Complete engine removal and reinstallation procedure for the 2015-2020 Ford F-150 3.5L EcoBoost V6 engine, including disconnection of all major systems and engine bay components.

Warnings

Tools required

Parts

• Engine oil and filter × 1 — Use OEM specification
• Engine coolant × 1 — Motorcraft Orange Coolant
• Transmission fluid × 1 — Motorcraft MERCON LV ATF
• Oil drain plug crush washer × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Turbocharger oil feed line gaskets × 2 — Use OEM specification
• Anti-seize compound × 1 — Copper-based high-temp

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt
• Motorcraft Orange Coolant — 13 qt
• Motorcraft MERCON LV ATF — 11 qt

Preparation

1. Park vehicle on level surface, engage parking brake, and place wheel chocks behind rear wheels
2. Disconnect negative battery cable, then positive cable. Remove battery and battery tray for access
3. Drain engine coolant from radiator petcock and lower radiator hose into suitable container
4. Drain engine oil completely and remove oil filter
5. Raise vehicle on lift or jack stands to working height with front end elevated
6. Remove engine under-shield and splash guards
7. Have A/C system professionally evacuated and recover refrigerant
8. Relieve fuel system pressure: remove fuel pump fuse, start engine and allow to stall, crank for 5 seconds to ensure pressure relief
9. Remove hood by marking hinge positions and disconnecting washer hose, requires two people
10. Remove front grille and upper radiator cover for access

Procedure

1. 1

   Remove cooling system components
   Disconnect upper and lower radiator hoses at engine. Remove radiator fan shroud assembly (four bolts). Disconnect transmission cooler lines at radiator. Remove radiator by lifting straight up. Disconnect heater hoses at firewall. Remove coolant expansion tank. Label and disconnect all coolant temperature sensor connectors.
2. 2

   Disconnect air intake and charge air system
   Remove engine air filter and housing assembly. Disconnect mass airflow sensor connector. Remove intake tubing from turbochargers to throttle body, including charge air cooler (CAC) inlet and outlet pipes. Remove CAC mounting bolts and set aside. Disconnect electronic throttle body connector and PCV hoses.
3. 3

   Disconnect fuel system
   Using fuel line disconnect tools, disconnect fuel supply line at fuel rail. Cap open fuel line immediately to prevent contamination. Disconnect fuel rail pressure sensor connector. Remove fuel rail mounting bolts and carefully lift fuel rail with injectors attached. Cap or plug injector ports in intake manifold.
4. 4

   Remove accessory drive components
   Release serpentine belt tensioner and remove belt. Disconnect alternator electrical connections (main power cable and field connector). Remove alternator mounting bolts and set alternator aside. Disconnect A/C compressor electrical connector. Remove A/C compressor mounting bolts but leave refrigerant lines connected; secure compressor to frame. Disconnect power steering pressure sensor if equipped (this vehicle uses electric steering).
   Torque spec

   AC Compressor Bolts25 Nm (18 lb-ft)

   Alternator Mounting Bolts50 Nm (37 lb-ft)
5. 5

   Disconnect exhaust system
   From underneath vehicle, disconnect oxygen sensor connectors (four total: two upstream, two downstream). Remove exhaust Y-pipe to manifold nuts on both banks. Support exhaust with jack and separate from manifolds. Lower exhaust system and secure out of way. If removing manifolds with engine, remove manifold nuts working from hot center to cold outer in reverse torque sequence.
   ⚠Apply penetrating oil to exhaust fasteners 24 hours before removal to reduce risk of broken studs
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
6. 6

   Disconnect engine wiring harnesses
   Locate main engine harness connectors at firewall (typically two large multi-pin connectors). Release locking tabs and disconnect. Disconnect camshaft position sensor connectors (four total). Disconnect crankshaft position sensor. Disconnect knock sensors (two). Disconnect ignition coil connectors (six). Disconnect variable valve timing solenoid connectors. Disconnect turbo wastegate actuator connectors. Disconnect oil pressure sensor. Label all connections with tape and marker.
7. 7

