Cylinder Head Resurface

This procedure covers removing, resurfacing, and reinstalling cylinder heads on the 2015-2020 Ford F-150 5.0L Coyote V8 engine, including valve train disassembly and timing component removal.

Warnings

Tools required

Parts

• Cylinder head gaskets (left and right) × 2 — Use OEM Ford specification
• Cylinder head bolts (TTY) × 20 — Use OEM Ford specification
• Valve cover gaskets × 2 — Use OEM Ford specification
• Intake manifold gaskets × 1 — Use OEM Ford specification
• Exhaust manifold gaskets × 2 — Use OEM Ford specification
• Timing cover gasket × 1 — Use OEM Ford specification
• VCT solenoid O-rings × 4 — Use OEM Ford specification
• Coolant temperature sensor O-ring × 1 — Use OEM Ford specification
• Anti-seize compound × 1 — Use nickel-based high-temp

Fluids

• Motorcraft 0W-20 Full Synthetic engine oil — 7.5 qt
• Motorcraft Orange Coolant — 16 qt

Preparation

1. Ensure engine is completely cool (minimum 4 hours after last operation)
2. Disconnect negative battery cable and isolate
3. Remove engine cover and air intake system completely
4. Drain engine coolant into appropriate container and dispose properly
5. Drain engine oil and remove oil filter
6. Remove radiator upper hose and heater hoses from engine
7. Take photos of all electrical connections, vacuum lines, and routing before disassembly
8. Label all electrical connectors with their locations for reassembly
9. Support engine with hoist or fixture to prevent movement during work
10. Create a clean, organized workspace for cylinder head storage during machining

Procedure

1. 1

   Remove valve covers and accessory components
   Disconnect all electrical connectors from ignition coils and VCT solenoids. Remove ignition coils and spark plugs, keeping them in order. Remove valve covers by loosening bolts in reverse of tightening sequence (outside to inside pattern). Disconnect PCV hoses and any remaining vacuum lines attached to valve covers. Remove accessory drive belt and alternator.
2. 2

   Remove intake manifold assembly
   Disconnect throttle body electrical connector and all fuel injector connectors. Relieve fuel system pressure using the fuel rail Schrader valve. Disconnect fuel supply line from fuel rail. Remove intake manifold bolts in reverse sequence (outside to inside). Carefully lift intake manifold assembly off engine, removing any remaining vacuum lines or breather hoses. Check for and remove any coolant crossover tubes.
   ⚠️Fuel system is under high pressure. Relieve pressure completely before disconnecting fuel lines. Have fire extinguisher nearby.
3. 3

   Remove exhaust manifolds
   Disconnect oxygen sensor electrical connectors on both banks. Unbolt exhaust pipes from manifold flanges. Remove exhaust manifold nuts working from the hottest center area toward the cooler outer bolts (hot-to-cold sequence). Remove both exhaust manifolds and gaskets. Inspect manifold studs for damage.
4. 4

   Remove timing chain cover
   Remove crankshaft pulley and harmonic balancer using appropriate puller tool. Remove water pump if necessary for access. Remove all timing cover bolts, noting different lengths and locations. Carefully separate timing cover from engine block, breaking RTV seal if present. Remove timing cover gasket.
5. 5

   Lock timing chain position and mark timing
   Rotate engine to TDC on cylinder #1 (compression stroke) by aligning crankshaft and camshaft timing marks. Use permanent marker to mark timing chain links at all camshaft sprocket timing marks and crankshaft sprocket mark. Take detailed photos of timing chain position. Install camshaft holding tools on all four camshafts to prevent rotation.
   ⚠Accurate timing marks are critical. Mark chain-to-sprocket relationship on all four camshaft sprockets and the crankshaft sprocket before proceeding.
6. 6

   Remove timing chains and camshafts
   Compress timing chain tensioners using appropriate tool and lock in compressed position. Remove timing chain tensioner arms and guides. Carefully remove both timing chains, keeping them organized by bank. Note: VCT units (Variable Cam Timing) are integrated with camshaft sprockets. Remove VCT solenoids. Remove camshaft bearing cap bolts in reverse sequence (outside to inside, multiple passes). Carefully lift out all four camshafts, keeping them identified by position (left/right, intake/exhaust). Store camshafts on clean surface where lobes won't be damaged.
   ⚠Camshaft bearing caps must be reinstalled in exact original positions. Mark each cap with permanent marker before removal.
7. 7

   Remove rocker arms and lash adjusters
   Remove all rocker arms, keeping them in order by cylinder and position (intake/exhaust). Remove hydraulic lash adjusters from cylinder head bores. Store all components in organized container maintaining position identification. Inspect rocker arms and lash adjusters for wear or damage.
8. 8

   Remove cylinder heads
   Remove any remaining coolant temperature sensors, VCT solenoids, or other components from cylinder heads. Remove cylinder head bolts in reverse of tightening sequence (outside to inside pattern) in multiple passes. Use hoist or assistant to carefully lift cylinder heads off engine block. Place heads on clean work surface with combustion chambers facing up. Remove and discard old head gaskets. Inspect block surface for damage.
9. 9

   Inspect and prepare heads for machining
   Use straight edge and feeler gauges to check cylinder head deck surface for warpage. Check multiple directions (lengthwise, crosswise, and diagonally). Warpage exceeding 0.003 inches requires resurfacing. Transport cylinder heads to qualified machine shop for resurfacing. Provide specifications: Ford Coyote 5.0L heads, maximum material removal 0.010 inches total, maintain valve seat geometry. Machine shop should also perform valve seat inspection, pressure test for cracks, and thorough cleaning.
   ℹ️Excessive resurfacing will affect compression ratio and may require thicker head gaskets. Consult with machine shop on total material removal limits.
10. 10

