Complete replacement of both cylinder head gaskets on the 5.0L Coyote V8 engine, including removal of intake manifold, valve covers, exhaust manifolds, timing chains, and cylinder heads.

Warnings

Tools required

Parts

• Cylinder head gasket (left) × 1 — Use OEM specification
• Cylinder head gasket (right) × 1 — Use OEM specification
• Cylinder head bolt set (both banks) × 1 — Use OEM - head bolts are torque-to-yield
• Valve cover gaskets (both) × 2 — Use OEM specification
• Intake manifold gaskets (upper and lower) × 1 — Use OEM specification
• Exhaust manifold gaskets (both sides) × 2 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Water pump O-rings × 1 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Spark plugs (set of 8) × 8 — Motorcraft SP-515 or equivalent
• Oil filter × 1 — Motorcraft FL-910-S or equivalent
• RTV silicone sealant (high-temp) × 1 — Motorcraft TA-357 or equivalent

Fluids

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

Preparation

1. Ensure engine is completely cold (minimum 4 hours after last operation)
2. Disconnect negative battery cable and isolate from battery terminal
3. Remove engine cover (plastic cover over engine)
4. Drain engine coolant completely from radiator and engine block drain plugs into appropriate container
5. Drain engine oil and remove oil filter
6. Remove air intake system including air filter housing and intake tube
7. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
8. Disconnect fuel lines from fuel rail (have rags ready for residual fuel)
9. Label and disconnect all vacuum lines, electrical connectors, and hoses attached to intake manifold and cylinder heads
10. Remove serpentine belt and tensioner
11. Support engine with engine support bar across fender rails or attach hoist
12. Remove upper radiator hose and heater hoses
13. Tag all ignition coils for position reference and remove coils and spark plugs from both banks

Procedure

1. 1

   Remove valve covers and accessories
   Remove PCV hoses from both valve covers. Remove valve cover bolts in reverse of tightening sequence (work from outside to center). Carefully lift valve covers off cylinder heads. If covers are stuck, gently tap with rubber mallet - do not pry on mating surfaces. Remove ignition coil bracket assemblies from both sides. Remove coolant crossover tube if equipped.
2. 2

   Remove intake manifold assembly
   Disconnect throttle body electrical connector and coolant hoses. Remove upper intake manifold bolts and lift off upper intake plenum. Disconnect fuel injector electrical connectors (all 8) and fuel rail. Remove fuel rail with injectors as an assembly. Remove lower intake manifold bolts working from outside to inside. Carefully lift lower intake manifold off engine and remove old gaskets. Inspect manifold mating surfaces for damage.
3. 3

   Remove exhaust manifolds
   Raise vehicle and support securely on jack stands. Disconnect exhaust Y-pipe from both exhaust manifolds at the flange (may require penetrating oil on studs). Lower vehicle. From engine bay, remove exhaust manifold heat shields. Remove exhaust manifold nuts working from center outward. Remove both exhaust manifolds and discard old gaskets. Inspect manifold flanges for cracks or warpage.
4. 4

   Remove front timing cover
   Remove power steering pump and set aside without disconnecting lines. Remove A/C compressor mounting bolts and secure compressor aside without disconnecting lines. Remove water pump pulley. Remove crankshaft pulley bolt (use breaker bar - this bolt is very tight, typically 150+ lb-ft). Remove crankshaft pulley. Remove all timing cover bolts (note different length bolts for proper reassembly). Carefully remove timing cover by gently prying at designated pry points. Remove old gasket material and O-rings.
5. 5

   Mark and remove timing chains
   Rotate crankshaft to TDC for cylinder #1 (camshaft lobes for cylinder #1 pointing outward, crankshaft timing mark aligned). Use paint marker or chalk to mark timing chain links at all camshaft sprockets and crankshaft sprocket positions. Take photos for reference. Install camshaft holding tools on both banks to prevent camshaft rotation. Compress timing chain tensioners and lock in place with pins or wire. Remove timing chain tensioner arms. Remove timing chain guides. Remove camshaft sprocket bolts while holding camshafts with holding tool. Remove both timing chains and camshaft sprockets as assemblies. Mark left and right chains to prevent mixing.
6. 6

