Complete removal and replacement of the long block assembly on a 2015-2020 Ford F-150 5.0L Coyote V8, including all external components transfer and reassembly.

Warnings

Tools required

Parts

• 5.0L Coyote long block assembly × 1 — Use OEM specification
• Engine oil and filter × 1 — FL910S or equivalent
• Motorcraft Orange engine coolant concentrate × 2 — VC-3DIL-B
• Valve cover gaskets (left and right) × 2 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Exhaust manifold gaskets (left and right) × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Thermostat and housing gasket × 1 — Use OEM specification
• Water pump gasket/O-rings × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil (0W-20 full synthetic) × 8 — Motorcraft XO-0W20-QSP
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Anti-seize compound × 1 — For exhaust manifold studs

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake. Chock rear wheels.
2. Disconnect negative battery cable, then positive cable. Remove battery from vehicle to provide working clearance.
3. Drain engine coolant completely from radiator petcock and engine block drain plugs into appropriate container.
4. Drain engine oil and remove oil filter. Allow adequate time for complete drainage.
5. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls.
6. Have A/C system professionally evacuated by certified technician.
7. Remove engine cover and air intake system including air box, intake tube, and mass air flow sensor.
8. Document all electrical connector positions with photos or labels before disconnection.
9. Raise and safely support vehicle on jack stands at manufacturer recommended lift points.
10. Remove front skid plate if equipped.
11. Place drain pans and absorbent materials under work area.

Procedure

1. 1

   Remove cooling system components
   Disconnect upper and lower radiator hoses at engine. Remove heater hoses from thermostat housing and water pump. Disconnect coolant overflow hose. Remove radiator fan shroud assembly by removing mounting bolts and lifting upward. Remove radiator by releasing mounting brackets.
2. 2

   Disconnect fuel and A/C lines
   Using appropriate disconnect tools, separate fuel supply and return lines at engine-mounted connections. Cap all open fuel lines immediately to prevent contamination. Disconnect A/C compressor lines at firewall connections and cap immediately to prevent moisture intrusion.
   ⚠️Ensure fuel pressure is fully relieved before disconnecting lines. Residual pressure can spray fuel.
3. 3

   Remove accessories and brackets
   Remove serpentine belt by releasing tensioner. Remove alternator with mounting bracket, leaving wiring harness connected and securing assembly to side. Remove A/C compressor mounting bolts and secure compressor to frame without disconnecting lines (if not already evacuated). Remove power steering pump with lines attached and secure aside. Remove coolant reservoir tank.
   Torque spec

   Mounting Bolts60 Nm (44 lb-ft)
4. 4

   Disconnect electrical connections
   Disconnect all engine harness connectors including: both ignition coil connectors (8 total), throttle body connector, fuel injector main harness, camshaft position sensors (both banks), crankshaft position sensor, oil pressure sensor, coolant temperature sensor, knock sensors, oxygen sensors (all 4), and variable valve timing solenoids. Release harness from all engine-mounted clips and route harness away from engine.
   Torque spec

   Electrical Connector Bolts8 Nm (6 lb-ft)

   Sensor Bolts14 Nm (10 lb-ft)
5. 5

   Remove intake and throttle components
   Disconnect throttle body inlet tube. Remove intake manifold by disconnecting vacuum lines, PCV hoses, and brake booster vacuum line. Remove intake manifold mounting bolts in reverse of tightening sequence (outside to inside). Lift intake manifold assembly from engine, noting orientation for reinstallation.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
6. 6

   Remove exhaust system connections
   From underneath vehicle, disconnect exhaust Y-pipe at both exhaust manifold flanges. Remove exhaust manifold flange nuts working from center outward to prevent warping. Support exhaust system with wire or strap to prevent damage. If removing exhaust manifolds from old engine, apply penetrating oil to studs 24 hours prior if possible.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
7. 7

   Separate transmission from engine
   Place transmission jack or support bar under transmission to support weight. Remove transmission-to-engine bellhousing bolts working in star pattern. Note bolt lengths and positions as they vary. Remove flywheel access cover. Remove starter motor mounting bolts and secure starter aside. Carefully separate transmission from engine, ensuring torque converter remains with transmission.
   ⚠Transmission must be fully supported before removing bellhousing bolts. Transmission weighs over 200 lbs and can cause severe injury if it falls.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)

   Flywheel Bolts95 Nm (70 lb-ft)
8. 8

   Prepare engine for removal
   Attach engine hoist lifting chains or strap to factory lifting eyes on engine (one at front, one at rear). Ensure hoist is rated for minimum 1500 lb capacity. Adjust leveler to balance engine. Apply slight upward tension to take weight off engine mounts but do not lift yet. Remove engine mount through-bolts from both driver and passenger side mounts.
   ⚠️Double-check all connections are disconnected before lifting. Engine restrained by hidden connections can damage vehicle or cause hoist failure.
   Torque spec

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

   Remove engine from vehicle
   Perform final visual inspection to ensure all hoses, wires, and mounts are disconnected. Slowly raise engine approximately 2 inches and verify nothing is binding or still attached. Continue raising engine while simultaneously tilting and angling forward to clear transmission input shaft, firewall, and radiator support. Once clear of engine bay, carefully lower onto engine stand or suitable work surface.
10. 10

    Transfer components from old engine to new long block
    Remove and transfer the following components from old engine to new long block: throttle body, fuel rails and injectors, ignition coils, valve covers (if not included), oil pan and pickup tube (if not included), timing cover (if not included), water pump, thermostat housing, coolant crossover tubes, oil filter adapter, all sensors (coolant temp, oil pressure, cam sensors, crank sensor, knock sensors, VVT solenoids), motor mounts, flywheel or flexplate, exhaust manifolds with studs, dipstick tube, and all brackets. Clean all gasket surfaces thoroughly with plastic scraper and brake cleaner before installing new gaskets.
    ⚠Apply anti-seize to exhaust manifold studs before installation to prevent future seizure. Do not apply anti-seize to threads that receive TTY bolts.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)

    Cover Bolts20 Nm (15 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Mounting Bolts60 Nm (44 lb-ft)
11. 11

    Install flywheel and rear seal
    Install new rear main seal into seal bore, lubricating seal lip with clean engine oil. Ensure seal is seated evenly and fully. Clean flywheel mounting surface on crankshaft. Install flywheel with new bolts (if TTY), aligning dowel pin. Tighten flywheel bolts in star pattern to specification. Apply thread locker if specified by manufacturer.
    ℹ️Flywheel bolts are often TTY and must not be reused. Consult service manual for specific torque angle specifications.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
12. 12

    Install new long block into vehicle
    Attach lifting chains to new engine and raise to level slightly higher than required for installation. Carefully guide engine into engine bay, tilting and angling as needed to clear firewall and radiator support. Align engine with transmission bellhousing while lowering. Guide transmission input shaft into clutch disc or pilot bearing (manual) or align torque converter pilot with crankshaft (automatic). Continue lowering until engine mount bosses align with frame mounts.
    ⚠Do not force engine into position. Misalignment can damage transmission input shaft, crankshaft pilot bearing, or torque converter.
13. 13

    Reconnect transmission and install mounts
    Install engine mount through-bolts and tighten to specification. Install transmission-to-engine bellhousing bolts in star pattern, ensuring correct bolt lengths in proper locations. Verify torque converter is fully seated (automatic transmission). Install starter motor. Install flywheel access cover. Remove engine hoist once engine is fully secured.
    Torque spec

    Mounting Bolts60 Nm (44 lb-ft)

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
14. 14

    Reinstall exhaust system
    Install new exhaust manifold gaskets. Position exhaust Y-pipe to manifold flanges and install new exhaust manifold nuts. Tighten in sequence from center outward (hot-to-cold) to prevent warping. Verify exhaust hangers are properly positioned and system has adequate clearance from frame and body components.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
15. 15

    Reconnect all systems and fill fluids
    Reconnect all electrical connectors using photos and labels for reference. Ensure positive lock engagement on all connectors. Route engine harness through proper clips. Install intake manifold with new gaskets, tightening bolts in proper sequence. Reconnect throttle body and air intake system. Install serpentine belt. Reconnect all coolant hoses. Install radiator and fan shroud assembly. Reconnect A/C lines with new O-rings (system will need recharge). Reconnect fuel lines ensuring positive lock engagement. Install new oil filter and fill engine with 7.5 quarts of 0W-20 synthetic oil. Fill cooling system with 50/50 mix of Motorcraft Orange coolant. Reinstall battery and connect positive then negative terminals.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Torque all fasteners in specified sequences where applicable (cylinder heads, intake manifold, valve covers)
2. Replace all TTY bolts - never reuse torque-to-yield fasteners
3. Use new gaskets for all mating surfaces - do not reuse old gaskets
4. Apply anti-seize only to exhaust manifold studs, not to TTY bolt threads
5. Ensure all wiring harness connectors are fully locked and secured in proper clips
6. Verify serpentine belt is properly routed and seated on all pulleys before starting engine

Verification

• With engine oil cap removed, crank engine (do not start) until oil pressure is indicated on gauge or warning light extinguishes
• Inspect all connection points for fluid leaks before starting engine
• Start engine and verify immediate oil pressure indication - shut down immediately if no pressure shown
• Allow engine to warm to operating temperature while monitoring for coolant, oil, or fuel leaks
• Verify cooling fans engage at proper temperature
• Check for exhaust leaks at manifold connections
• Scan for diagnostic trouble codes and verify no engine-related codes are present
• Road test vehicle to verify proper operation under load and at highway speeds
• Recheck all fluid levels after test drive and top off as necessary
• Verify A/C system has been properly recharged and operates correctly
• Recheck critical fastener torques after engine reaches operating temperature (valve covers, intake manifold, exhaust manifolds)

More procedures for this vehicle