This procedure covers the removal and replacement of a single cylinder head gasket on the 2011-2014 Ford F-150 5.0L Coyote V8 engine, including disassembly of intake manifold, exhaust manifolds, timing components, and valve train.

Warnings

Tools required

Parts

• Cylinder head gasket (specify left or right bank) × 1 — Motorcraft or OEM Ford
• Cylinder head bolts (set) × 1 — Ford OEM - TTY bolts, do not reuse
• Valve cover gasket × 1 — Use OEM specification
• Intake manifold gaskets (upper and lower) × 1 — Use OEM specification
• Exhaust manifold gaskets × 1 — Use OEM specification
• Thermostat housing gasket/O-ring × 1 — Use OEM specification
• Coolant hose clamps (assorted) × 1 — Replace any damaged clamps
• Spark plugs × 4 — Motorcraft SP-534 or equivalent
• Timing chain tensioner seals × 1 — Use OEM specification
• VVT solenoid O-rings × 1 — Use OEM specification
• Engine oil and filter × 1 — Motorcraft FL-910S filter

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake. Chock rear wheels.
2. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge.
3. Remove engine cover by pulling upward on front clips.
4. Relieve fuel system pressure: remove fuel pump fuse, start engine and let it stall, then crank for 5 seconds.
5. Drain engine coolant completely from radiator petcock and engine block drain plugs into appropriate container.
6. Drain engine oil and remove oil filter.
7. Remove air intake system from air box to throttle body.
8. Label and photograph all vacuum lines, electrical connectors, and hose routing for reference during reassembly.
9. Support engine using engine hoist or support fixture from above to take load off motor mounts if working on passenger side.

Procedure

1. 1

   Remove upper intake manifold
   Disconnect throttle body electrical connector and all vacuum lines from upper intake manifold. Remove PCV hoses from both valve covers. Remove the 8 upper intake manifold bolts and carefully lift manifold away. Inspect lower intake gaskets and set upper manifold aside on clean surface.
2. 2

   Remove lower intake manifold
   Disconnect fuel rail lines using spring-lock coupling tools. Disconnect all fuel injector electrical connectors. Remove fuel rail mounting bolts and carefully lift fuel rail with injectors as an assembly. Remove the 8 lower intake manifold bolts and carefully remove manifold. Clean all gasket surfaces thoroughly with plastic scraper.
   ⚠Fuel injectors are fragile. Do not damage injector tips or electrical connectors during removal.
3. 3

   Remove valve cover and ignition coils
   Disconnect ignition coil electrical connectors on the affected bank. Remove coil hold-down bolts and extract coils with gentle twisting motion. Remove valve cover bolts in reverse of tightening sequence and carefully remove valve cover. Remove spark plugs from affected bank using spark plug socket and extensions.
4. 4

   Remove exhaust manifold
   For passenger side: unbolt and lower exhaust Y-pipe from both manifolds. For driver side: may require removal of steering shaft and better access from below. Remove oxygen sensor connectors. Remove exhaust manifold heat shield. Remove all exhaust manifold nuts and carefully remove manifold. Inspect studs for damage.
   ℹ️Exhaust studs may break due to corrosion. Have extraction tools ready if needed.
5. 5

   Remove accessory drive components
   Remove serpentine belt using tensioner release tool. If working on passenger side, remove alternator and bracket. If working on driver side, remove power steering pump and set aside without disconnecting hydraulic lines. Remove accessory drive belt idler pulleys as needed for access.
6. 6

   Remove timing chain cover access and components
   Remove crankshaft pulley bolt using breaker bar (engine must be prevented from rotating). Remove harmonic balancer using puller tool. Remove the timing chain cover bolts that interfere with head removal (may not need full cover removal). Remove water pump if necessary for clearance.
   ⚠Do not use impact wrench on crankshaft bolt as this can damage crankshaft sensor reluctor ring.
7. 7

   Position engine at TDC and secure timing components
   Rotate crankshaft to Top Dead Center (TDC) on cylinder #1 compression stroke. Verify timing marks align on camshaft sprockets and crankshaft. Install camshaft holding tool (Ford 303-1248) to lock camshafts in position. Mark timing chain to sprocket positions with paint pen for reference.
   ⚠️Engine MUST be at TDC and camshafts locked before proceeding. Failure to do so will result in valve damage when head is removed.
8. 8

   Remove timing chain tensioners and guides
   Compress timing chain tensioner using appropriate tool and lock it in compressed position with pin or paper clip. Remove tensioner mounting bolts. Remove timing chain guides (both fixed and pivoting) from affected bank. Keep all timing components organized and clean.
9. 9

   Remove VVT components and camshaft caps
   Remove Variable Valve Timing (VVT) solenoids from affected bank. Remove VVT sprocket bolts while holding camshafts with holding tool. Carefully remove VVT sprockets and timing chain from camshafts, supporting chain with wire to prevent falling into engine. Remove camshaft cap bolts in reverse sequence (from outside to inside) and carefully lift camshafts out. Store camshafts on clean surface with lobes facing up.
   ⚠Camshaft caps are position-specific and must be reinstalled in exact same location. Mark each cap with its position before removal.
10. 10

    Remove cylinder head bolts
    Remove cylinder head bolts in reverse of tightening sequence (work from outside to inside in stages). Loosen each bolt 1/4 turn at a time in sequence to prevent warping. Once all bolts are loose, remove them completely. Note that these TTY bolts cannot be reused and must be discarded.
    ⚠Do not attempt to remove head bolts in random order. Uneven loosening can warp the cylinder head.
11. 11

