3.5L Engine Complete Assembly for 2014-2017 Ford & Lincoln • Expedition, F-150, Navigator

A quick look at your own vehicle makes sure the right engine shows up:

• Verify the 8th digit of the 17-digit VIN is 'G' (2015-2016 F-150) or 'T' (2014 F-150, Expedition, Navigator).
• Confirm drivetrain layout (4x4 vs 4x2) to determine if transferring the oil pan or differential brackets is required.
• Visually confirm the vehicle has a twin-turbocharged setup, not a naturally aspirated 3.5L V6.
• Verify the presence of a mechanical vacuum pump on the back of the passenger-side cylinder head.
• Locate the engine identification label on the driver's side valve cover to match specs.

What the install really takes — plan and budget with confidence:

Special tools this job needs:

• Camshaft Holding Tool / Alignment Kit (Ford 303-1248)
• Crankshaft Vibration Damper Remover/Installer (Ford 303-1521)
• Quick-Disconnect Tool Set (for fuel and turbo coolant lines)
• Engine lifting equipment
• Torque wrenches (ft-lbs and in-lbs)

Budget for these consumables at install:

• Turbo Gasket & Seal Kit (oil feed/drain gaskets, coolant line O-rings, exhaust-to-turbo gaskets)
• Exhaust Manifold Gaskets & Upgraded Studs/Nuts
• 6 New OE-spec Spark Plugs (Motorcraft SP-580 or SP-534, manually gapped to 0.030 inches)
• 6 Quarts of Full-Synthetic 5W-30 Engine Oil (Ford WSS-M2C946-A/B1)
• New Motorcraft FL-500S Oil Filter
• Motorcraft Orange or Yellow Concentrated Coolant (mixed 50/50 with distilled water)
• Motorcraft TA-357 High-Performance Engine RTV Silicone

What your vehicle’s computers will need after the swap:

What’s involved: Crankshaft Position (CKP) Sensor Relearn & PATS Key Relearn

sources differ: Arm 1 states no security programming is needed if original ECU is kept, but a CKP relearn is required (can use FORScan). Arm 2 states a PATS key relearn and adaptive memory resets are required, highly recommending a dealer-level scan tool (IDS). Cautious choice: 'yes' for programming, as CKP relearn and adaptive resets are required for proper operation.

Pro tips for a smooth first start-up — hand them to whoever does the install:

• Turbo Oil Feed Line Filters: Tiny mesh filters inside the block oil feed ports must be replaced to prevent immediate turbo oil starvation and failure.
• Mechanical Vacuum Pump Hazard: The fragile pump on the rear passenger-side head must be removed before dropping the engine to avoid cracking it or the head against the firewall.
• Fragile Turbo Coolant Line Quick-Connects: Jiffy-tite fittings become extremely brittle and almost always leak if reused; replace them during the swap.
• Torque-to-Yield Balancer Bolt: The crankshaft pulley bolt (Ford HB1) is TTY and cannot be reused. Follow the specific torque-plus-angle sequence.
• Oil Pan Sealing: The oil pan uses RTV silicone instead of a gasket. Surface prep is critical (TSB 20-2015) and the pan must be installed within 10 minutes of RTV application.
• Fragile Plastic Cooling Fittings: The cooling system's plastic Y-pipe and fittings become brittle and crack easily during removal/installation.
• Broken Exhaust Manifold Studs: Inspect and replace broken studs on the donor engine before installing turbos.

Easy to get right once you know them:

• Ordering for a Transverse Vehicle: Buying this longitudinal engine for a Ford Explorer Sport, Taurus SHO, or Ford Flex.
• Reusing Clogged Turbo Oil Lines: Reusing old lines that contain trapped metal debris or sludge from a previous engine failure.
• Assuming 'Pre-Gapped' Spark Plugs Are Ready: Failing to manually gap plugs to 0.030 inches, leading to spark blowout and misfires under boost.
• Damaging the Crankshaft Reluctor Wheel: Forcing the engine and transmission together when the torque converter is not fully seated, bending the reluctor wheel teeth.
• Not Replacing the Timing Components: Failing to replace the timing chain, tensioner, and phasers while the engine is out of the vehicle.
• Reusing Turbo Coolant Fittings: Trying to save money by reusing old quick-connect fittings, which almost always leak after being disturbed.

Not issues with the units on this page — the manufacturer documented these for every engine of this family, wherever you buy one. Handy for your installer: