Cylinder Head R&R

Complete removal and reinstallation of cylinder heads on the 5.0L Coyote V8 engine, including disassembly of valve train components, gasket replacement, and proper torque sequence reassembly.

Warnings

Tools required

Parts

• Cylinder head gasket set × 2 — Use OEM Ford specification
• Cylinder head bolts (TTY - must replace) × 20 — Use OEM Ford specification
• Valve cover gaskets × 2 — Use OEM Ford specification
• Spark plugs × 8 — Motorcraft SP-515 or equivalent
• Intake manifold gaskets × 1 — Use OEM Ford specification
• Exhaust manifold gaskets × 2 — Use OEM Ford specification
• Coolant temperature sensor O-ring × 1 — Use OEM Ford specification
• Timing chain cover gasket × 1 — Use OEM Ford specification

Fluids

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

Preparation

1. Ensure engine is completely cold (minimum 2 hours after last operation)
2. Disconnect negative battery terminal and wait 10 minutes for airbag system discharge
3. Remove engine cover and air intake assembly
4. Drain cooling system completely into appropriate container by opening radiator petcock and engine block drain plugs
5. Drain engine oil and remove oil filter
6. Support engine from above using engine hoist or support fixture attached to lifting eyes
7. Remove both front wheels if additional access is needed for exhaust work
8. Label and photograph all electrical connectors, vacuum lines, and fuel lines before disconnection

Procedure

1. 1

   Remove intake manifold assembly
   Disconnect throttle body electrical connector and coolant hoses. Remove fuel rail with injectors as an assembly (relieve fuel system pressure first by removing fuel pump fuse and running engine until it stalls). Unbolt intake manifold using proper sequence (reverse of installation torque sequence) and lift away. Keep bolts organized by location.
2. 2

   Remove valve covers
   Disconnect ignition coil connectors and remove all 8 coil-on-plug assemblies. Remove PCV hoses and any breather tubes. Unbolt valve covers and carefully remove. Note position of any wiring harness brackets attached to cover bolts.
   Torque spec

   Cover Bolts20 Nm (15 lb-ft)
3. 3

   Remove exhaust manifolds
   From underneath vehicle, disconnect exhaust Y-pipe from both manifolds. Remove exhaust manifold heat shields. Unbolt exhaust manifolds from cylinder heads, working from center bolts outward to prevent warping. Support manifolds to prevent strain on oxygen sensor wiring.
   ⚠Exhaust studs may break during removal due to corrosion. Have stud extractor tools available.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
4. 4

   Remove timing chain cover and set engine to TDC
   Remove harmonic balancer using puller tool (do not use jaw-type puller that grips outer ring). Remove water pump if necessary for access. Unbolt timing chain cover and carefully remove. Rotate crankshaft to bring cylinder #1 to top dead center (TDC) on compression stroke - timing marks on camshaft sprockets should align with marks on cylinder head. Mark timing chain position relative to sprockets with paint pen.
   ⚠️Do not rotate crankshaft or camshafts independently once timing chain is loosened or removed. This will cause valve-to-piston contact and severe engine damage.
   Torque spec

   Cover Bolts20 Nm (15 lb-ft)
5. 5

   Remove timing chain and camshafts
   Remove timing chain tensioners and guides. Slip timing chain off sprockets while keeping sprockets engaged with camshafts. Remove camshaft position sensor reluctor wheels if present. Gradually loosen camshaft bearing cap bolts in reverse order of torque sequence (outside to inside) in multiple passes to prevent camshaft distortion. Remove bearing caps, keeping them organized by position and orientation. Carefully lift camshafts from cylinder heads, keeping them identified as intake or exhaust, left or right bank.
   ⚠Camshaft bearing caps are NOT interchangeable. Mark each cap with cylinder head position and orientation before removal.
6. 6

   Remove cylinder head bolts
   Remove spark plugs from all cylinders. Loosen cylinder head bolts in reverse order of the tightening sequence (consult Ford service manual for exact sequence - typically starting from outer bolts working inward). Loosen bolts gradually in 3-4 stages to prevent head distortion. Once all bolts are loose, remove them completely and discard - these are torque-to-yield bolts and cannot be reused.
   ⚠️Cylinder head bolts MUST be replaced with new bolts. These are one-time-use torque-to-yield fasteners.
7. 7

   Remove cylinder heads
   Check that all accessories, brackets, and sensors have been removed from cylinder heads. Carefully break cylinder head gasket seal by gently prying at designated pry points only (consult service manual - never pry between gasket surfaces). Lift cylinder heads straight up and off the engine block. Place heads on clean wooden blocks with combustion chambers facing up. Cover cylinder bores immediately with clean shop towels.
   ⚠Do not pry between cylinder head and block mating surfaces. Use only designated pry points to avoid damaging sealing surfaces.
8. 8

