Complete replacement of the 3.5L EcoBoost V6 long block assembly, including removal of all external components, engine extraction, installation of new long block, and reinstallation of all accessories and systems.

Warnings

Tools required

Parts

• 3.5L EcoBoost V6 Long Block Assembly × 1 — Use OEM specification
• Engine oil and filter × 1 — FL-820-S oil filter
• Engine coolant × 2 — Motorcraft Orange Coolant
• Transmission fluid × 1 — MERCON LV
• Intake manifold gaskets × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Thermostat and housing gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine mount hardware kit × 1 — Use OEM specification
• Serpentine belt × 1 — Use OEM specification

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt
• Motorcraft Orange Coolant — 13 qt
• Motorcraft MERCON LV ATF — 2 qt

Preparation

1. Position vehicle on level surface and engage parking brake
2. Disconnect negative battery cable, then positive cable
3. Remove engine cover and air intake system completely
4. Have AC system professionally evacuated and recover refrigerant
5. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
6. Drain engine oil completely and remove oil filter
7. Drain cooling system from radiator petcock and engine block drain plugs
8. Raise and support vehicle on jack stands at all four corners
9. Remove front wheels and splash shields for access
10. Label and photograph all electrical connections, vacuum lines, and hose routing

Procedure

1. 1

   Remove cooling system and radiator
   Disconnect upper and lower radiator hoses, heater hoses, and overflow tank. Remove radiator fan assembly and shroud. Unbolt and remove radiator. Disconnect transmission cooler lines if equipped and cap openings.
2. 2

   Disconnect fuel system and AC
   Use fuel line disconnect tools to remove fuel supply and return lines. Cap all openings immediately. Disconnect AC compressor electrical connector and unbolt compressor from engine, securing it to frame without disconnecting refrigerant lines.
   ⚠️Fuel will spray when lines are disconnected. Have absorbent rags ready and work in ventilated area away from ignition sources.
3. 3

   Remove turbocharger system components
   Disconnect both turbocharger inlet and outlet pipes. Remove intercooler pipes and charge air cooler connections. Unbolt and remove heat shields. Disconnect turbocharger oil feed and drain lines, capping openings to prevent contamination.
4. 4

   Disconnect exhaust system
   From underneath vehicle, unbolt exhaust Y-pipe from both exhaust manifolds. Support exhaust system and lower away from engine. May require penetrating oil on studs and heat cycles to remove.
   ⚠Exhaust studs are prone to breaking. Apply penetrating oil 24 hours before removal if possible.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
5. 5

   Remove intake manifold and throttle body
   Disconnect throttle body electrical connector and all vacuum lines from intake manifold. Remove PCV hoses and breather tubes. Unbolt intake manifold in reverse of tightening sequence and remove complete assembly with fuel rails attached.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
6. 6

   Disconnect all engine electrical connections
   Disconnect and label: both ignition coil harnesses, fuel injector connectors, camshaft position sensors, crankshaft position sensor, knock sensors, oil pressure sender, coolant temperature sensors, oxygen sensors, and main engine harness connector. Secure all harnesses away from engine.
   Torque spec

   Electrical Connector Bolts8 Nm (6 lb-ft)

   Sensor Bolts12 Nm (9 lb-ft)

   Mounting Bolts31 Nm (23 lb-ft)
7. 7

   Remove accessory drive components
   Using serpentine belt tensioner tool, remove drive belt. Unbolt power steering pump and secure to frame without disconnecting lines. Remove alternator and starter motor. Disconnect any remaining brackets or accessories mounted to engine block.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Separate transmission from engine
   Support transmission with transmission jack or support fixture. Remove transmission inspection cover if equipped. Mark torque converter to flexplate orientation. Remove flexplate-to-torque converter bolts through starter opening by rotating crankshaft. Remove all transmission-to-engine mounting bolts.
   Torque spec

