Head Gasket - Single

This procedure covers replacement of a single cylinder head gasket on the 5.0L Coyote V8 engine, including removal and installation of the affected cylinder head, camshafts, and associated components.

Warnings

Tools required

Parts

• Cylinder head gasket × 1 — Use OEM Ford gasket
• Valve cover gasket × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets × 1 — Use OEM specification
• Cylinder head bolts × 10 — Use OEM Ford head bolts - torque-to-yield, replace required
• Engine oil and filter × 1 — Motorcraft FL-910S or equivalent
• Spark plugs × 4 — Motorcraft SP-546 or equivalent
• Coolant × 1 — Motorcraft Orange Coolant VC-7-B

Fluids

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

Preparation

1. Ensure engine is completely cold before beginning work
2. Disconnect negative battery cable and wait 10 minutes for airbag system to deplete
3. Remove engine cover by pulling upward on cover clips
4. Drain cooling system completely using radiator petcock and engine block drain plugs
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. Place vehicle on level ground with parking brake engaged and wheel chocks installed
8. Take photos of all electrical connections, vacuum lines, and routing before disconnection

Procedure

1. 1

   Remove intake manifold assembly
   Disconnect all electrical connectors, vacuum lines, and PCV hoses from intake manifold. Remove throttle body connections. Unbolt intake manifold in reverse of tightening sequence (work from outside bolts toward center). Lift intake manifold assembly away from engine and set aside on clean surface.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
2. 2

   Remove valve cover and ignition components
   Disconnect ignition coil electrical connectors and remove coils from spark plug tubes. Remove spark plugs and store in order. Remove valve cover bolts in reverse sequence (outside to inside) and carefully lift valve cover away. Clean any residual gasket material from valve cover mating surface.
3. 3

   Remove exhaust manifold
   Disconnect oxygen sensor electrical connectors. Remove exhaust manifold heat shield if equipped. Unbolt exhaust manifold from cylinder head and separate from exhaust pipe connection. Remove exhaust manifold and gaskets. Inspect studs for damage.
   ⚠Exhaust manifold studs can break during removal on high-mileage engines. Apply penetrating oil and allow to soak if fasteners are corroded.
   Torque spec

   Exhaust Manifold Nuts25 Nm (18 lb-ft)
4. 4

   Position engine to TDC and lock timing
   Rotate engine clockwise using crankshaft bolt until cylinder #1 (or appropriate cylinder for the head being removed) is at top dead center on compression stroke. Both camshaft lobes for cylinder #1 should point outward. Install timing chain locking tool to prevent chain movement. Mark timing chain position relative to camshaft sprockets with paint marker.
   ⚠️Failure to properly lock timing will result in valve-to-piston contact when engine is reassembled. Triple-check timing marks before proceeding.
5. 5

   Remove camshaft components
   Install camshaft holding tool to prevent rotation. Remove camshaft sprocket bolts (do not allow chain to fall into timing cover). Carefully slide sprockets off camshafts while keeping timing chain supported with wire or zip ties. Remove camshaft cap bolts in reverse sequence (outside to inside, working in multiple passes). Carefully lift camshaft caps and camshafts away, keeping them in order for reinstallation. Remove camshaft followers and hydraulic lash adjusters, keeping them organized by cylinder position.
   ⚠Camshaft caps are position-specific and marked. Mixing caps will cause bearing damage. Keep all components in order.
6. 6

   Remove cylinder head
   Disconnect any remaining coolant hoses, electrical sensors, and ground straps from cylinder head. Remove cylinder head bolts in reverse of tightening sequence (work from outside toward center in multiple passes). Use plastic pry points to break head gasket seal - never pry between head and block surfaces. Lift cylinder head straight up and away from block. Place on clean padded surface with combustion chambers facing up.
   ⚠Cylinder head is heavy (approximately 50 lbs). Use assistance or engine hoist to prevent dropping and injury.
   Torque spec

   Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
7. 7

   Clean and inspect mating surfaces
   Remove old head gasket from engine block. Use plastic gasket scraper to carefully clean all gasket material from block deck surface and cylinder head surface. Clean surfaces with brake cleaner and lint-free towels. Inspect block deck and cylinder head surfaces with straight edge and feeler gauge - maximum allowable warpage is 0.003 inches. Check for cracks, scoring, or damage. Inspect cylinder bores for damage or excessive wear.
   ⚠Never use metal scrapers on aluminum cylinder head or block surfaces. Even small gouges can cause gasket failure.
   ℹ️If cylinder head warpage exceeds 0.003 inches, head must be resurfaced by machine shop or replaced.
8. 8

   Install new head gasket and position cylinder head
   Verify block deck is completely clean and dry. Install new head gasket on block with orientation marks facing up (TOP or FRONT markings visible). Align gasket over dowel pins. Carefully lower cylinder head onto block, aligning with dowel pins. Ensure head seats fully on gasket with no shifting.
   ⚠Head gasket orientation is critical. Installing upside-down or backwards will cause immediate failure. Verify orientation markings before installation.
9. 9

   Install and torque cylinder head bolts
   Install new cylinder head bolts finger-tight in all positions. Using proper sequence (start at center, work outward in spiral pattern), torque all bolts to Step 1: 25 lb-ft. In same sequence, torque to Step 2: 45 lb-ft. In same sequence, perform Step 3: rotate each bolt an additional 90 degrees using torque angle gauge. Verify all bolts have been properly torqued and angled.
   ⚠️Cylinder head bolts must be NEW torque-to-yield bolts. Sequence and angle torque must be followed precisely or gasket failure will occur.
   Torque spec

   Cylinder Head Bolts - Step 140 Nm (30 lb-ft)
10. 10

    Reinstall camshafts and timing components
    Lubricate camshaft journals and lobes with clean engine oil. Install hydraulic lash adjusters in their original positions (or new if replacing). Install camshaft followers in original positions. Place camshafts in cylinder head in correct positions. Install camshaft caps in correct positions and orientation (match cap markings to head markings). Torque camshaft cap bolts in sequence from center outward in multiple passes. Install camshaft sprockets aligned to timing marks, engage timing chain, and torque sprocket bolts while holding camshafts. Remove timing chain locking tool and verify timing marks align correctly.
    ⚠Verify timing chain alignment three times before proceeding. Rotate engine two full revolutions by hand and recheck timing marks.
11. 11

    Install exhaust manifold
    Install new exhaust manifold gaskets on cylinder head studs. Position exhaust manifold and install nuts finger-tight. Torque exhaust manifold nuts in sequence from center outward. Reconnect exhaust pipe connection. Reconnect oxygen sensor electrical connectors. Install heat shield if equipped.
    Torque spec

    Exhaust Manifold Nuts25 Nm (18 lb-ft)
12. 12

    Install valve cover and ignition components
    Install new valve cover gasket in valve cover groove, ensuring proper seating. Apply small dab of RTV sealant at camshaft cap corners (front and rear). Place valve cover on cylinder head and install bolts finger-tight. Torque valve cover bolts in sequence from center outward. Install new spark plugs to specification. Install ignition coils and reconnect electrical connectors.
13. 13

    Reinstall intake manifold
    Install new intake manifold gaskets on cylinder heads. Position intake manifold assembly onto engine. Install intake manifold bolts finger-tight. Torque intake manifold bolts in proper sequence from center outward. Reconnect all vacuum lines, PCV hoses, electrical connectors, and throttle body connections per photos taken during disassembly.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
14. 14

    Refill fluids and final preparation
    Install new oil filter and torque to specification. Refill engine with 7.5 quarts of Motorcraft 0W-20 full synthetic oil. Close coolant drain plugs and refill cooling system with 16 quarts of Motorcraft Orange Coolant (50/50 pre-mix or equivalent mixture). Burp cooling system by running engine with heater on high until thermostat opens. Reinstall engine cover. Reconnect negative battery cable.
    ℹ️Cooling system may require additional coolant after initial fill and burping procedure. Check level when engine is cold.

Reassembly

1. All reassembly torque specifications and sequences are included in the steps above
2. Ensure all electrical connectors are fully seated with positive click engagement
3. Verify all vacuum lines and hoses are routed correctly per photos taken during disassembly
4. Double-check that no tools or rags remain in engine bay before starting engine

Verification

• Before starting engine, rotate crankshaft two complete revolutions by hand to verify no binding or interference
• Verify timing marks align correctly after manual rotation
• Check engine oil level on dipstick - should read between min and max marks
• Check coolant level in reservoir - should be at cold fill line
• Start engine and listen for unusual noises - valve train should be quiet after initial startup
• Allow engine to reach operating temperature and verify no coolant or oil leaks from head gasket, valve cover, intake manifold, or exhaust manifold
• Check for smooth idle and proper engine operation with no misfires
• After initial test drive, recheck all fluid levels and inspect for leaks when engine is cold
• Monitor coolant level for first 100 miles - may require topping off as air pockets evacuate from system

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