Complete major tune-up service including spark plugs, ignition coils, air filter, cabin filter, oil change, and throttle body cleaning for the 3.5L EcoBoost V6 engine.

Warnings

Tools required

Parts

• Spark plugs (6) × 6 — Motorcraft SP-546 or equivalent iridium
• Ignition coils (6) × 6 — Motorcraft DG-511
• Engine air filter × 1 — Motorcraft FA-1927
• Cabin air filter × 1 — Motorcraft FP-67
• Engine oil filter × 1 — Motorcraft FL-910-S
• Oil drain plug crush washer × 1 — Use OEM specification
• PCV valve × 1 — Motorcraft EV-239

Fluids

• Motorcraft 5W-20 Synthetic Blend — 6 qt

Preparation

1. Ensure engine is completely cold (minimum 2 hours after running)
2. Park vehicle on level surface and engage parking brake
3. Place wheel chocks behind rear wheels
4. Open hood and ensure adequate lighting of engine bay
5. Disconnect negative battery terminal and wait 5 minutes
6. Raise front of vehicle with jack and secure on jack stands
7. Remove engine cover by pulling upward on cover (press-fit clips)

Procedure

1. 1

   Remove engine air intake system
   Release the air box clips and disconnect the mass airflow sensor electrical connector. Loosen the intake tube clamp at the throttle body. Remove the entire air box assembly by lifting upward and out of the engine bay. Inspect the intake tube for oil residue which may indicate turbo seal issues.
   Torque spec

   Air Box Clips5 Nm (4 lb-ft)
2. 2

   Replace engine air filter and clean throttle body
   Remove old air filter from air box housing. Install new engine air filter ensuring proper seating. With intake removed, spray throttle body cleaner onto a cloth and wipe the throttle plate and bore clean. Do not spray directly into throttle body. Allow to dry before reassembly.
3. 3

   Remove ignition coils
   Disconnect all six ignition coil electrical connectors by pressing the release tab and pulling straight up. Remove the single bolt securing each coil-on-plug assembly. Carefully twist and pull each coil straight out of the spark plug well. Inspect coil boots for damage or carbon tracking.
   ⚠Do not pull on coil wires. Grasp the coil body firmly and twist gently while pulling to break the seal.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Remove old spark plugs
   Use compressed air or a clean cloth to remove any debris from around each spark plug well to prevent contamination. Using a 16mm spark plug socket, carefully unthread each spark plug. Check each plug condition and gap to assess engine health. EcoBoost plugs should have light tan deposits; black or wet plugs indicate problems.
   ⚠If a plug is difficult to turn, apply penetrating oil and wait 15 minutes. Forcing a seized plug can strip threads.
5. 5

   Install new spark plugs
   Verify new spark plugs are pre-gapped to 0.035 inches (0.9mm) for EcoBoost application. Apply a small amount of anti-seize to the threads (avoiding the electrode end). Thread each plug by hand first to ensure proper engagement. Torque spark plugs to 15 Nm (11 lb-ft) using a torque wrench. Do not over-torque.
   ⚠️Spark plug torque is critical on EcoBoost engines. Use 15 Nm (11 lb-ft) only. Over-torquing will strip aluminum threads.
6. 6

   Install new ignition coils
   Apply a thin coating of dielectric grease to the inside of each new coil boot. Insert each coil into the spark plug well, ensuring it seats fully onto the spark plug terminal. Install and torque the mounting bolt for each coil. Reconnect all six electrical connectors until they click.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
7. 7

   Replace PCV valve
   Locate the PCV valve on the driver side valve cover. Disconnect the vacuum hose from the PCV valve. Twist and pull the PCV valve from the grommet in the valve cover. Install new PCV valve by pressing firmly into the grommet until seated. Reconnect vacuum hose.
8. 8

   Replace cabin air filter
   Open glove box and remove contents. Press inward on both sides of glove box to release stops and lower fully. Remove cabin air filter access door. Slide out old cabin air filter noting airflow direction arrow. Install new filter with arrow pointing toward rear of vehicle. Reinstall access door and glove box.
9. 9

   Drain engine oil
   Position drain pan under oil drain plug on oil pan (accessible from underneath). Remove drain plug using appropriate socket and allow oil to drain completely (approximately 10 minutes). Inspect drain plug threads and sealing surface. Discard old crush washer.
   ⚠Engine oil may still be warm. Wear gloves to prevent skin contact.
10. 10

    Install drain plug and replace oil filter
    Install new crush washer on drain plug. Thread drain plug by hand, then torque to specification. Locate oil filter on driver side of engine (cartridge-style). Use oil filter wrench to remove old filter housing. Replace filter element and O-rings per filter kit instructions. Hand-tighten filter housing until snug, then add 1/4 turn.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)
11. 11

    Refill engine oil
    Lower vehicle from jack stands. Remove oil filler cap on driver side valve cover. Using funnel, add 5.5 quarts of Motorcraft 5W-20 synthetic blend oil. Replace filler cap. Wait 2 minutes, then check dipstick. Add remaining oil in small increments to reach full mark. Do not overfill.
12. 12

    Reinstall air intake system
    Position air box assembly back into engine bay. Connect intake tube to throttle body and tighten clamp securely. Reconnect mass airflow sensor electrical connector. Secure air box clips. Ensure all connections are tight and no hoses are kinked.
    Torque spec

    Air Box Clips5 Nm (4 lb-ft)
13. 13

    Reinstall engine cover and reconnect battery
    Align engine cover with mounting points and press down firmly until all clips engage. Reconnect negative battery terminal and tighten securely. Battery may need relearning procedure after reconnection.

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Confirm engine cover is properly secured at all mounting points
3. Double-check that no tools or rags were left in engine bay
4. Ensure air intake system is completely assembled with no loose connections

Verification

• Start engine and verify it idles smoothly without misfires or rough running
• Check for any oil leaks around drain plug and oil filter after 1 minute of running
• Verify check engine light does not illuminate after 30 seconds of running
• Allow engine to reach operating temperature and verify no oil leaks develop
• Check oil level on dipstick after engine reaches temperature and shut off for 5 minutes
• Road test vehicle and verify smooth acceleration with no hesitation or misfires
• Scan for diagnostic trouble codes using OBD-II scanner to confirm no issues
• Recheck oil level after road test and top off if necessary

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