Complete replacement of the short block assembly on a 2015-2020 Ford F-150 3.5L EcoBoost engine, including removal of cylinder heads, timing components, oil pan, and all internal rotating assembly components.

Warnings

Tools required

Parts

• Short block assembly (complete with pistons, rods, crankshaft) × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 1 — Use OEM specification
• Cylinder head gasket set × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Timing chain kit (chains, guides, tensioners) × 1 — Use OEM specification
• Oil pump × 1 — Use OEM specification
• Oil filter × 1 — Motorcraft FL-910S
• Oil drain plug crush washer × 1 — Use OEM specification
• Crankshaft pulley bolt (if TTY) × 1 — Use OEM specification
• Flywheel bolts (if TTY) × 1 — Use OEM specification
• RTV silicone sealant (Motorcraft TA-357) × 1 — TA-357

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt
• Motorcraft Orange Coolant — 13 qt
• Assembly lube — 0.5 qt

Preparation

1. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
2. Drain engine oil completely and remove oil filter
3. Drain cooling system at radiator petcock and block drains
4. Remove engine from vehicle following manufacturer procedure (disconnect all electrical connectors, fuel lines, coolant hoses, exhaust, transmission)
5. Mount engine securely on engine stand using transmission mounting holes
6. Clean external engine surfaces thoroughly before disassembly
7. Label and organize all removed components systematically to ensure correct reassembly
8. Prepare clean workspace with all gaskets, seals, and new short block assembly ready

Procedure

1. 1

   Remove valve covers and accessories
   Remove both valve covers, intake manifolds, fuel rails, ignition coils, and spark plugs. Remove turbocharger assemblies with coolant and oil lines. Cap all open turbo ports to prevent debris entry. Remove alternator, A/C compressor (leave hoses attached and secure aside), power steering pump if applicable, and all belt-driven accessories.
2. 2

   Remove timing cover and components
   Remove crankshaft pulley using impact wrench or holding tool. Remove timing cover bolts in reverse of tightening sequence. Carefully remove timing cover, noting any dowel pin locations. Remove primary and secondary timing chains, guides, and tensioners. Mark or photograph chain routing and cam phaser positions before removal.
   ⚠Timing chain components are under spring tension. Release tensioner pressure before removing chains.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

   Cover Bolts19 Nm (14 lb-ft)
3. 3

   Remove cylinder heads
   Remove cylinder head bolts in reverse of tightening sequence (consult service manual for sequence). Carefully lift cylinder heads off block using proper lifting points. Place heads on clean surface with combustion chambers facing up. Remove and discard old head gaskets. Clean all gasket surfaces on heads thoroughly.
   ⚠Cylinder heads are heavy (approximately 50 lbs each). Use proper lifting technique or assistance.
4. 4

   Remove oil pan and pickup tube
   Remove oil pan bolts in crisscross pattern. Carefully separate oil pan from block using gasket scraper if necessary, being careful not to damage sealing surfaces. Remove oil pickup tube and discard O-ring. Remove oil pan gasket and clean all RTV residue from block and pan surfaces using gasket scraper and brake cleaner.
5. 5

   Remove oil pump and front cover components
   Remove oil pump mounting bolts and withdraw pump from block. Inspect pump drive chain and sprockets for wear. Remove any remaining front cover components, balance shaft components, or chain guides still attached to block.
   Torque spec

   Oil Pump Bolts12 Nm (9 lb-ft)
6. 6

   Remove pistons and connecting rods
   Rotate crankshaft to access each connecting rod. Mark each rod and cap with cylinder number and orientation using permanent marker. Remove connecting rod bolts and caps. Push each piston/rod assembly up and out through top of cylinder bore. Keep rod caps with their respective rods. Inspect cylinder bores for scoring or damage.
   ℹ️Keep pistons, rods, and bearings organized by cylinder number if reusing any components for reference or inspection.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
7. 7

   Remove crankshaft and main bearing caps
   Mark main bearing caps with position and orientation if not already marked from factory. Remove main bearing cap bolts in sequence from outside to center. Carefully remove main bearing caps and set aside in order. Lift crankshaft out of block using proper lifting technique. Remove main bearing inserts from block and caps, noting orientation and position.
   ⚠Crankshaft weighs approximately 60 lbs. Use proper lifting technique and assistance.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
8. 8

   Clean and inspect old block
   Thoroughly clean all mating surfaces, bolt holes, and oil passages in old block. Inspect for cracks, damage, or root cause of failure. Document failure mode for reference. This inspection helps prevent repeat failures with new short block.
9. 9

   Prepare new short block assembly
   Unpack new short block and inspect for shipping damage. Verify all rotating assembly components are properly installed and torqued. Check that main bearing caps and connecting rod caps are properly marked. Verify oil galley plugs are installed. Clean any protective shipping oil from machined surfaces. Install oil pump with new bolts, torquing to specification.
   ℹ️New short block should come with crankshaft, pistons, rods, and bearings already assembled. Verify all clearances meet specification if assembly is required.
   Torque spec

   Oil Pump Bolts12 Nm (9 lb-ft)
10. 10

    Install timing components
    Install crankshaft timing sprocket and balance shaft components per factory procedure. Install new timing chains, guides, and tensioners following manufacturer timing marks and procedures. Verify all timing marks align correctly before proceeding. Apply assembly lube to chain contact points.
    ⚠️Incorrect timing chain installation will cause catastrophic engine damage. Triple-check all timing marks before proceeding.
11. 11

    Install timing cover
    Install new timing cover gasket or apply RTV sealant per manufacturer specification to timing cover mating surface. Carefully position timing cover over crankshaft nose, aligning all dowel pins. Install timing cover bolts hand-tight, then torque in proper sequence starting from center and working outward. Install crankshaft pulley, torquing bolt to specification. If TTY bolt, follow torque-plus-angle procedure.
    ⚠Apply small bead of RTV at cylinder head-to-block joints where timing cover seals. Timing cover must be installed within 15 minutes of RTV application.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
12. 12

    Install cylinder heads
    Position new cylinder head gaskets on block, ensuring all alignment dowels are properly seated and gaskets are oriented correctly (TOP or UP markings visible). Carefully lower cylinder heads onto block. Install new cylinder head bolts and torque in proper sequence using torque-plus-angle method per service manual specification. Do not reuse old head bolts.
    ⚠️Cylinder head bolts are torque-to-yield. Follow exact torque sequence and angle specifications from service manual. Improper torque will cause head gasket failure.
    Torque spec

    Gasket Bolts23 Nm (17 lb-ft)
13. 13

    Install oil pan and pickup
    Install new oil pickup tube with new O-ring, ensuring proper seating in block. Apply thin bead of RTV sealant to oil pan gasket contact surfaces per manufacturer specification. Position new oil pan gasket. Install oil pan and torque bolts in crisscross pattern from center outward to specification. Allow RTV to cure for specified time before adding oil.
    ℹ️Some applications require RTV in addition to gasket at specific locations. Consult service manual for exact RTV application points.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)
14. 14

    Install external components and accessories
    Reinstall all external sensors, oil filter adapter, dipstick tube, and engine covers. Install all accessories including alternator, A/C compressor, turbochargers with new gaskets and coolant/oil lines. Reinstall intake manifolds, fuel rails, ignition coils, and spark plugs. Torque all mounting bolts to specification. Install valve covers with new gaskets.
    ⚠Use new turbocharger oil feed and drain gaskets. Ensure oil feed lines are clean and unobstructed before installation.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)

    Cover Bolts19 Nm (14 lb-ft)

    Mounting Bolts31 Nm (23 lb-ft)
15. 15

    Install engine and reconnect systems
    Remove engine from stand and install in vehicle using engine hoist. Align engine mounts and torque mounting bolts to specification. Reconnect transmission, torquing bolts to specification in star pattern. Reconnect all electrical connectors, fuel lines, coolant hoses, exhaust system, and EVAP lines. Install new oil drain plug crush washer and install drain plug to specification.
    ⚠Verify all electrical connectors are fully seated and locked. A single missed connector can cause no-start or engine damage.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)

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

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Fill engine with 6 quarts of Motorcraft 0W-20 full synthetic oil and install new oil filter
2. Fill cooling system with 13 quarts of Motorcraft Orange Coolant and bleed air from system
3. Refill transmission with Motorcraft MERCON LV ATF if drained during removal (approximately 11 quarts total capacity)
4. Double-check all fasteners, hose connections, and electrical connectors before starting
5. Prime oil system by cranking engine with fuel pump fuse removed until oil pressure is observed
6. Reconnect battery and clear any diagnostic trouble codes

Verification

• Start engine and verify immediate oil pressure on gauge (should show pressure within 2-3 seconds)
• Listen for abnormal noises including knocking, ticking, or rattling that could indicate assembly issues
• Check for oil, coolant, or fuel leaks around all gaskets and connections while engine is running
• Allow engine to reach operating temperature and verify cooling fans cycle properly
• Check for coolant leaks at head gaskets and timing cover after reaching temperature
• Verify no check engine lights or fault codes related to engine mechanical operation
• Road test vehicle under light load initially, then gradually increase to full load operation
• Perform final inspection after 50-100 miles including oil level check and leak inspection
• Monitor oil consumption and engine performance over first 500 miles of operation
• Consider oil and filter change at 500 miles to remove any break-in debris

More procedures for this vehicle