   Disconnect transmission from engine
   Support transmission with transmission jack. Remove starter motor mounting bolts and position starter aside with wiring connected. Remove torque converter access cover. Mark torque converter to flexplate orientation with paint. Remove torque converter to flexplate bolts (rotate crankshaft with 22mm socket on crank bolt to access all four). Remove upper and lower transmission bell housing bolts. Ensure transmission is properly supported before removing final bolts.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
8. 8

   Prepare engine for lifting
   Attach engine lifting sling or chains to factory lifting eyes on engine (one at front, one at rear of each cylinder head). Connect to engine hoist. Take up slack in hoist chain until slight tension is on engine mounts but engine is not yet lifted. Double-check all disconnections: coolant hoses, fuel lines, vacuum lines, electrical connectors, ground straps, exhaust, transmission, and accessories.
   ⚠️Verify engine is balanced on hoist and lifting points are secure before removing any mount bolts. Improper balance can cause engine to shift suddenly.
9. 9

   Remove engine mounts
   Remove left and right engine mount through-bolts (upper bolts securing mount to frame). With engine supported by hoist, remove engine mount-to-block bolts on both sides. Carefully raise engine slightly (1-2 inches) to verify it is free from mounts. Check for any remaining connections or interference.
   Torque spec

   Engine Mount-to-Block Bolts65 Nm (48 lb-ft)

   Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)
10. 10

    Remove engine from vehicle
    Slowly raise engine with hoist while guiding it forward and up. Angle engine slightly nose-up to clear transmission input shaft. Continue lifting while pulling engine forward. Watch for any snagged hoses, wires, or components. Once clear of transmission, lift engine high enough to clear radiator support. Carefully move engine forward and out of engine bay. Lower onto engine stand and secure with flywheel bolts.
    ⚠Have an assistant guide the engine and watch for clearance issues. Move slowly and stop immediately if resistance is felt.

Reassembly

1. Clean all mounting surfaces, especially transmission bell housing mating surface and engine block mating surface
2. Inspect and replace engine mounts if rubber is cracked, separated, or oil-soaked
3. Install new exhaust manifold gaskets and apply anti-seize to manifold studs before installation
4. Replace all crush washers, O-rings, and gaskets that were disturbed during removal
5. Ensure torque converter is fully seated in transmission (should click three times) before mating engine to transmission
6. Align torque converter to flexplate using marks made during disassembly
7. Torque all fasteners in reverse order of removal, following specified torque values and sequences
8. Reconnect all electrical connectors ensuring positive engagement and locking tabs are secured
9. Install new oil filter and fill engine with 6 quarts of Motorcraft 0W-20 synthetic oil
10. Fill cooling system with 13 quarts of Motorcraft Orange Coolant mixture (50/50 with distilled water)
11. Have A/C system recharged by qualified technician
12. Check and top off transmission fluid to proper level after initial start

Verification

• Perform visual inspection of all connections, hoses, and electrical connectors before first start
• Verify no tools or parts remain in engine bay
• Check that all ground straps are reconnected securely
• With engine oil and coolant filled, crank engine for 5-10 seconds without starting to build oil pressure
• Check oil pressure gauge or warning light behavior during cranking
• Start engine and immediately check for leaks: oil, coolant, fuel, and exhaust
• Allow engine to reach operating temperature while monitoring temperature gauge
• Check for proper operation of all accessories: alternator charging, A/C compressor engagement
• Bleed cooling system completely by running engine with heat on full, adding coolant as needed until no bubbles appear
• Perform test drive to verify transmission engagement, engine performance, and absence of abnormal noises or vibrations
• Recheck all fluid levels after test drive and top off as necessary
• Clear any diagnostic trouble codes and verify no new codes are present
• Recheck torque on all critical fasteners after engine has cooled
• Monitor for leaks and unusual sounds over first 100 miles of operation

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