This procedure replaces the ignition coils on a 2011-2014 Ford F-150 3.5L EcoBoost engine. Note: This engine uses coil-on-plug ignition with no traditional spark plug wires.

Warnings

Tools required

Parts

• Ignition coils (set of 6) × 6 — Motorcraft DG-511 or equivalent
• Spark plugs × 6 — Motorcraft SP-534 (iridium, pre-gapped)

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery cable and wait 2 minutes for capacitors to discharge
3. Remove engine cover by pulling upward on cover to release clips

Procedure

1. 1

   Access ignition coils
   With the engine cover removed, locate all six ignition coils on top of the valve covers (three per bank). Note the coil positions for proper reassembly if using the original coils.
2. 2

   Disconnect ignition coil electrical connectors
   Press the locking tab on each coil connector and pull straight up to disconnect. Work from passenger side (Bank 1) first, then driver side (Bank 2). Mark or photograph connector positions if needed.
3. 3

   Remove ignition coil mounting bolts
   Using an 8mm socket with extension, remove the single bolt securing each ignition coil. Store bolts in order by cylinder position. Note that coils may be tight due to heat cycling and may require gentle twisting while pulling upward.
   Torque spec

   Ignition Coil Bolt12 Nm (9 lb-ft)
4. 4

   Remove ignition coils
   Grasp each coil firmly and pull straight upward with a twisting motion to break the seal. Inspect the coil boot for cracks, tears, or carbon tracking. If boot is damaged, replacement is required.
5. 5

   Clean spark plug wells
   Use compressed air or a vacuum to remove any debris, dirt, or oil from each spark plug well. Ensure no foreign material can fall into the cylinder when spark plugs are removed. If oil is present in the wells, inspect valve cover gaskets for leaks.
   ⚠Any debris left in the cylinder can cause serious engine damage. Clean thoroughly before removing spark plugs.
6. 6

   Remove spark plugs
   Using a spark plug socket with extension, carefully remove each spark plug. Turn counterclockwise and maintain straight alignment to avoid cross-threading. Inspect old plugs for wear patterns, oil fouling, or abnormal electrode wear which may indicate engine problems.
7. 7

   Prepare new spark plugs
   Verify spark plug gap is set to 0.035 inches (0.9mm) using a gap tool. Apply a small amount of anti-seize compound to the threads only, avoiding the electrode end. Do not over-apply as excess can contaminate the combustion chamber.
   ⚠Never apply anti-seize to the electrode end or allow it to drip into the cylinder. Keep threads lightly coated only.
8. 8

   Install new spark plugs
   Thread each spark plug by hand to ensure proper alignment and prevent cross-threading. Once hand-tight, use the torque wrench and spark plug socket to tighten to specification. Work in a crisscross pattern between banks if possible to maintain even torque.
   Torque spec

   Spark Plug23 Nm (17 lb-ft)
9. 9

   Prepare ignition coils for installation
   If reusing original coils, inspect boots carefully for damage. Apply a thin layer of dielectric grease inside each coil boot to prevent moisture intrusion and ensure good connection. If installing new coils, verify they match the original part specifications.
10. 10

    Install ignition coils
    Align each ignition coil over its corresponding spark plug and press down firmly until the coil seats fully. The boot should make complete contact with the spark plug terminal. Install the mounting bolt for each coil and torque to specification using an 8mm socket.
    Torque spec

    Ignition Coil Bolt12 Nm (9 lb-ft)
11. 11

    Reconnect electrical connectors
    Push each electrical connector onto its corresponding ignition coil until you hear or feel a positive click. Gently tug on each connector to verify it is locked in place. Ensure wiring is routed properly and not pinched or stretched.
12. 12

    Reinstall engine cover and reconnect battery
    Align the engine cover clips with their mounting points on the engine and press down firmly until all clips engage. Reconnect the negative battery cable. The PCM will need to relearn idle and fuel trims during initial startup.

Reassembly

1. Ensure all ignition coil connectors are fully seated and locked
2. Verify engine cover is properly secured to all mounting clips
3. Double-check that no tools or parts are left in the engine compartment

Verification

• Start the engine and listen for smooth idle with no misfires or rough running
• Check for diagnostic trouble codes using an OBD-II scanner; clear any codes set during battery disconnect
• Allow engine to reach operating temperature and verify smooth operation under light acceleration
• Inspect for any spark arcing or abnormal noises from the ignition system during idle in darkness if possible

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