Cylinder Head Resurface

Remove, machine, and reinstall cylinder heads on the 5.0L Coyote V8, including disassembly of intake/exhaust manifolds, timing components, and valve train.

Warnings

Tools required

Parts

• Cylinder head gaskets (left and right) × 2 — Use OEM Ford Motorcraft specification
• Cylinder head bolts (TTY - do not reuse) × 20 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Timing chain tensioner gaskets × 2 — Use OEM specification
• VCT solenoid O-rings × 4 — Use OEM specification
• Coolant temperature sensor O-ring × 1 — Use OEM specification
• Spark plugs × 8 — Motorcraft SP-515 or equivalent
• Anti-seize compound × 1 — Nickel-based high temp

Fluids

• Motorcraft 5W-20 Synthetic Blend — 7.5 qt
• Motorcraft Orange Coolant — 16 qt

Preparation

1. Ensure engine is completely cold. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and secure away from terminal
3. Drain cooling system completely at radiator petcock and engine block drain plugs into appropriate container
4. Drain engine oil and remove oil filter
5. Remove engine cover and air intake system including air filter housing
6. Remove serpentine belt and mark routing for reinstallation
7. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
8. Label and photograph all vacuum lines, electrical connectors, and hose routing before disconnection
9. Support engine weight with engine support bar or overhead hoist before beginning work

Procedure

1. 1

   Remove Valve Covers and Ignition Components
   Disconnect ignition coil connectors and remove all eight coil-on-plug assemblies. Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve covers from heads. Remove spark plugs and store in order by cylinder number.
   Torque spec

   Cover Bolts20 Nm (15 lb-ft)
2. 2

   Remove Intake Manifold Assembly
   Disconnect throttle body, fuel rails with injectors (relieve residual pressure first), PCV hoses, and all electrical connectors from intake manifold. Remove intake manifold bolts in reverse sequence starting from outer bolts working inward. Lift intake manifold assembly off engine and set aside. Cover intake ports with clean shop towels to prevent debris entry.
   ⚠Fuel will drain from fuel rails. Have absorbent rags ready and ensure adequate ventilation.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
3. 3

   Remove Exhaust Manifolds
   Disconnect oxygen sensors from exhaust manifolds (four sensors total). From underneath vehicle, unbolt exhaust Y-pipe from manifold flanges. Remove exhaust manifold nuts working from hot center runners to cold outer runners. Remove exhaust manifolds and gaskets. Inspect studs for damage.
   ℹ️Some studs may come out with nuts. If threads are damaged, replace studs before reassembly.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
4. 4

   Remove Front Timing Cover and Accessories
   Remove power steering pump and set aside without disconnecting lines. Remove A/C compressor mounting bolts and secure compressor aside without disconnecting refrigerant lines. Remove water pump. Remove all timing cover bolts noting different lengths and locations. Carefully remove timing cover - may require gentle prying. Remove crankshaft position sensor.
   Torque spec

   Cover Bolts20 Nm (15 lb-ft)

   Mounting Bolts34 Nm (25 lb-ft)
5. 5

   Lock Camshaft Timing and Remove Timing Chains
   Rotate crankshaft to TDC cylinder #1 (compression stroke). Verify all timing marks align: crankshaft keyway at 12 o'clock, camshaft slots horizontal. Install camshaft holding tools (Ford 303-1248) to lock all four camshafts. Mark timing chain-to-sprocket relationship with paint marker. Remove timing chain tensioners. Remove timing chain guides. Carefully remove both timing chains and VCT assemblies as complete units. Do NOT rotate any shafts.
   ⚠️With timing chains removed, rotating crankshaft or camshafts will cause immediate valve-to-piston contact and severe engine damage.
6. 6

   Remove Camshafts and Valve Train Components
   Before removing camshafts, photograph cam cap positions and markings. Remove camshaft cap bolts in reverse sequence (inside to outside, multiple passes). Keep caps organized by position. Remove all four camshafts and set aside in order. Remove rocker arms and hydraulic lash adjusters. Place in numbered compartments or labeled bags by cylinder number for reinstallation in exact original positions.
   ⚠Camshaft caps are not interchangeable and have directional arrows. Improper installation will cause immediate bearing failure.
7. 7

   Remove Cylinder Head Bolts
   Remove cylinder head bolts in proper reverse sequence (consult Ford service manual for specific pattern - typically outside to inside, alternating sides). Loosen in multiple passes, 1/4 turn at a time. Remove all bolts and discard - these are TTY and cannot be reused. Check bolt holes for coolant or oil - if present, clean and inspect block for cracks.
   ⚠️Never reuse TTY cylinder head bolts. Reused bolts will not achieve proper clamping force and will cause head gasket failure or bolt breakage.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
8. 8

   Remove Cylinder Heads
   Carefully break cylinder head seal using plastic or brass pry tools at designated pry points only (typically cast pry bosses at front and rear corners). Never pry between sealing surfaces. Lift cylinder heads straight up - heads weigh approximately 40 lbs each. Place on clean padded surface with combustion chambers facing up. Remove and discard old head gaskets. Cover cylinder bores with clean shop towels.
   ⚠Do not allow debris, tools, or fasteners to fall into cylinder bores or oil passages. Contamination will cause immediate bearing damage on startup.
9. 9

