Complete replacement of the long block assembly on a 2015-2020 Ford F-150 with 3.5L EcoBoost V6 engine, including removal of all external components and installation of new short block or complete long block assembly.

Warnings

Tools required

Parts

• Long block assembly (3.5L EcoBoost) × 1 — Use OEM specification
• Engine coolant × 1 — Motorcraft Orange Coolant
• Engine oil and filter × 1 — Motorcraft 0W-20
• Valve cover gaskets × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Turbocharger gaskets and seals × 2 — Use OEM specification
• Water pump gasket/O-rings × 1 — Use OEM specification
• Engine mount hardware × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Anti-seize compound × 1 — Use copper-based anti-seize
• RTV silicone sealant × 1 — Motorcraft TA-357 or equivalent

Fluids

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

Preparation

1. Park vehicle on level ground with wheels chocked. Engage parking brake.
2. Disconnect negative battery cable, then positive cable. Remove battery from vehicle.
3. Remove engine cover and plastic intake snorkel assembly.
4. Relieve fuel system pressure: Remove fuel pump fuse, start engine and let it stall, crank 3-5 seconds to ensure depressurization.
5. Drain engine coolant completely from radiator petcock and engine block drains into appropriate container.
6. Drain engine oil and remove oil filter.
7. Recover A/C refrigerant using certified recovery equipment.
8. Raise vehicle on lift or support securely on jack stands at manufacturer lift points.
9. Remove front skid plate if equipped.
10. Clear workspace around vehicle for engine hoist operation and have all tools readily accessible.

Procedure

1. 1

   Remove intake and charge air cooling system
   Disconnect intake air temperature sensor and mass airflow sensor. Remove complete air filter housing and intake tube. Disconnect charge air cooler inlet and outlet tubes from turbochargers and throttle body. Remove charge air cooler radiator assembly from front of vehicle. Disconnect all vacuum lines from intake manifold, labeling each connection.
2. 2

   Disconnect fuel system and injector harnesses
   Using proper line disconnect tool, separate fuel supply line at fuel rail. Cap open fuel line to prevent contamination. Disconnect fuel injector electrical harness (both banks). Disconnect fuel pressure sensor. Remove fuel rail mounting bolts and carefully remove fuel rails with injectors attached. Store safely away from work area.
   ⚠Even after depressurization, residual fuel pressure may remain. Have shop towels ready to catch fuel spillage.
3. 3

   Remove turbocharger and exhaust components
   From underneath vehicle, disconnect downstream oxygen sensors. Remove exhaust Y-pipe from catalytic converters. Disconnect oil supply and return lines from both turbochargers (capture residual oil). Disconnect wastegate actuator vacuum lines. Remove turbocharger heat shields. Remove turbocharger-to-exhaust manifold nuts and carefully remove both turbochargers as assemblies. Remove exhaust manifolds from cylinder heads.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
4. 4

   Disconnect cooling system and A/C components
   Disconnect upper and lower radiator hoses at engine. Disconnect heater hoses at bulkhead connections. Disconnect A/C compressor electrical connector. Remove A/C compressor mounting bolts and secure compressor to frame without disconnecting lines (if lines were already disconnected during recovery, cap immediately). Disconnect coolant temperature sensors and thermostat housing connections. Remove coolant crossover tube if equipped.
5. 5

   Remove accessory drive system
   Using breaker bar on tensioner, release serpentine belt tension and remove belt. Remove power steering pump mounting bolts and secure pump to frame without disconnecting lines (electric assist system has no fluid lines). Remove alternator electrical connections and mounting bolts, remove alternator. Disconnect crankshaft position sensor at front timing cover.
6. 6

   Disconnect all engine electrical connections
   Disconnect main engine harness connector(s) at firewall. Disconnect both ignition coil harness connectors. Disconnect camshaft position sensors (both banks). Disconnect knock sensors. Disconnect oil pressure sensor. Disconnect variable valve timing solenoids. Disconnect throttle body electrical connector. Verify all electrical connections are free from engine and route harnesses away from removal path.
7. 7

   Separate transmission from engine
   Support transmission securely with transmission jack. Remove transmission bellhousing inspection cover. Mark flywheel-to-torque converter relationship. Remove torque converter-to-flywheel bolts through access opening while rotating crankshaft. Remove all transmission-to-engine mounting bolts. Carefully slide transmission rearward approximately 2 inches to disengage from engine, ensuring torque converter remains with transmission. Lower transmission slightly and secure on transmission jack.
   ⚠Ensure torque converter is fully seated in transmission pump before separating. Mark converter position to prevent dropping during separation.
   Torque spec

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

   Flywheel Bolts95 Nm (70 lb-ft)
8. 8

   Remove engine mounts and attach lifting equipment
   Attach engine hoist lifting chains to factory lifting eyes on engine (both front and rear). Adjust leveling to balance engine weight. Take up slight tension on hoist to support engine weight. Remove driver side engine mount-to-frame bolts. Remove passenger side engine mount-to-frame bolts. Remove any remaining mount-to-engine bracket bolts. Verify all connections, hoses, lines, and wiring are disconnected from engine.
   ⚠️Double-check that all connections are free. An attached component can cause equipment failure or vehicle damage during lift.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
9. 9

   Remove engine from vehicle
   Slowly raise engine with hoist while guiding clear of transmission input shaft and engine bay. Adjust leveling as needed to clear radiator support and firewall. Tilt engine slightly nose-up to clear frame rails. Once clear of vehicle, carefully lower onto engine stand or sturdy work surface. Verify engine is securely supported before releasing hoist tension.
10. 10

    Transfer external components to new long block
    If new long block is bare, transfer the following components from old engine: valve covers (with new gaskets), intake manifold (with new gaskets), oil pan (with new gasket), timing cover (with new gasket), water pump, oil filter adapter, all sensors (coolant temp, oil pressure, cam position, crank position, knock sensors), VVT solenoids, ignition coils, motor mounts, flywheel (if automatic) or clutch assembly (if manual), exhaust manifolds with new gaskets. Clean all mating surfaces thoroughly with proper gasket remover and surface prep.
    ⚠Apply anti-seize to exhaust manifold studs before installing nuts. Work from hottest point (center) toward cooler ends to prevent warping.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Sensor Bolts12 Nm (9 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)
11. 11

    Install prepared long block into vehicle
    Attach hoist to new/rebuilt long block at factory lift points. Verify all transferred components are secure and properly torqued. Raise engine and carefully guide into engine bay, reversing removal path. Tilt as necessary to clear radiator support and frame. Align engine with transmission bellhousing and motor mount locations. Slowly lower while aligning transmission input shaft with pilot bearing/clutch disc or torque converter. Guide engine onto motor mounts.
    ⚠Do not force engine into position. Misalignment can damage transmission input shaft, crankshaft, or clutch components.
12. 12

    Install engine mounts and reconnect transmission
    Install engine mount-to-frame bolts on both sides and torque to specification. Raise transmission on jack and align with engine bellhousing. Verify torque converter is properly seated and aligned with flywheel marks. Install all transmission-to-engine bolts and torque in sequence. Install torque converter-to-flywheel bolts and torque in star pattern. Install bellhousing inspection cover.
    Torque spec

    Mounting Bolts55 Nm (40 lb-ft)

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

    Flywheel Bolts95 Nm (70 lb-ft)
13. 13

    Reconnect all engine systems and accessories
    Install A/C compressor to mounting bracket and torque bolts. Install alternator and connect electrical. Install power steering pump if removed. Install serpentine belt over all pulleys and tensioner. Reconnect all coolant hoses (upper radiator, lower radiator, heater hoses, crossover). Install both turbochargers with new gaskets and torque nuts in hot-to-cold sequence. Connect turbo oil feed and return lines. Connect wastegate actuators. Install turbo heat shields.
    ℹ️Verify turbocharger oil feed lines are clean and free of debris. Contamination can destroy new turbochargers immediately on startup.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
14. 14

    Complete electrical and fuel system connections
    Reconnect all engine harness connectors: main harness at firewall, ignition coil connectors, cam/crank position sensors, knock sensors, oil pressure sensor, coolant temp sensors, VVT solenoids, throttle body, and MAF/IAT sensors. Install fuel rails with injectors using new O-rings if needed. Connect fuel injector harnesses. Connect fuel supply line to fuel rail. Reconnect charge air cooler system and intake air path. Install air filter housing and intake snorkel.
15. 15

    Fill fluids and perform initial startup procedure
    Install new oil drain plug crush washer and torque drain plug. Fill engine with 6 quarts Motorcraft 0W-20 synthetic oil. Install new oil filter. Fill cooling system with 13 quarts Motorcraft Orange coolant (may require bleeding). Reconnect battery (positive first, then negative). Turn ignition to ON position (do not start) and listen for fuel pump priming. Check for fuel leaks at connections. Cycle ignition 3-4 times to build fuel pressure. Perform initial start: engine should start within 5 seconds. Monitor oil pressure gauge immediately (should register within 2-3 seconds). Allow engine to idle and check for leaks (coolant, oil, fuel). Monitor temperature gauge for proper thermostat operation. Check for abnormal noises or vibrations.
    ⚠️If oil pressure does not register within 5 seconds of startup, shut down immediately. Lack of oil pressure will destroy the new engine.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. After successful startup and initial warm-up, shut down engine and recheck all fluid levels when cold.
2. Inspect all connection points for leaks (coolant, oil, fuel, exhaust).
3. Reinstall engine cover and any remaining trim pieces.
4. Lower vehicle and torque wheel lug nuts to specification.
5. Recharge A/C system to proper specification using certified equipment.
6. Clear any diagnostic trouble codes that may have set during the procedure.
7. Verify all warning lights function properly and extinguish after startup.
8. Test drive vehicle to verify proper operation, monitoring gauges closely for first 50-100 miles.

Verification

• Confirm oil pressure reads within normal range (40-70 PSI at operating temp, idle).
• Verify coolant temperature reaches and maintains normal operating range (195-220°F).
• Check that no warning lights remain illuminated on instrument cluster.
• Scan for diagnostic trouble codes using OBD-II scanner - address any codes present.
• Inspect underneath vehicle for any fluid leaks after test drive.
• Verify smooth idle (approximately 650-750 RPM when warm) with no misfires or rough running.
• Confirm turbocharger boost operates normally under acceleration with no unusual noises.
• Verify A/C system operates and cools properly after recharge.
• After 500 miles, perform first oil change and recheck all fluid levels and inspect for leaks.
• Monitor oil consumption for first 3,000 miles as new rings seat (slight consumption is normal during break-in).

More procedures for this vehicle