This procedure covers the replacement of the boost pressure sensor on the 3.5L EcoBoost engine, which monitors turbocharger boost pressure for engine management.

Warnings

Tools required

Parts

• Boost pressure sensor × 1 — Use OEM Ford specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely for at least 30 minutes
3. Disconnect negative battery terminal and wait 2 minutes for system capacitors to discharge
4. Locate boost pressure sensor on the intake manifold or turbocharger outlet pipe (typically passenger side of engine bay)

Procedure

1. 1

   Access the boost pressure sensor
   Open the hood and identify the boost pressure sensor location. On the 3.5L EcoBoost, the sensor is typically mounted on the intake manifold or intercooler piping on the passenger side. Remove any engine cover if present to gain clear access to the sensor area.
2. 2

   Disconnect electrical connector
   Locate the electrical connector on the boost pressure sensor. Press the release tab on the connector and carefully pull it straight off the sensor. If the connector is stuck, gently wiggle it while pulling. Use a pick tool if necessary to release the locking tab, but avoid damaging the connector.
3. 3

   Remove the boost pressure sensor
   Using a 10mm socket, carefully loosen and remove the boost sensor mounting bolt or unthread the sensor itself (depending on mounting style). If the sensor is threaded directly into the manifold, rotate it counterclockwise by hand once loosened. Support the sensor while removing to prevent it from falling. Note the orientation of the sensor for proper installation of the replacement.
4. 4

   Inspect sensor port and seal
   Examine the sensor mounting port on the intake manifold or intercooler pipe for any debris, damage, or carbon buildup. Clean the threads and sealing surface with a shop towel. Check the O-ring or gasket on the old sensor to ensure it came out completely. If an O-ring remains in the port, carefully extract it with a pick tool.
5. 5

   Install new boost pressure sensor
   Verify the new sensor has a proper O-ring or gasket installed. If applicable, lightly coat the O-ring with dielectric grease to aid installation and prevent future corrosion. Insert the new sensor into the mounting port in the same orientation as the original. Thread or position it carefully by hand to ensure proper alignment before tightening.
   ⚠Start threading by hand to avoid cross-threading the sensor. Do not force the sensor if resistance is felt.
   Torque spec

   Boost Sensor15 Nm (11 lb-ft)
6. 6

   Torque sensor to specification
   Using a torque wrench, tighten the boost pressure sensor to 15.0 Nm (11.0 lb-ft). Apply torque slowly and steadily. Do not exceed the specified torque as the sensor housing or mounting threads can be damaged easily.
   Torque spec

   Boost Sensor15 Nm (11 lb-ft)
7. 7

   Reconnect electrical connector
   Align the electrical connector with the pins on the new boost pressure sensor. Push the connector straight onto the sensor until you hear or feel a positive click, indicating the locking tab has engaged. Gently tug on the connector to verify it is fully seated and locked in place.
8. 8

   Reinstall engine covers and reconnect battery
   If an engine cover was removed, reinstall it and secure with the appropriate fasteners. Reconnect the negative battery terminal. Ensure all tools and materials are removed from the engine bay before closing the hood.

Reassembly

1. Ensure the electrical connector is fully seated and latched on the boost pressure sensor
2. Verify the sensor is torqued to specification and not loose
3. Confirm no tools or shop towels were left in the engine bay

Verification

• Start the engine and allow it to idle for 1-2 minutes, listening for any unusual vacuum leaks or hissing sounds near the sensor
• Use a scan tool to verify the boost pressure sensor is reading properly (should show near atmospheric pressure at idle, typically 14.5-14.7 psi absolute)
• Test drive the vehicle under light acceleration to confirm no boost pressure fault codes are present
• Re-scan for diagnostic trouble codes to ensure no P0236, P0237, P0238, or related boost pressure codes are stored
• Monitor boost pressure readings during moderate acceleration to verify sensor is responding correctly to turbocharger operation

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