   Prepare Heads for Machining and Clean Block Surface
   Transport cylinder heads to qualified machine shop for inspection, pressure testing, and resurfacing. Specify maximum material removal to maintain minimum deck height (consult Ford specifications). While heads are at machine shop, meticulously clean block deck surfaces using razor blade scraper and approved gasket remover. Do NOT use abrasive pads that leave residue. Clean all bolt holes with brake cleaner and blow out with compressed air. Inspect block deck for damage, cracks, or warpage.
   ℹ️Machine shop should verify valve seats, guides, and check for cracks. Maximum allowable head resurfacing maintains compression ratio within specification.
10. 10

    Install Resurfaced Cylinder Heads
    Verify all block deck and head surfaces are perfectly clean and dry. Install NEW cylinder head gaskets on block - observe orientation marks and coolant/oil passage alignment. Carefully lower cylinder heads onto block, aligning dowel pins. Install NEW TTY cylinder head bolts finger-tight in all positions. Using proper sequence (consult manual - typically center outward), torque all bolts to 48 lb-ft (65 Nm). Then tighten each bolt an additional 90 degrees. Finally, tighten each bolt another 90 degrees (total 180 degrees additional after initial torque).
    ⚠️Follow torque sequence exactly. Failure to follow proper sequence and angle tightening will result in warped heads and blown head gaskets.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
11. 11

    Reinstall Valve Train Components
    Lubricate all hydraulic lash adjusters with clean engine oil and install in original positions. Install rocker arms in original positions. Lubricate camshaft journals and lobes with assembly lube or clean engine oil. Install camshafts in original positions, ensuring intake and exhaust cams are correctly placed. Install camshaft caps in exact original positions observing directional arrows. Torque cam cap bolts in proper sequence (outside to inside) per Ford specification in multiple passes.
    ⚠Ensure lash adjusters are fully seated in bores and rocker arms engage valve stems and adjusters properly before installing camshafts.
12. 12

    Reinstall Timing Chains and Set Timing
    Verify crankshaft is still at TDC #1. Install camshaft alignment tools to lock all four cams in position. Install VCT assemblies on camshafts with NEW bolts to specification. Route timing chains over sprockets matching paint marks made during disassembly. Install chain guides. Install timing chain tensioners with NEW gaskets - ensure tensioners are in compressed/locked position before installation, then release. Verify all timing marks align correctly. Remove camshaft locking tools and manually rotate engine two complete revolutions. Recheck timing alignment.
    ⚠️Incorrect timing will cause valve-to-piston contact immediately upon starting. Triple-check all timing marks before proceeding.
13. 13

    Install Front Cover and Accessories
    Install NEW front cover gasket. Apply small bead of RTV sealant at cylinder head-to-block joints. Install timing cover with all bolts to 15 lb-ft (20 Nm). Install crankshaft position sensor with NEW O-ring. Install water pump with NEW gasket. Reinstall A/C compressor and power steering pump to mounting bolt specifications.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

    Sensor Bolts14 Nm (10 lb-ft)

    Mounting Bolts34 Nm (25 lb-ft)
14. 14

    Install Exhaust Manifolds
    Install NEW exhaust manifold gaskets. Apply anti-seize compound to exhaust manifold studs. Install exhaust manifolds and tighten nuts to 22 lb-ft (30 Nm) working from hot center runners to cold outer runners as specified. Connect exhaust Y-pipe to manifolds with NEW gaskets. Reconnect oxygen sensors - apply anti-seize to threads if not pre-applied.
    ℹ️Anti-seize is critical on exhaust fasteners to prevent seizure from heat cycling.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
15. 15

    Install Intake Manifold and Valve Covers
    Install NEW intake manifold gaskets. Position intake manifold and install bolts finger-tight. Torque intake manifold bolts to 18 lb-ft (25 Nm) in proper sequence (center outward pattern). Reconnect all fuel lines, PCV system, and electrical connectors to intake. Install NEW valve cover gaskets in covers. Position valve covers and install bolts finger-tight. Torque valve cover bolts to 7 lb-ft (10 Nm) in proper sequence (outside to inside). Install NEW spark plugs to specification. Install ignition coils and connect all electrical connectors.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Cover Bolts20 Nm (15 lb-ft)
16. 16

    Final Assembly and Fill Fluids
    Install serpentine belt following routing diagram. Reinstall air intake system and engine cover. Install NEW oil filter and fill engine with 7.5 quarts Motorcraft 5W-20 synthetic blend oil. Fill cooling system with 16 quarts Motorcraft Orange coolant - use vacuum fill method if available to eliminate air pockets. If vacuum fill not available, fill and burp system multiple times. Reconnect negative battery cable.
    ⚠Ti-VCT system is very sensitive to air in cooling system. Incomplete bleeding will cause overheating and VCT performance codes.

Reassembly

1. Double-check all electrical connectors, vacuum lines, and hoses are reconnected per photos taken during disassembly
2. Verify all fasteners have been installed and torqued to specification
3. Ensure no tools or rags remain in engine compartment
4. Check that all fluid levels are correct before starting engine

Verification

• Before starting, manually rotate crankshaft two full revolutions by hand to verify no binding or interference
• Prime oil system by cranking engine with fuel pump fuse removed and coil connectors disconnected until oil pressure registers
• Start engine and immediately verify oil pressure. Allow to idle and monitor for unusual noises, leaks, or smoke
• Check for coolant, oil, fuel, and exhaust leaks while engine warms to operating temperature
• Verify cooling fans cycle properly and engine reaches normal operating temperature without overheating
• Check for diagnostic trouble codes - address any VCT timing codes immediately
• After engine cools, recheck all fluid levels and top off as necessary
• Test drive vehicle under light load, then recheck for leaks and proper operation
• After 500 miles, recheck valve cover and intake manifold bolt torque as fasteners may settle

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