This procedure covers removal and replacement of the engine oil cooler on the 3.5L EcoBoost V6 engine, including coolant and oil system service.

Warnings

Tools required

Parts

• Engine oil cooler assembly × 1 — Use OEM specification
• Oil cooler gasket/seal kit × 1 — Use OEM specification
• Engine oil filter × 1 — Motorcraft FL-500S or equivalent
• Coolant hose clamps (if damaged) × 2 — Use OEM specification

Fluids

• Motorcraft 0W-20 Full Synthetic Engine Oil — 6 qt
• Motorcraft Orange Coolant — 2 qt

Preparation

1. Ensure engine is completely cool to the touch
2. Raise and safely support vehicle on jack stands or lift
3. Remove engine splash shield and driver side wheelwell liner for improved access
4. Place large drain pan under engine oil pan and oil cooler area
5. Disconnect negative battery terminal

Procedure

1. 1

   Drain engine oil and coolant
   Remove the engine oil drain plug and allow oil to drain completely into drain pan. Remove the oil filter to allow additional drainage. Open the radiator drain plug or remove the lower radiator hose to drain coolant into a separate coolant drain pan. Remove the coolant drain plug if accessible.
   Torque spec

   Coolant Drain Plug15 Nm (11 lb-ft)
2. 2

   Disconnect coolant hoses from oil cooler
   Locate the oil cooler on the driver side of the engine block, below and forward of the turbocharger. Use hose clamp pliers to release the spring clamps or loosen screw-type clamps on the coolant inlet and outlet hoses connected to the oil cooler. Carefully twist and pull hoses off the oil cooler fittings. Expect residual coolant spillage.
   ⚠Mark hose positions or take photos before removal to ensure correct reconnection.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Remove oil filter adapter housing
   The oil cooler is integrated with or directly connected to the oil filter adapter housing. Remove the housing bolts using appropriate socket. There are typically 2-3 bolts securing the adapter housing to the engine block. Keep track of bolt locations as they may be different lengths.
   Torque spec

   Housing Bolts16 Nm (12 lb-ft)
4. 4

   Disconnect oil cooler mounting
   Locate and remove the oil cooler mounting bolts that secure the cooler assembly to the engine block. These are typically located on the lower portion of the cooler. Support the oil cooler while removing the final bolts to prevent it from dropping.
   ⚠Oil cooler assembly may still contain residual oil and coolant. Have shop towels ready.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
5. 5

   Remove oil cooler assembly
   Carefully maneuver the oil cooler assembly away from the engine block. The assembly may require rotation or angling to clear surrounding components such as the turbocharger oil feed lines and frame rails. Remove all old gaskets and O-rings from the engine block mating surfaces.
6. 6

   Clean mounting surfaces
   Thoroughly clean all mating surfaces on the engine block where the oil cooler mounts. Remove all traces of old gasket material, oil residue, and coolant deposits using a plastic scraper. Do not use metal scrapers that could damage sealing surfaces. Wipe clean with lint-free shop towels.
   ⚠Ensure no debris or gasket material falls into open oil or coolant passages. Cover openings with clean shop towels during cleaning.
7. 7

   Prepare new oil cooler
   Unpack the new oil cooler assembly and verify it matches the original unit. Install new O-rings and gaskets from the seal kit onto the new oil cooler. Lightly lubricate all seals with clean engine oil to aid installation and prevent damage during assembly.
8. 8

   Install oil cooler assembly
   Carefully position the new oil cooler assembly onto the engine block, ensuring all alignment pins or dowels are properly seated. Thread in the mounting bolts by hand first to ensure proper alignment and prevent cross-threading.
9. 9

   Torque oil cooler mounting bolts
   Tighten the oil cooler mounting bolts to specification using a torque wrench. Follow a crossing pattern if multiple bolts are present to ensure even pressure on the gasket and prevent leaks.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
10. 10

    Install oil filter adapter housing
    Position the oil filter adapter housing with new gasket onto the oil cooler and engine block. Install the housing bolts and tighten to specification in a crossing pattern.
    Torque spec

    Housing Bolts16 Nm (12 lb-ft)
11. 11

    Reconnect coolant hoses
    Reconnect the coolant inlet and outlet hoses to the oil cooler fittings. Ensure hoses are fully seated onto the fittings. Install new hose clamps if originals are damaged, or reposition original clamps and tighten to specification.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
12. 12

    Install new oil filter and close drain plug
    Install a new engine oil filter, lubricating the gasket with clean oil before installation. Hand-tighten plus 3/4 turn as per filter instructions. Reinstall the oil drain plug with new crush washer if applicable. Torque drain plug to manufacturer specification (not listed in provided torque specs - follow service manual).
13. 13

    Refill fluids
    Close the coolant drain plug if opened and torque to specification. Refill the cooling system with Motorcraft Orange Coolant to the appropriate level, accounting for approximately 2 quarts loss during oil cooler replacement. Refill engine with 6 quarts of Motorcraft 0W-20 Full Synthetic engine oil.
    Torque spec

    Coolant Drain Plug15 Nm (11 lb-ft)
14. 14

    Bleed cooling system
    Start the engine and allow it to reach operating temperature with the radiator cap loosened or coolant reservoir cap off (depending on bleeding point). Monitor coolant level and add as necessary as air purges from the system. Rev engine gently to 2000 RPM several times to help purge air. Once at operating temperature and thermostat opens, top off coolant and secure cap.
    ⚠Monitor engine temperature closely during bleeding process. If temperature rises abnormally, shut off engine immediately and allow to cool.

Reassembly

1. Reinstall driver side wheelwell liner and engine splash shield
2. Reconnect negative battery terminal
3. Lower vehicle from lift or jack stands
4. Check coolant level again after engine has cooled and top off if necessary

Verification

• Inspect oil cooler area, oil filter, and coolant hose connections for any signs of leaks while engine is running
• Allow engine to idle for 10 minutes and verify oil pressure is normal on instrument cluster
• Check engine oil level on dipstick after engine has been running and add if necessary
• Verify coolant level is correct in overflow reservoir when engine is cold
• Test drive vehicle and monitor temperature gauge to ensure proper cooling system operation
• Re-inspect all connections for leaks after test drive and first 100 miles of operation

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