3.5L Engine Complete Assembly (Less Turbochargers) for 2018-2021 Ford

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

• Verify the 8th digit of the VIN is T (Expedition) or G/4 (F-150).
• Check the vehicle build date on the door jamb (must be 03/19/2018 or later for Expedition, 02/26/2018 or later for F-150).
• Confirm drivetrain configuration (2WD vs 4WD/AWD) to ensure oil pan compatibility.
• Acknowledge that turbochargers are not included and must be transferred.

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

Special tools this job needs:

• Heavy-duty engine hoist and load leveler
• Quick-disconnect tool set for fuel and A/C lines
• Ford Camshaft Alignment Tool Kit (OTC 303-1655)
• Diagnostic scan tool (Ford IDS/FDRS or FORScan)
• Engine Lift Plate (STECK 50133)
• Torque wrenches

Budget for these consumables at install:

• Engine Oil (SAE 5W-30 synthetic blend or full synthetic meeting WSS-M2C961-A1 or WSS-M2C946-B1)
• Motorcraft FL-500S Oil Filter
• Motorcraft Yellow or Orange Prediluted Antifreeze/Coolant
• Six new spark plugs (Motorcraft SP-580 or SP-594, pre-gapped to 0.030"-0.032")
• Intake and exhaust manifold gaskets
• Turbocharger mounting gaskets, oil feed/return line gaskets, and coolant line O-rings
• High-pressure fuel pump mounting bolts and O-ring (one-time-use)
• Crankshaft pulley (harmonic balancer) bolt (one-time-use)
• Valve cover gaskets
• Front and rear main seals

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

What’s involved: Crankshaft Position (CKP) Sensor Relearn and PATS Security Re-marriage

sources differ: Arm 1 states ECU remarriage is not required if original computer is reused, requiring only a CKP relearn. Arm 2 states a PATS security/immobilizer re-marriage is required. Cautious value 'yes' selected for dealer tool and programming requirements.

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

• Turbocharger Line Replacement: Must replace quick-connect fittings and O-rings to prevent immediate coolant leaks.
• Oil Pan & Pickup Tube Compatibility: Mismatched plastic/aluminum pans and pickup tubes will cause oil starvation.
• Torque-to-Yield (TTY) Fasteners: Crankshaft pulley, flywheel, and HPFP bolts cannot be reused.
• Harmonic Balancer Installation: Do not use an impact gun; hand torque only.
• Turbocharger Priming: Must prime turbos with fresh oil before first start to prevent bearing failure.
• Lifting the Body: Many technicians find it easier to lift the cab off the frame for access.

Easy to get right once you know them:

• Reusing old turbocharger coolant/oil lines and quick-connect fittings.
• Ignoring build date cutoffs for oil pan and pickup tube compatibility.
• Skipping the mandatory Crankshaft Position Sensor relearn procedure.
• Ordering this engine for a Lincoln Navigator or transverse applications.
• Skipping the PATS security relearn procedure.
• Not cleaning or replacing the intercooler after a previous engine failure.

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: