This procedure covers complete short block replacement for the 3.5L EcoBoost V6 engine, including engine removal, disassembly of cylinder heads and timing components, installation of new short block, and reassembly with all timing and sealing components.

Warnings

Tools required

Parts

• Short block assembly (3.5L EcoBoost) × 1 — Use OEM specification
• Cylinder head gasket set × 1 — Use OEM specification
• Timing chain kit with guides and tensioners × 1 — Use OEM specification
• Oil pump × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Turbocharger gasket kit × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Water pump gasket × 1 — Use OEM specification
• Oil filter × 1 — FL-910S or equivalent
• Oil drain plug crush washer × 1 — Use OEM specification
• Connecting rod bolts (set) × 1 — Use OEM specification
• Main bearing cap bolts (set) × 1 — Use OEM specification
• Flywheel bolts × 8 — Use OEM specification

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake. Chock rear wheels.
2. Disconnect negative battery cable, then positive cable. Remove battery and battery tray.
3. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls.
4. Drain engine coolant completely from radiator and engine block drain plugs into suitable container.
5. Drain engine oil and remove oil filter.
6. Remove engine cover and air intake system including intercooler piping.
7. Remove hood for clearance - mark hinge positions before removal.
8. Raise vehicle on lift to access underside components.
9. Remove front skid plate if equipped.
10. Support transmission with transmission jack.

Procedure

1. 1

   Disconnect all engine connections
   Disconnect all electrical connectors including alternator, starter, sensors (CKP, CMP, O2 sensors, knock sensors), and engine harness. Label each connection for reassembly. Disconnect fuel supply and return lines using proper disconnect tools. Disconnect vacuum lines, PCV hoses, and brake booster vacuum line. Remove serpentine belt and accessory drive components including alternator, A/C compressor (do not disconnect refrigerant lines - secure to frame), and power steering pump if equipped with hydraulic assist.
   Torque spec

   Electrical Connector Bolts8 Nm (6 lb-ft)
2. 2

   Remove cooling system components
   Disconnect upper and lower radiator hoses, heater hoses, and all coolant passages to engine. Remove radiator fan shroud assembly. Disconnect transmission cooler lines from radiator. Remove radiator support brackets and lift radiator from vehicle. Remove thermostat housing and coolant crossover pipes.
3. 3

   Disconnect exhaust system and turbochargers
   From underneath vehicle, disconnect exhaust system at the catalytic converters. Remove exhaust Y-pipe. Support turbochargers and remove all oil feed and return lines. Disconnect wastegate actuator rods. Remove turbocharger-to-exhaust manifold mounting nuts. Turbochargers will be removed with engine as an assembly.
4. 4

   Separate transmission from engine
   Remove transmission inspection cover. Mark torque converter to flexplate relationship for reassembly. Remove torque converter to flexplate bolts (rotate engine via crankshaft bolt for access to all bolts). Remove all transmission-to-engine mounting bolts. Support transmission securely with transmission jack. Remove starter motor mounting bolts and secure starter aside.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
5. 5

   Remove engine mounts and extract engine
   Attach engine hoist with lifting chains to designated engine lift points (front and rear). Take up slack in hoist ensuring engine is balanced. Remove left and right engine mount through-bolts and mounting nuts. Slowly raise engine while monitoring all clearances. Separate engine from transmission ensuring torque converter remains with transmission. Tilt engine slightly as needed to clear firewall and lift from engine bay. Transfer engine to engine stand and secure via bellhousing bolt holes.
   ⚠️Verify engine is properly balanced on hoist before removing final mount bolts. Have assistant guide engine during extraction to prevent contact with body panels.
   Torque spec

   Mounting Bolts54 Nm (40 lb-ft)
6. 6

   Remove valve covers and timing components
   With engine on stand, remove both valve covers and gaskets. Remove crankshaft pulley using harmonic balancer puller. Remove timing cover bolts in reverse of tightening sequence and remove timing cover. Rotate engine to TDC cylinder #1 and verify all timing marks align. Install camshaft locking tools per Ford procedure to lock camshafts in position. Mark timing chain to sprocket relationship before removal. Release timing chain tensioners and remove tensioner locking pins if present. Remove timing chains, guides, and tensioners as an assembly. Remove camshaft sprockets.
   ⚠Do not rotate crankshaft or camshafts once timing chains are removed unless proper locking tools are installed. Valve-to-piston contact will occur.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)
7. 7

   Remove cylinder heads
   Remove cylinder head bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift cylinder heads from block using lifting eyes if equipped. Do not pry between head and block gasket surfaces. Place heads on clean padded surface. Remove and discard head gaskets. Inspect cylinder head surfaces for damage, warpage, or cracks. Have heads professionally inspected and resurfaced if needed.
   ℹ️Cylinder heads are aluminum and easily damaged. Support heads properly during removal and storage.
8. 8

   Remove oil pan and oil pump
   Remove oil pan bolts in cross pattern and remove oil pan. Remove oil pan gasket and thoroughly clean all gasket surfaces on pan and block. Remove oil pump mounting bolts and extract oil pump assembly with pickup tube. Remove oil pump gasket. Inspect crankshaft for seal surface damage.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)
9. 9

   Remove flywheel and rear seal
   Lock flywheel using holding tool or wedge. Remove flywheel bolts and remove flywheel. Remove rear main seal using seal removal tool or carefully pry out with seal puller. Clean rear seal bore thoroughly.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)
10. 10