    Remove cylinder head
    Carefully break cylinder head seal using plastic pry bars at designated pry points (never between gasket surfaces). Lift cylinder head straight up to avoid damaging block surface. Place head on clean wooden blocks with combustion chambers facing up. Remove and discard old head gasket. Inspect cylinder head mating surface for damage, warpage, or cracks.
    ⚠Cylinder head weighs approximately 50 lbs. Use assistance or proper lifting equipment to prevent injury or dropping the head.
12. 12

    Clean and inspect surfaces
    Thoroughly clean cylinder head and engine block mating surfaces using plastic gasket scraper. Remove all old gasket material and ensure surfaces are completely clean and dry. Use brake cleaner on rag for final cleaning. Check cylinder head for warpage using precision straightedge and feeler gauge. Maximum allowable warpage is 0.003 inches. If exceeds specification, head must be professionally machined. Cover open cylinders with clean shop towels to prevent debris entry.
    ℹ️Do not use metal scrapers on aluminum surfaces. This can cause scratches that will prevent proper gasket seal.
13. 13

    Install new head gasket and cylinder head
    Verify engine block surface is clean and dry. Install new head gasket on block, ensuring correct orientation (gasket will only fit one way, with alignment dowels). Verify all coolant and oil passages align correctly. Carefully lower cylinder head onto block, aligning with dowel pins. Ensure head seats fully on gasket before installing bolts.
    ⚠Head gasket is NOT interchangeable between banks. Verify you have correct gasket for left or right bank before installation.
14. 14

    Install and torque cylinder head bolts
    Install all NEW cylinder head bolts hand-tight following tightening sequence (start from center, work outward in spiral pattern). Using torque wrench, tighten all bolts to 25 lb-ft following sequence. Then tighten all bolts to 45 lb-ft following same sequence. Finally, using torque angle gauge, rotate each bolt an additional 90 degrees following sequence. Verify all bolts have been properly torqued.
    ⚠️Use ONLY new cylinder head bolts. Old TTY bolts will fail and cause catastrophic engine damage.
    Torque spec

    Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
15. 15

    Install camshafts and timing components
    Lubricate camshaft journals and lobes with clean engine oil. Install camshafts into cylinder head in correct positions (intake and exhaust are different). Install camshaft caps in their original positions with markings facing forward. Tighten camshaft cap bolts to specification following sequence from center caps outward. Install VVT sprockets and timing chain in correct positions according to timing marks made during disassembly. Install new VVT solenoid O-rings and reinstall solenoids. Install timing chain tensioners and guides. Remove camshaft holding tool and verify timing marks still align.
    ⚠Double-check timing chain alignment before proceeding. Incorrect timing will cause immediate engine damage on startup.
16. 16

    Install exhaust manifold and remaining components
    Install new exhaust manifold gasket. Position exhaust manifold and install all nuts hand-tight. Torque exhaust manifold nuts to specification in center-outward sequence. Install valve cover with new gasket, torquing bolts to specification in proper sequence. Install spark plugs and torque to specification. Install ignition coils. Reinstall all accessory components, water pump, timing cover, harmonic balancer, and crankshaft pulley in reverse order of removal.
    Torque spec

    Exhaust Manifold Nuts25 Nm (18 lb-ft)
17. 17

    Install intake manifolds and fuel system
    Install lower intake manifold with new gaskets. Torque lower intake manifold bolts to specification in proper sequence (center outward). Install fuel rail and injector assembly. Reconnect all fuel injector connectors and fuel lines. Install upper intake manifold with new gaskets and torque bolts to specification. Reconnect all vacuum lines, PCV hoses, and throttle body connections according to reference photos.
    Torque spec

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

    Refill fluids and final checks
    Install new oil filter and refill engine with 7.5 quarts of Motorcraft 5W-20 synthetic blend oil. Refill cooling system with 16 quarts of Motorcraft Orange coolant (may require multiple fill/bleed cycles). Reconnect battery. Before starting engine, manually rotate crankshaft two complete revolutions to verify no interference. Check that oil pressure is present before cranking (use scan tool if available). Double-check all connections, bolts, and hose clamps.

Reassembly

1. Reassembly is covered in the procedure steps above, following reverse order of disassembly with new gaskets and specified torque values.
2. Pay special attention to timing chain alignment and camshaft positioning - verify TDC alignment before final assembly.
3. All torque specifications must be followed exactly, particularly cylinder head bolts which use torque-to-yield procedure.
4. Ensure all electrical connectors, vacuum lines, and coolant hoses are properly reconnected per original routing.

Verification

• With engine cold, start engine and verify it runs smoothly without unusual noises, misfires, or rough idle.
• Check for coolant, oil, and fuel leaks around all disturbed components, particularly head gasket area, valve cover, intake manifold, and exhaust manifold.
• Allow engine to reach operating temperature while monitoring coolant level. Bleed cooling system as necessary using bleeder valves or vacuum fill method.
• Verify no coolant is entering combustion chambers (white smoke from exhaust) and no oil contamination in coolant or vice versa.
• Check for proper oil pressure using gauge or scan tool - should be 40-70 PSI at operating temperature and idle.
• Perform a test drive to verify proper engine performance, smooth acceleration, and no warning lights.
• After test drive and cool-down, recheck all fluid levels and inspect again for any leaks.
• After 500 miles, inspect valve cover bolts and intake manifold bolts for proper torque retention (may require slight retightening).

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