   Inspect and clean mating surfaces
   Inspect cylinder head and block mating surfaces for damage, warping, or corrosion. Use straight edge and feeler gauge to check flatness - maximum allowable warpage is 0.003 inches. Carefully remove all gasket material from block and head surfaces using plastic gasket scraper. Clean surfaces thoroughly with brake cleaner and lint-free cloths. Inspect cylinder head bolt holes in block and chase threads if necessary. Ensure bolt holes are clean and dry (oil in blind holes can cause hydraulic lock and cracked block).
9. 9

   Install new cylinder head gaskets and heads
   Verify cylinder head gaskets are correct for left and right banks (they are not interchangeable). Install locating dowels if removed. Position new head gaskets on block - gaskets should drop onto dowel pins and lay flat without force. Do NOT use any sealant on MLS (multi-layer steel) gaskets. Carefully lower cylinder heads onto block, guiding onto dowel pins. Heads should seat fully without forcing.
   ⚠Left and right cylinder head gaskets are different. Verify correct gasket orientation - UP marks must face toward cylinder head.
10. 10

    Install and torque cylinder head bolts
    Lightly oil threads and underside of bolt heads with clean engine oil. Install NEW cylinder head bolts finger-tight in all positions. Following the exact Ford-specified torque sequence: Step 1 - Torque all bolts to 25 lb-ft. Step 2 - Torque all bolts to 45 lb-ft. Step 3 - Rotate all bolts an additional 90 degrees using torque angle gauge. Perform each step completely on all bolts before proceeding to next step. Verify 90-degree rotation by marking bolt heads before rotation.
    ⚠️Cylinder head bolt torque sequence is critical. Follow exact sequence from Ford service manual for this engine. Improper sequence will cause head gasket failure.
    Torque spec

    Cylinder Head Bolts34 Nm (25 lb-ft) + 90°
11. 11

    Reinstall camshafts and timing components
    Lubricate camshaft journals and lobes with assembly lube or clean engine oil. Install camshafts in correct positions (intake/exhaust, left/right bank). Install camshaft bearing caps in exact original positions with orientation marks pointing toward intake side. Torque bearing cap bolts gradually in multiple passes from inside to outside to avoid binding. Install camshaft position sensor reluctor wheels if equipped. Verify camshafts rotate freely. Install timing chain, aligning marks made during disassembly. Install timing chain guides and tensioners.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
12. 12

    Install timing cover and front accessories
    Install new timing cover gasket. Apply small bead of RTV sealant at engine block-to-oil pan sealing surface intersections only. Install timing cover and torque bolts to specification. Reinstall water pump if removed. Install harmonic balancer using installation tool - torque balancer bolt to specification. Verify crankshaft rotates freely through two complete revolutions and recheck timing marks alignment.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)
13. 13

    Reinstall exhaust manifolds
    Install new exhaust manifold gaskets. Position exhaust manifolds and install bolts finger-tight. Torque manifold bolts from center outward in cross pattern to prevent warping. Install heat shields. Reconnect exhaust Y-pipe using new gaskets and hardware.
    Torque spec

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

    Reinstall valve covers and intake manifold
    Install new valve cover gaskets. Install valve covers and torque bolts in sequence from center outward. Reconnect PCV and breather hoses. Install new intake manifold gaskets. Position intake manifold and install bolts finger-tight. Torque intake manifold bolts in proper sequence. Reinstall fuel rail assembly and reconnect fuel lines. Reconnect throttle body and all vacuum lines per labels/photos.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

    Gasket Bolts25 Nm (19 lb-ft)
15. 15

    Install spark plugs and ignition coils
    Install new spark plugs gapped to specification (consult vehicle emission control information label). Torque spark plugs to specification. Install ignition coils and torque mounting bolts. Reconnect all coil electrical connectors.
    Torque spec

    Sensor Bolts14 Nm (10 lb-ft)

Reassembly

1. Reinstall engine cover and air intake assembly
2. Reconnect all sensors, wiring harnesses, and vacuum lines per documentation
3. Reinstall front wheels if removed and torque lug nuts to specification
4. Remove engine support fixture or hoist
5. Reconnect negative battery terminal

Verification

• Fill cooling system with new Motorcraft Orange Coolant to proper level - bleed air from system using bleeder screws
• Fill engine with new 5W-20 synthetic blend oil to proper level with new oil filter
• Perform visual inspection of all connections, bolts, and hoses
• Start engine and verify no coolant, oil, or vacuum leaks while engine warms up
• Check for proper oil pressure within 5 seconds of starting
• Listen for any abnormal noises - ticking, knocking, or rattling may indicate timing or valve train problems
• Allow engine to reach operating temperature and verify cooling fans cycle properly
• Check coolant and oil levels after engine cools and top off if necessary
• Road test vehicle and verify normal operation, smooth acceleration, and no misfires
• Scan for diagnostic trouble codes - there should be no codes related to engine mechanical issues
• Recheck all fluid levels after test drive
• Inspect for leaks after test drive with engine at operating temperature

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