    Clean engine block mating surfaces
    While heads are at machine shop, thoroughly clean engine block deck surfaces using plastic gasket scraper. Remove all old gasket material without scratching aluminum surface. Clean oil passages and bolt holes with brake cleaner. Blow out bolt holes with compressed air to remove any coolant or oil. Inspect block deck surface for damage or warpage. Cover exposed cylinders with clean shop towels to prevent debris from falling into engine.
11. 11

    Install resurfaced cylinder heads
    Retrieve cylinder heads from machine shop and inspect resurfacing work. Ensure all surfaces are clean and dry. Install new head gaskets on block, ensuring correct orientation (UP marks facing up, FRONT toward front of engine). Carefully position cylinder heads onto block, aligning dowel pins. Install NEW cylinder head bolts (TTY bolts must never be reused) hand-tight initially. Following Ford tightening sequence (consult service manual diagram), torque all head bolts to 48 ft-lb in multiple passes. Then tighten all bolts an additional 90 degrees using angle gauge. Finally, tighten all bolts an additional 90 degrees (total 180 degrees beyond torque).
    ⚠️Using old TTY head bolts will result in improper clamping force and likely head gasket failure or catastrophic engine damage. Always use new bolts.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
12. 12

    Reinstall valve train components
    Lubricate hydraulic lash adjusters with fresh engine oil and install in original positions. Install rocker arms in original positions, ensuring they properly seat on valve stems and lash adjusters. Lubricate camshaft journals and lobes with assembly lube or fresh engine oil. Carefully install camshafts in original positions (note: intake and exhaust cams are different). Install camshaft bearing caps in original positions and orientation. Torque bearing cap bolts in proper sequence (inside to outside pattern) gradually in multiple passes per Ford specification.
13. 13

    Reinstall timing chains with precise alignment
    Install crankshaft sprocket if removed. Position both timing chains on crankshaft sprocket aligned with marked links. Rotate each camshaft to TDC position using holding tools. Install timing chains onto camshaft VCT sprockets, ensuring marked chain links align precisely with sprocket timing marks. Double-check all four camshaft sprocket alignments and crankshaft alignment with marks made during disassembly. Install timing chain guides and tensioner arms. Release timing chain tensioners. Rotate engine two complete revolutions by hand and recheck all timing marks align correctly.
    ⚠Incorrect timing chain installation will cause immediate engine damage upon startup. Verify timing marks three times before proceeding.
14. 14

    Install timing cover and front accessories
    Clean timing cover mating surfaces thoroughly. Install new timing cover gasket or apply RTV sealant per Ford specification. Install timing cover and torque bolts to specification in sequence. Install water pump with new gasket if removed. Install harmonic balancer and crankshaft pulley, torquing to specification. Install accessory drive belt.
    Torque spec

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

    Install exhaust manifolds
    Install new exhaust manifold gaskets. Apply anti-seize compound to exhaust manifold studs. Position exhaust manifolds and install nuts hand-tight. Torque exhaust manifold nuts to 22 ft-lb working from center (hot) to outer (cold) bolts. Reconnect exhaust pipes to manifold flanges. Reconnect oxygen sensor electrical connectors.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
16. 16

    Install intake manifold
    Install new intake manifold gaskets, ensuring proper orientation and alignment with coolant passages. Position intake manifold assembly onto cylinder heads. Install intake manifold bolts and torque to 18 ft-lb in proper sequence (inside to outside pattern). Reconnect all fuel injector connectors and throttle body connector. Connect fuel supply line to fuel rail. Reconnect all vacuum lines and breather hoses to original positions using photos taken during disassembly.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
17. 17

    Install valve covers and ignition components
    Install new valve cover gaskets onto valve covers. Ensure VCT solenoid O-rings are replaced. Position valve covers onto cylinder heads. Install valve cover bolts and torque to 7 ft-lb in proper sequence (inside to outside pattern). Install spark plugs torqued to specification. Install ignition coils in original positions and reconnect electrical connectors. Reconnect PCV hoses and any remaining connections.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

Reassembly

1. Reinstall all coolant hoses, heater hoses, and radiator connections
2. Fill cooling system with 16 quarts of Motorcraft Orange Coolant using proper bleeding procedure to remove air pockets
3. Install new oil filter and fill engine with 7.5 quarts of Motorcraft 0W-20 Full Synthetic oil
4. Reconnect negative battery cable
5. Double-check all electrical connectors, hoses, and fasteners are properly secured
6. Check that no tools or rags remain in engine compartment

Verification

• Prime oil system by cranking engine for 5-10 seconds without starting (disable fuel or ignition)
• Start engine and immediately check for oil pressure on gauge - should register within 3-5 seconds
• Check for any coolant, oil, or vacuum leaks while engine idles
• Listen for any unusual valve train noise - slight ticking for first 30 seconds is normal as lash adjusters pump up
• Allow engine to reach operating temperature and verify cooling fans cycle properly
• Check for exhaust leaks at manifold gaskets
• Perform several gentle acceleration cycles to verify smooth operation and no misfires
• Recheck coolant level after engine cools - top off as needed
• Check engine oil level and top off as needed
• Monitor for any fault codes using scan tool - clear any codes related to battery disconnect
• Road test vehicle under various loads to verify proper performance and no overheating
• Recheck all fluid levels after test drive and inspect for any leaks
• After 500 miles, recheck valve cover bolt torque and inspect for any oil seepage

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