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

   Flywheel Bolts95 Nm (70 lb-ft)
9. 9

   Disconnect engine mounts and prepare for extraction
   Attach engine hoist with load leveler to engine lifting eyes or brackets. Apply slight tension to support engine weight. Remove both left and right engine mount through-bolts and bracket mounting bolts. Ensure all connections to vehicle are disconnected.
   ⚠️Verify hoist is properly rated and securely attached before removing engine mounts. Engine will shift when mounts are removed.
   Torque spec

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

    Extract engine from vehicle
    Slowly raise engine while adjusting load leveler angle to clear transmission input shaft and bellhousing. Guide engine forward and up, ensuring no wires, hoses, or components are still connected. May need to tilt engine significantly to clear firewall and frame rails. Once clear, lower engine onto engine stand.
11. 11

    Transfer components from old to new long block
    Transfer all external components to new long block: exhaust manifolds with new gaskets, turbochargers, oil pan, timing cover, water pump, thermostat housing, oil filter adapter, valve covers, intake manifold components, sensors, and brackets. Use all new gaskets and seals. Follow torque specifications and sequences for all fasteners.
    ⚠Apply anti-seize compound to exhaust manifold studs as specified. Clean all gasket surfaces thoroughly before installation.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Cover Bolts19 Nm (14 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)

    Gasket Bolts23 Nm (17 lb-ft)

    Gasket Surface Bolts23 Nm (17 lb-ft)

    Sensor Bolts12 Nm (9 lb-ft)

    Mounting Bolts31 Nm (23 lb-ft)
12. 12

    Install new long block into vehicle
    Attach hoist to new long block assembly. Carefully raise and guide engine into engine bay, reversing removal procedure. Align engine with transmission, being careful to properly seat torque converter onto flexplate. Adjust load leveler angle as needed to maneuver engine into position.
    ⚠Ensure torque converter is fully seated in transmission pump before mating engine to transmission. Should feel three distinct clicks when properly installed.
13. 13

    Install engine mounts and reconnect transmission
    Install engine mount brackets and through-bolts, torquing to specification. Install all transmission-to-engine bolts and torque in star pattern. Install flexplate-to-torque converter bolts with thread locker, torquing in star pattern. Remove transmission support.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)

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

    Flywheel Bolts95 Nm (70 lb-ft)
14. 14

    Reconnect all systems and accessories
    Install starter motor and alternator. Reconnect power steering pump and AC compressor. Install new serpentine belt. Reconnect all electrical connections using labels and photos from disassembly. Reconnect fuel lines, vacuum lines, turbocharger piping, intercooler system, and exhaust system. Install radiator, fan assembly, and reconnect all cooling system hoses.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
15. 15

    Fill fluids and final preparation
    Install new oil filter and fill engine with 6 quarts of Motorcraft 0W-20 synthetic oil. Fill cooling system with 13 quarts Motorcraft Orange coolant using vacuum fill method if available to eliminate air pockets. Check transmission fluid level and top off with MERCON LV as needed. Install new drain plug crush washer. Reconnect battery cables (positive first, then negative). Double-check all connections.
    ℹ️Use vacuum fill tool for cooling system to prevent air pockets in EcoBoost engine which can cause overheating.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Reinstall front wheels and torque lug nuts to specification
2. Remove jack stands and lower vehicle to ground
3. Install air intake system and engine cover
4. Have AC system recharged by certified technician
5. Perform initial start procedure: verify oil pressure within 5 seconds of cranking
6. Allow engine to reach operating temperature and check for leaks at all connections
7. Bleed cooling system by running engine with heater on maximum until thermostat opens
8. Check and adjust transmission fluid level per Ford procedure with engine at operating temperature

Verification

• Verify no fluid leaks from engine oil, coolant, transmission, fuel, or AC systems
• Confirm oil pressure reads normal (40-70 psi at operating temperature)
• Verify coolant temperature remains in normal range (195-220°F)
• Check that all warning lights are off and no diagnostic codes are present
• Test drive vehicle and verify normal acceleration, no unusual noises, and proper turbocharger boost
• Recheck all fluid levels after test drive and top off as necessary
• Verify transmission shifts smoothly through all gears
• Perform final torque check on engine mount bolts and transmission-to-engine bolts after first heat cycle

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