or underhood label. Install ignition coils and torque to specification. Install new spark plugs with anti-seize on threads.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
13. 13

    Reconnect turbocharger system and exhaust
    From underneath vehicle, connect exhaust downpipes to turbocharger outlets using new gaskets. Tighten nuts/bolts evenly to prevent warping flanges. Install turbocharger heat shields. Connect all intercooler charge air tubes to turbochargers and intercooler (4 connections). Ensure all clamps are tight and properly positioned. Reconnect turbocharger wastegate actuators and speed sensors.
14. 14

    Reconnect cooling system and fuel system
    Install radiator and cooling fan assembly with new mounts if needed. Connect transmission cooler lines. Install AC condenser. Connect upper and lower radiator hoses, heater hoses, and coolant reservoir hose using new clamps. Install new thermostat with gasket/O-ring if not already installed. Connect fuel supply and return lines using new O-rings. Install new oil filter and tighten to specification. Install oil drain plug with new crush washer.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)
15. 15

    Reconnect all electrical connections and fill fluids
    Reconnect main engine wiring harness connectors at bulkhead. Reconnect all sensor connectors: throttle body, MAF sensors, oxygen sensors (4), turbo wastegate actuators, turbo speed sensors, knock sensors, cam/crank position sensors, oil pressure sender, coolant temperature sensors. Install battery tray and battery. Connect positive then negative battery cables. Fill engine with 6 quarts of Motorcraft 5W-20 synthetic blend oil. Fill cooling system with 13 quarts of Motorcraft Orange coolant (50/50 premix). Bleed cooling system by running engine with heater on high, adding coolant as level drops, until thermostat opens and no air bubbles appear. Check transmission fluid level and add approximately 2 quarts of MERCON LV to replace spillage (full refill not required unless transmission was drained).

Reassembly

1. Torque all fasteners to specification using torque wrench - do not rely on feel, especially for critical TTY bolts
2. Verify serpentine belt is properly routed and tensioner operates smoothly through full range
3. Double-check that all electrical connectors are fully seated with locking tabs engaged
4. Verify all coolant hoses are secured with proper clamps and no leaks are present
5. Ensure turbocharger oil feed and return lines are properly routed without kinks or sharp bends
6. Install front skid plate if equipped
7. Have AC system recharged by certified technician to proper refrigerant capacity

Verification

• Before first start: Verify engine oil level is correct on dipstick, coolant level is full, and no tools or rags are left in engine compartment
• Perform initial start: Turn key to ON position (do not start) and listen for fuel pump priming (2-3 seconds). Check for fuel leaks. Crank engine and allow to start. Engine may take longer than normal to start on first attempt due to fuel system priming.
• Monitor oil pressure immediately after start - pressure should rise to normal range (20+ PSI) within 5-10 seconds. If no pressure develops, shut down immediately and investigate.
• Allow engine to idle and warm up to operating temperature while monitoring for leaks - inspect oil pan, valve covers, timing cover, coolant hoses, turbocharger oil lines, and exhaust connections
• Check for abnormal noises including knocking, ticking, or rattling that could indicate assembly issues
• Verify both turbochargers are functioning by monitoring boost pressure with scan tool (should show positive pressure under acceleration)
• Monitor coolant temperature to ensure thermostat opens properly and temperature stabilizes at normal range (190-210°F)
• After engine reaches operating temperature, shut off and recheck all fluid levels when cool. Top off as needed.
• Perform test drive under various loads - light acceleration, moderate acceleration, and highway speeds. Monitor engine temperature, oil pressure, and listen for abnormal sounds.
• Check for diagnostic trouble codes with OBD-II scan tool. Address any codes related to sensors that may not have been reconnected properly.
• After test drive, recheck all fluid levels and inspect for leaks with vehicle on lift. Look for oil leaks, coolant leaks, exhaust leaks, and turbocharger oil leaks.
• Retorque cylinder head bolts after initial heat cycle if required by long block manufacturer (some assemblies are pre-torqued and seated)
• Change engine oil and filter after first 500 miles of operation to remove any assembly residue or break-in contaminants

More procedures for this vehicle