This procedure covers the inspection and replacement of ignition coils on the 2015-2020 Ford F-150 5.0L Coyote V8, as this engine uses a coil-on-plug design without traditional spark plug wires.

Warnings

Tools required

Parts

• Ignition coil (if faulty) × 8 — Motorcraft DG-511 or equivalent
• Spark plugs (if replacing) × 8 — Motorcraft SP-534 or equivalent

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Open hood and support with prop rod
4. Disconnect negative battery cable and wait 5 minutes for capacitor discharge
5. Remove engine cover by pulling upward on cover to release retaining clips

Procedure

1. 1

   Access ignition coils
   Locate all eight ignition coils on top of the valve covers. The coils are positioned directly above each spark plug. Note the cylinder numbering: passenger side (right bank) is cylinders 1-4 from front to rear, driver side (left bank) is cylinders 5-8 from front to rear.
2. 2

   Disconnect electrical connectors
   Press the release tab on each ignition coil electrical connector and pull straight up to disconnect. Work on one coil at a time to avoid mixing up cylinder positions. Note any connector damage or corrosion.
3. 3

   Remove ignition coil hold-down bolts
   Using a 7mm socket, remove the single bolt securing each ignition coil. Keep bolts organized by cylinder number if they show any differences in condition. The bolt is located at the top center of each coil.
   Torque spec

   Ignition Coil Bolt14 Nm (10 lb-ft)
4. 4

   Extract ignition coils
   Grasp each coil firmly and pull straight up with a twisting motion to break the seal. The coil boot may stick to the spark plug due to heat cycling. If stuck, gently twist while pulling upward. Inspect the rubber boot inside the coil for tears, carbon tracking, or oil contamination.
   ⚠Do not pry on the coil body as this can crack the plastic housing. Use only twisting and pulling motions.
5. 5

   Inspect spark plug wells
   Use compressed air or a clean cloth to remove any debris from the spark plug wells. Check for oil pooling in the wells, which indicates valve cover gasket failure. Oil contamination will damage new coils and must be addressed before reassembly.
   ⚠If oil is present in spark plug wells, valve cover gaskets must be replaced before installing ignition coils to prevent premature coil failure.
6. 6

   Inspect or replace spark plugs (optional)
   If replacing spark plugs, use a 5/8 inch spark plug socket to remove them. Inspect electrode wear and gap. New plugs for this engine should be gapped to 0.030-0.035 inches (verify with specific plug manufacturer). Apply a small amount of anti-seize to the threads (avoid getting any on the electrode).
   ℹ️Ford recommends replacing spark plugs every 100,000 miles under normal driving conditions. Use only the specified plug type to avoid engine damage.
   Torque spec

   Spark Plug25 Nm (19 lb-ft)
7. 7

   Prepare new ignition coils
   Apply a thin coat of dielectric grease to the inside of each new coil boot where it contacts the spark plug insulator. This prevents moisture intrusion and makes future removal easier. Do not over-apply as excess grease can cause misfires.
8. 8

   Install ignition coils
   Align each coil over its corresponding spark plug and press down firmly until the coil seats completely against the valve cover. The coil should drop into position with moderate hand pressure. Ensure the mounting hole aligns with the threaded hole in the valve cover.
9. 9

   Install and torque coil hold-down bolts
   Install the 7mm bolt for each ignition coil and torque to specification. Do not overtighten as this can crack the coil housing. Work in a pattern from front to rear on each bank.
   Torque spec

   Ignition Coil Bolt14 Nm (10 lb-ft)
10. 10

    Reconnect electrical connectors
    Push each electrical connector onto its corresponding coil until you hear and feel a distinct click. Gently tug on each connector to verify it is locked in place. Apply a small amount of dielectric grease to the connector terminals if operating in wet or corrosive environments.
11. 11

    Reinstall engine cover
    Position the engine cover over the engine and press down firmly on all clip locations until each clip snaps into place. Verify the cover is secure and seated properly.
    Torque spec

    Engine Cover Clips3 Nm (3 lb-ft)
12. 12

    Reconnect battery and perform system check
    Reconnect the negative battery cable and tighten securely. Do not start the engine yet. Turn the ignition to ON position (without cranking) for 5 seconds, then off. Repeat this three times to allow the PCM to initialize the ignition system.

Reassembly

1. Ensure all electrical connectors are fully seated with audible clicks
2. Verify all ignition coil bolts are torqued to specification
3. Confirm engine cover clips are fully engaged
4. Double-check that no tools or parts remain in engine compartment

Verification

• Start the engine and listen for smooth idle with no misfires or rough running
• Check for any Check Engine Light illumination
• If available, use a scan tool to verify no misfire codes are present (P0300-P0308)
• Rev engine gently to 2000-3000 RPM and confirm smooth acceleration with no hesitation
• Inspect all coil connections for proper seating and no visible arcing after dark (engine running)
• Test drive vehicle under various loads to confirm normal operation and performance

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