    Transfer components to new short block
    Verify new short block matches old block exactly including casting numbers and specifications. Install new rear main seal using seal driver, ensuring seal is seated evenly and flush. Install flywheel with new bolts, aligning dowel pin. Torque flywheel bolts in star pattern per specification. Install new oil pump with new gasket. Install oil pan with new gasket, cleaning all surfaces thoroughly first. Torque oil pan bolts in cross pattern from center outward.
    ⚠Use only new TTY flywheel bolts. Reusing old bolts will result in improper clamping force and potential flywheel detachment.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
11. 11

    Install cylinder heads with new gaskets
    Clean all gasket surfaces on block and cylinder heads with plastic scraper and brake cleaner. Ensure surfaces are completely free of old gasket material and oil. Install new head gaskets ensuring all alignment dowels are properly seated and gaskets are oriented correctly (noting oil and coolant passage alignment). Carefully lower cylinder heads onto block. Install new head bolts (if TTY type) and torque in proper sequence per Ford specification (typically center-out pattern). Follow multi-stage torque plus angle procedure exactly.
    ⚠Head gasket orientation is critical. Verify TOP marking faces upward and all passages align before torquing.
    Torque spec

    Gasket Bolts23 Nm (17 lb-ft)

    Gasket Surface Bolts23 Nm (17 lb-ft)
12. 12

    Install timing components and set timing
    Install new front crankshaft seal using seal driver. Install camshaft sprockets with alignment marks noted. Install timing chain guides and ensure they are properly seated. Route new timing chains over sprockets following factory routing diagram. Verify all timing marks align with TDC marks. Install timing chain tensioners with locking pins installed. Install timing cover with new gasket, torquing bolts in sequence. Remove camshaft locking tools and verify engine rotates freely by hand through two complete revolutions. Reinstall camshaft locking tools and verify timing marks still align. Install crankshaft pulley using new bolt if TTY type.
    ⚠After timing chain installation, manually rotate engine two full revolutions and recheck timing alignment before installing covers. Incorrect timing will destroy engine on startup.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
13. 13

    Install valve covers and accessories
    Install valve covers with new gaskets, torquing bolts in sequence from center outward. Install all sensors including CKP, CMP, knock sensors, and temperature sensors using new seals where applicable. Install alternator, A/C compressor, and power steering pump if equipped. Install new serpentine belt and verify proper routing and tension.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Sensor Bolts12 Nm (9 lb-ft)

    Mounting Bolts54 Nm (40 lb-ft)
14. 14

    Reinstall engine into vehicle
    Attach engine to hoist and carefully lower into engine bay, tilting as needed for clearance. Align engine with transmission bellhousing, ensuring dowel pins engage properly and torque converter pilot engages crankshaft. Install transmission-to-engine bolts and torque to specification. Install engine mount bolts and torque to specification. Remove hoist and reconnect all previously disconnected components in reverse order of removal: turbochargers with new gaskets, exhaust system, fuel lines, coolant hoses, electrical connectors, and vacuum lines. Install radiator, fan shroud, and all cooling system components.
    Torque spec

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

    Mounting Bolts54 Nm (40 lb-ft)
15. 15

    Fill fluids and perform initial start
    Install new oil filter and install oil drain plug with new crush washer. Fill engine with 6 quarts of Motorcraft 0W-20 synthetic oil. Fill cooling system with 13 quarts of Motorcraft Orange coolant, purging air from system per Ford procedure. Reconnect battery cables (positive first, then negative). Perform PCM relearn procedure if required. Prime fuel system by cycling ignition on/off three times without cranking. Start engine and verify oil pressure within 5 seconds. Check for leaks at all gasket surfaces, particularly head gaskets, timing cover, and oil pan. Allow engine to reach operating temperature while monitoring for leaks and abnormal noises.
    ⚠️If oil pressure does not register within 5 seconds of startup, immediately shut down engine and investigate. Running without oil pressure will destroy new short block.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. All assembly torque specifications must be followed exactly, particularly TTY bolts which require torque-plus-angle method.
2. Replace all TTY bolts including main bearing cap bolts, connecting rod bolts, flywheel bolts, and head bolts.
3. Use only new gaskets and seals throughout reassembly - never reuse gaskets.
4. Follow proper timing chain installation procedure with alignment tools - incorrect timing causes immediate engine failure.
5. Ensure all electrical connectors are properly seated and locked - check each connection twice.
6. Verify all fluid levels are correct before initial startup.
7. Prime oil system if possible before first start to prevent dry startup damage.

Verification

• Verify no coolant, oil, or fuel leaks at all connections and gasket surfaces after initial startup and warm-up cycle.
• Check engine oil level and condition - should be clean with no coolant contamination.
• Verify coolant level is correct after system purge and no air pockets remain.
• Confirm oil pressure reads within normal range (typically 25-80 PSI depending on RPM and temperature).
• Listen for abnormal engine noises including knocking, ticking, or grinding that would indicate timing or bearing issues.
• Scan for diagnostic trouble codes using professional scan tool - address any codes before returning to service.
• Perform test drive and verify normal operation including power delivery, boost pressure (10-15 PSI typical), and transmission engagement.
• Recheck all fluid levels after test drive and verify no new leaks have developed.
• Allow engine to cool completely, then recheck torque on critical fasteners including cylinder head bolts per manufacturer retorque specifications if required.
• Document repair with all part numbers, torque values used, and initial startup parameters for customer records.

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