   Remove camshaft bearing caps
   With camshafts secured by holding tool, loosen camshaft bearing cap bolts in reverse sequence (outside to inside, in multiple passes to prevent warping). Remove camshaft bearing caps and keep in order - they are numbered and position-specific. Carefully lift camshafts from cylinder heads (4 total - 2 per head). Place camshafts on clean surface and mark intake/exhaust and left/right bank. Inspect camshaft lobes and journals for wear or damage.
7. 7

   Remove cylinder head bolts and heads
   Loosen cylinder head bolts in reverse of tightening sequence (work from outside to center in multiple passes). Remove all cylinder head bolts and discard - these are torque-to-yield and must not be reused. Carefully break cylinder head loose from block using plastic pry points (do not pry on mating surfaces). Lift cylinder head straight up to avoid damaging head gasket surface or alignment dowels. Place heads on clean padded surface with combustion chambers facing up. Remove and discard old head gaskets. Repeat for second cylinder head.
8. 8

   Clean and inspect all mating surfaces
   Using plastic gasket scraper (never metal), carefully remove all old gasket material from cylinder block deck surfaces and cylinder head mating surfaces. Clean surfaces with brake cleaner or degreaser and lint-free cloths. Inspect cylinder head mating surfaces with straightedge and feeler gauge - maximum allowable warpage is 0.003 inches. Check for cracks in combustion chambers and coolant passages. Inspect block deck surface similarly. Verify cylinder head alignment dowels are present and not damaged (2 per head location). Clean all bolt holes in block with brake cleaner and compressed air - any oil or debris will affect torque readings.
9. 9

   Install new head gaskets and cylinder heads
   Install new cylinder head gaskets on block, ensuring proper orientation (gaskets are marked 'TOP' and 'FRONT'). Verify gasket alignment dowels engage properly. Do NOT use any sealant on head gaskets. Carefully lower cylinder heads onto block, aligning with dowel pins. Ensure heads are fully seated before installing bolts. Install new cylinder head bolts (finger tight only at this stage). Verify all bolts are started properly before torquing.
10. 10

    Torque cylinder head bolts to specification
    Using proper torque sequence (consult service manual diagram - typically starting at center and working outward in spiral pattern), torque cylinder head bolts in three stages: Step 1 - torque all bolts to 25 lb-ft. Step 2 - torque all bolts to 45 lb-ft in same sequence. Step 3 - rotate all bolts an additional 90 degrees using angle gauge in same sequence. Verify all bolts have been torqued in all three steps. Repeat entire sequence for second cylinder head.
    Torque spec

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

    Install camshafts and bearing caps
    Lubricate camshaft journals and lobes with clean engine oil. Install camshafts in correct positions (intake and exhaust are different, verify timing marks). Ensure camshafts are positioned with lobes for cylinder #1 pointing outward. Lubricate bearing cap journals. Install bearing caps in correct numbered positions and orientation. Install camshaft bearing cap bolts and torque in sequence from center outward to 15 lb-ft (20 Nm). Verify camshafts rotate freely by hand. Install camshaft holding tools to lock camshafts in position.
    Torque spec

    Camshaft Cap Bolts20 Nm (15 lb-ft)
12. 12

    Install timing chains and components
    Verify crankshaft is still at TDC position. Install camshaft sprockets onto camshafts with timing marks visible. Install timing chains onto crankshaft sprocket first, then route over camshaft sprockets, aligning painted links with timing marks (marks should align exactly as photographed during disassembly). Install camshaft sprocket bolts and torque while holding camshafts with holding tool. Install timing chain guides. Install timing chain tensioner arms. Release and remove tensioner locking pins to tension chains. Remove camshaft holding tools and rotate engine two full revolutions by hand. Verify all timing marks realign at TDC - if not, timing is incorrect and must be corrected before proceeding.
13. 13

