Cylinder Head R&R

This procedure covers the removal and reinstallation of one or both cylinder heads on the 2015-2020 Ford F-150 5.0L Coyote V8 engine, including timing chain access and head gasket replacement.

Warnings

Tools required

Parts

• Cylinder head gasket(s) × 2 — Use OEM specification
• Cylinder head bolts (set) × 1 — TTY bolts - replace every time
• Valve cover gaskets × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Water pump gasket × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Spark plugs × 8 — Motorcraft SP-546 or equivalent
• Engine oil and filter × 1 — 0W-20 synthetic
• Coolant × 1 — Motorcraft Orange

Fluids

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

Preparation

1. Ensure engine is completely cool and vehicle is on level ground with parking brake applied
2. Disconnect negative battery cable and wait 10 minutes for airbag system capacitors to discharge
3. Remove engine cover and air intake system completely
4. Drain engine coolant completely from radiator petcock and engine block drain plugs into appropriate container
5. Drain engine oil and remove oil filter
6. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
7. Remove radiator, cooling fans, and upper/lower radiator hoses for access
8. Support engine from above using engine hoist or support fixture attached to lifting eyes
9. Label all electrical connectors, vacuum lines, and hoses with tape for reassembly reference
10. Take photos of routing for ignition coils, fuel lines, and accessory brackets before removal

Procedure

1. 1

   Remove accessory drive components
   Remove serpentine belt by rotating tensioner clockwise. Remove alternator, A/C compressor (do not disconnect refrigerant lines - support aside), and power steering pump (electric so no lines). Remove accessory bracket mounting bolts and set brackets aside.
   Torque spec

   Mounting Bolts60 Nm (44 lb-ft)
2. 2

   Remove valve covers and ignition components
   Disconnect all ignition coil electrical connectors. Remove ignition coil mounting bolts and pull coils straight up from spark plug tubes. Remove valve cover bolts in reverse of tightening pattern (outside-to-inside). Carefully lift valve covers off, breaking gasket seal with plastic pry tool if necessary. Remove and inspect spark plugs.
   Torque spec

   Cover Bolts20 Nm (15 lb-ft)

   Electrical Connector Bolts8 Nm (6 lb-ft)
3. 3

   Remove timing chain cover
   Remove crankshaft pulley center bolt (requires 21mm socket and significant force - may need impact). Use harmonic balancer puller to remove crankshaft pulley. Remove all timing cover bolts (various sizes - keep organized). Carefully pry timing cover off using designated pry points only. Clean all old gasket material from timing cover and block mating surfaces.
   ⚠Crankshaft pulley bolt is very tight (approximately 148 lb-ft). Use proper pulley holding tool or have assistant apply brakes in gear
   Torque spec

   Cover Bolts20 Nm (15 lb-ft)

   Gasket Surface Bolts26 Nm (19 lb-ft)
4. 4

   Lock timing and remove timing chains
   Rotate crankshaft to TDC on cylinder #1 (both camshaft timing marks aligned with their corresponding marks on timing chain guides). Install camshaft locking tools to prevent rotation. Mark timing chain-to-sprocket relationship with paint pen. Remove timing chain tensioners by compressing and locking with pins. Remove timing chain guides. Carefully remove both primary and secondary timing chains with sprockets.
   ⚠️Do not rotate crankshaft or camshafts independently once timing chains are removed. Engine damage will occur
   Torque spec

   Mounting Bolts60 Nm (44 lb-ft)
5. 5

   Disconnect exhaust manifolds
   From underneath vehicle, spray exhaust manifold flange bolts with penetrating oil and allow to soak. Disconnect oxygen sensors electrical connectors. Remove exhaust manifold-to-exhaust pipe flange nuts (14mm) on both sides. Support exhaust pipes and lower away from manifolds. Remove exhaust manifold heat shields if equipped.
   Torque spec

   Sensor Bolts14 Nm (10 lb-ft)
6. 6

   Remove intake manifold
   Disconnect all fuel injector electrical connectors, throttle body connector, and intake manifold sensors. Remove fuel rail mounting bolts and carefully lift fuel rail with injectors attached - set aside safely. Disconnect brake booster vacuum line, PCV hoses, and any remaining vacuum connections. Remove intake manifold mounting bolts in reverse of tightening sequence (outside-to-inside). Lift intake manifold off carefully.
   Torque spec

   Gasket Bolts25 Nm (19 lb-ft)

   Electrical Connector Bolts8 Nm (6 lb-ft)
7. 7

   Remove exhaust manifolds from heads
   With heads still on engine, remove exhaust manifold-to-cylinder head mounting bolts (8 bolts per manifold). Work from center outward to prevent warping. Remove exhaust manifolds and set aside. This provides necessary clearance for head removal and allows manifold stud inspection.
   Torque spec

   Gasket Bolts25 Nm (19 lb-ft)
8. 8

   Remove cylinder head bolts and heads
   Remove all remaining cylinder head external components (coolant crossover tube, temperature sensors, camshaft position sensors). Loosen cylinder head bolts in reverse of tightening sequence (outside-to-inside spiral pattern) in multiple passes, 1/4 turn at a time. Once all bolts are loose, remove completely. Heads have 10 bolts each. Use pry points only at designated locations to break gasket seal. Lift cylinder heads straight up off block. Do not pry between head and block gasket surfaces.
   ⚠Cylinder heads are heavy (approximately 50 lbs each). Use proper lifting technique or get assistance to prevent injury or dropping the head
   Torque spec

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

   Mounting Bolts60 Nm (44 lb-ft)
9. 9

   Clean and inspect mating surfaces
   Place heads on clean workbench with combustion chambers facing up. Use plastic gasket scraper to carefully remove all old gasket material from cylinder head deck surfaces and engine block deck. Do not gouge or scratch surfaces. Clean surfaces with brake cleaner and lint-free towels. Inspect for warpage using precision straightedge and feeler gauges - maximum allowable warp is 0.003 inches. Check block deck for flatness as well. Inspect for cracks using dye penetrant if available.
   ⚠Use only plastic scrapers on aluminum surfaces. Metal scrapers will damage the soft aluminum and ruin sealing surfaces
   Torque spec

   Gasket Surface Bolts26 Nm (19 lb-ft)
10. 10

    Install new head gaskets and position heads
    Verify block deck and head surfaces are completely clean and dry. Install new head gaskets onto block with orientation marks facing up (usually marked 'TOP' or 'FRONT'). Verify locating dowels are in place. Do not use any sealant on multi-layer steel head gaskets. Carefully lower cylinder heads onto block, aligning with dowel pins. Heads must seat fully on gaskets without gaps.
11. 11

    Install and torque cylinder head bolts
    Lightly oil new cylinder head bolt threads and underside of bolt heads with clean engine oil. Install all head bolts finger-tight. Using torque wrench, tighten all bolts to 25 lb-ft following the spiral pattern from center outward as specified in service manual. Then tighten all bolts to 45 lb-ft in same sequence. Finally, using angle gauge, rotate each bolt an additional 90 degrees in same sequence. Verify all bolts have been angle-torqued.
    ⚠️Head bolt tightening sequence is critical. Refer to Ford service manual for exact pattern diagram. Incorrect sequence will warp heads and cause head gasket failure
    ℹ️Step 1: 25 lb-ft, Step 2: 45 lb-ft, Step 3: additional 90 degrees rotation. All steps use same tightening sequence
    Torque spec

    Cylinder Head Bolts34 Nm (25 lb-ft) + 90°
12. 12

    Reinstall timing chains and components
    With camshaft locking tools still in place and crankshaft at TDC, install timing chain guides and tighten bolts. Install timing chains over sprockets aligning marks made during disassembly (or per service manual timing marks). Install timing chain tensioners - remove locking pins to tension chains. Verify all timing marks are correctly aligned. Remove camshaft locking tools and rotate engine 2 complete revolutions by hand (clockwise only). Re-check timing marks - they must realign at TDC.
    ⚠️Incorrect timing chain installation will cause severe engine damage when started. Triple-check timing mark alignment before proceeding
    Torque spec

    Mounting Bolts60 Nm (44 lb-ft)
13. 13

    Reinstall timing cover and front accessories
    Install new timing cover gasket. Position timing cover carefully ensuring proper alignment with dowel pins. Install all timing cover bolts and tighten to specification in crisscross pattern. Install crankshaft pulley onto crankshaft snout, ensuring it seats fully. Install and torque crankshaft pulley bolt to 148 lb-ft (use thread locker per Ford specification). Reinstall water pump with new gasket if removed.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

    Gasket Surface Bolts26 Nm (19 lb-ft)
14. 14

    Reinstall remaining cylinder head components
    Install exhaust manifolds to cylinder heads with new gaskets, tightening bolts from center outward. Reconnect exhaust pipes to manifold flanges with new gaskets. Install intake manifold with new gaskets, torquing bolts from center outward. Reinstall fuel rail and injectors. Reconnect all fuel lines, vacuum lines, and electrical connectors per photos/labels. Install new spark plugs torqued to specification. Install new valve cover gaskets and valve covers, tightening bolts from center outward.
    Torque spec

    Gasket Bolts25 Nm (19 lb-ft)

    Cover Bolts20 Nm (15 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)
15. 15

    Final assembly and fill fluids
    Reinstall accessory brackets, alternator, A/C compressor, and drive belt. Reinstall radiator, hoses, and cooling fans. Install new oil filter and refill engine with 7.5 quarts of 0W-20 synthetic oil. Refill cooling system with 16 quarts of Motorcraft Orange coolant (may require system bleeding procedure). Reconnect battery. Double-check all connections, bolts, and hoses before starting.
    Torque spec

    Mounting Bolts60 Nm (44 lb-ft)

Reassembly

1. Reassembly is covered in steps 10-15 above in sequential order
2. Ensure all electrical connectors are fully seated with locking tabs engaged
3. Verify serpentine belt is properly routed on all pulleys with correct tension
4. Check that no tools or rags are left in engine bay before starting

Verification

• Start engine and listen for unusual noises - any ticking, knocking, or rattling indicates timing or assembly problem
• Check for coolant, oil, and fuel leaks around all worked areas while engine warms up
• Monitor engine temperature gauge - should reach normal operating temperature without overheating
• Verify cooling fans cycle on and off properly
• Check for exhaust leaks at manifold connections
• Allow engine to reach full operating temperature, then shut off and re-check all fluid levels when cool
• Scan for diagnostic trouble codes - should be no codes related to timing, sensors, or misfires
• Test drive vehicle and verify normal power delivery and no hesitation
• Re-torque cylinder head bolts after 500 miles per Ford specification (if applicable to this engine)
• Check valve cover and timing cover areas for oil seepage after 100 miles

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