    Install timing cover and front accessories
    Install new timing cover gasket and O-rings (apply small amount of RTV at block-to-oil pan junction points as specified in service manual). Install timing cover and bolts, tightening in crisscross pattern. Install crankshaft pulley and torque bolt to specification (typically 150+ lb-ft - verify in service manual). Install water pump pulley. Reinstall A/C compressor and power steering pump to mounting brackets.
14. 14

    Install exhaust manifolds
    Install new exhaust manifold gaskets on cylinder heads. Position exhaust manifolds and install new nuts finger tight. Torque exhaust manifold nuts to 31 lb-ft (42 Nm) working from center outward in crisscross pattern. Install exhaust manifold heat shields. Raise vehicle and reconnect exhaust Y-pipe to manifold flanges with new gaskets and hardware.
    Torque spec

    Exhaust Manifold Nuts42 Nm (31 lb-ft)
15. 15

    Install intake manifold assembly
    Install new lower intake manifold gaskets (verify proper orientation and alignment with ports). Position lower intake manifold and install bolts finger tight. Torque intake manifold bolts to 23 lb-ft (31 Nm) in sequence from center outward. Install fuel rail with injectors, ensuring injectors seat properly in manifold. Connect fuel injector electrical connectors. Install new upper intake manifold gaskets. Position upper intake plenum and torque bolts to specification. Reconnect throttle body electrical connector and coolant hoses.
    Torque spec

    Intake Manifold Bolts31 Nm (23 lb-ft)
16. 16

    Install valve covers and final components
    Install new valve cover gaskets in valve cover grooves (use small dabs of RTV to hold in place if needed). Position valve covers on cylinder heads. Install valve cover bolts and torque in sequence from center outward to 13 lb-ft (17 Nm). Do not overtighten as this will distort covers and cause leaks. Install PCV hoses. Install new spark plugs and torque to specification. Install ignition coils in correct positions and connect electrical connectors. Reinstall ignition coil brackets.
    Torque spec

    Valve Cover Bolts17 Nm (13 lb-ft)

Reassembly

1. Reconnect all vacuum lines, electrical connectors, and hoses per reference photos taken during disassembly
2. Install serpentine belt on all pulleys and tensioner per belt routing diagram on fan shroud
3. Reconnect fuel lines to fuel rail and secure with clips
4. Install new oil filter and refill engine with 7.5 quarts of Motorcraft 5W-20 oil
5. Refill cooling system with 16 quarts of Motorcraft Orange Coolant (50/50 premix or diluted concentrate)
6. Reinstall air intake system and air filter housing
7. Reinstall engine cover
8. Reconnect negative battery cable
9. Reinstall fuel pump fuse

Verification

• Before starting engine, rotate crankshaft by hand two complete revolutions to verify no binding or interference
• Double-check that all electrical connectors, vacuum lines, and hoses are reconnected
• Verify all tools have been removed from engine bay
• Check that all fluids are at proper levels (oil dipstick and coolant reservoir)
• Prime fuel system by turning ignition to ON position (not start) 3-4 times, waiting 10 seconds between cycles
• Start engine and immediately check for any fluid leaks (oil, coolant, fuel)
• Allow engine to reach operating temperature while monitoring for leaks and unusual noises
• Bleed cooling system by running engine with heat on full, adding coolant as level drops, until thermostat opens and air is purged
• Check for proper engine idle and throttle response
• Test drive vehicle and monitor engine temperature gauge, check engine light, and performance
• After initial test drive, allow engine to cool and recheck all fluid levels
• Recheck valve cover and intake manifold areas for any signs of leakage after first heat cycle
• Monitor for any coolant or oil consumption over first 100 miles of operation

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