Complete head gasket replacement for both cylinder banks on the 2015-2020 Ford F-150 5.0L Coyote V8 engine, including removal of intake manifold, valve covers, timing chains, and cylinder heads.

Warnings

Tools required

Parts

• Cylinder head gasket - left × 1 — Use OEM Ford specification
• Cylinder head gasket - right × 1 — Use OEM Ford specification
• Cylinder head bolts (set of 20) × 1 — Use OEM - TTY bolts, do not reuse
• Valve cover gaskets (pair) × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Thermostat and gasket × 1 — Motorcraft RT-1258
• Engine oil and filter × 1 — Motorcraft FL-500S filter
• Spark plugs (set of 8) × 8 — Motorcraft SP-534
• VVT solenoid O-rings × 4 — Use OEM specification
• RTV silicone gasket maker × 1 — Motorcraft TA-357 or equivalent

Fluids

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

Preparation

1. Ensure vehicle is on level ground with transmission in Park and parking brake applied
2. Disconnect negative battery cable and wait 10 minutes for airbag system to deplete
3. Remove engine cover and air intake system including air filter housing
4. Relieve fuel system pressure by removing fuel pump fuse and running engine until it stalls
5. Drain engine coolant completely into appropriate container by opening radiator drain and removing lower radiator hose
6. Drain engine oil and remove oil filter
7. Remove radiator, cooling fans, and upper/lower radiator hoses
8. Label and photograph all electrical connectors, vacuum lines, and hose connections before removal
9. Support engine from above using engine support fixture or cherry picker with load leveler

Procedure

1. 1

   Remove Accessory Drive System
   Remove serpentine belt by rotating tensioner clockwise. Remove alternator, A/C compressor (do not disconnect refrigerant lines, support aside), and power steering pump mounting bracket. Remove engine oil dipstick tube. Remove accessory drive belt idler pulleys and tensioner assembly.
2. 2

   Remove Intake Manifold Assembly
   Disconnect throttle body electrical connector and all fuel injector connectors. Remove fuel rail mounting bolts and carefully lift fuel rail with injectors attached, support aside. Disconnect vacuum lines, PCV hoses, and all intake manifold connections. Remove intake manifold bolts in reverse of tightening sequence (outside to inside pattern) and lift manifold off. Remove and discard old gaskets.
   Torque spec

   Intake Manifold Bolts31 Nm (23 lb-ft)
3. 3

   Remove Valve Covers and Ignition Components
   Disconnect ignition coil electrical connectors and remove all eight coil-on-plug assemblies. Remove valve cover bolts in reverse sequence from outside to inside. Carefully break seal and remove both valve covers. Inspect valve train components for wear. Remove spark plugs from both heads to prevent damage during rotation.
   Torque spec

   Cover Bolts20 Nm (15 lb-ft)
4. 4

   Remove Front Timing Cover
   Remove harmonic balancer using appropriate puller tool - do not hammer on balancer. Remove water pump if not already removed. Remove all timing cover bolts including lower bolts accessible from underneath. Carefully pry cover away from engine block and remove. Note locations of different length bolts for reassembly.
   ⚠Mark harmonic balancer and crankshaft position before removal to maintain timing reference.
   Torque spec

   Cover Bolts20 Nm (15 lb-ft)
5. 5

   Lock Timing Chains and Remove Camshafts
   Rotate crankshaft to TDC cylinder #1 (timing marks aligned). Install camshaft holding tools on both banks. Mark timing chain position relative to camshaft sprockets. Compress timing chain tensioners and lock in place using tensioner pins or wire. Remove camshaft phaser bolts (left-hand thread on exhaust cams). Remove timing chains, guides, and tensioners. Remove camshaft cap bolts in reverse sequence (inside to outside) and carefully lift camshafts from heads. Keep camshafts identified by cylinder bank and position.
   ⚠️Camshaft phaser bolts on exhaust camshafts have LEFT-HAND THREADS. Turn clockwise to loosen.
   Torque spec

   Camshaft Cap Bolts20 Nm (15 lb-ft)
6. 6

   Remove Exhaust Manifolds
   From underneath vehicle, disconnect exhaust Y-pipe from both exhaust manifolds at flange connections. Remove exhaust manifold heat shields. Remove exhaust manifold nuts working from center outward. Remove exhaust manifolds and discard gaskets. Inspect manifolds for cracks or warpage.
   Torque spec

   Exhaust Manifold Nuts42 Nm (31 lb-ft)
7. 7

   Remove Cylinder Heads
   Disconnect all remaining electrical connectors from cylinder heads including coolant temperature sensors and VVT solenoids. Remove coolant crossover tube if equipped. Loosen cylinder head bolts in reverse of tightening sequence (outside to inside spiral pattern) in multiple passes. Remove all head bolts and discard - these are TTY bolts and cannot be reused. Carefully lift cylinder heads straight up to avoid damaging dowel pins. Place heads on clean padded surface with combustion chambers facing up.
   ⚠Cylinder heads are heavy (approximately 50 lbs each). Use proper lifting technique or get assistance to avoid injury or dropping the head.
   Torque spec

   Cylinder Head Bolts34 Nm (25 lb-ft) + 90°
8. 8

   Inspect and Clean Mating Surfaces
   Thoroughly inspect cylinder head and engine block mating surfaces for damage, corrosion, or warpage using straightedge and feeler gauge. Maximum allowable warpage is 0.003 inches. If beyond specification, heads and/or block must be resurfaced by machine shop. Remove all old gasket material using plastic scrapers only - do not use metal tools that could gouge surfaces. Clean surfaces with brake cleaner and lint-free cloths. Ensure all bolt holes are clean and dry. Check cylinder bores for scoring or damage.
   ⚠Any metal gouges or scratches in head or block surfaces will cause head gasket failure. Take extreme care during cleaning.
   Torque spec

   Gasket Surface Bolts26 Nm (19 lb-ft)
9. 9

   Install New Head Gaskets and Position Heads
   Verify engine block and head surfaces are completely clean and dry. Install new head gaskets onto engine block, ensuring correct orientation (TOP marking facing up, FRONT marking toward front of engine). Verify dowel pins are in place in block. Carefully lower cylinder heads onto block, aligning with dowel pins. Install new cylinder head bolts finger-tight in their correct positions (note different length bolts).
   ⚠Head gaskets are NOT symmetrical. Ensure correct orientation and front-to-rear direction or catastrophic failure will result.
10. 10

    Torque Cylinder Head Bolts
    Using proper torque sequence (spiral pattern starting from center, working outward), torque cylinder head bolts in three stages: Step 1 - torque all bolts to 25 lb-ft. Step 2 - torque all bolts to 45 lb-ft. Step 3 - rotate all bolts an additional 90 degrees using angle gauge. Ensure each bolt is torqued in sequence for each step before proceeding to next step. Double-check all bolts are properly tightened.
    ⚠Follow torque sequence exactly. Improper sequence will cause head gasket failure and possible head warpage.
    Torque spec

    Cylinder Head Bolts34 Nm (25 lb-ft) + 90°
11. 11

    Install Camshafts and Timing Components
    Lubricate camshaft journals and lobes with assembly lube or clean engine oil. Install camshafts in correct positions ensuring identification matches removed position. Install camshaft caps in correct positions and torque cap bolts to specification in sequence (inside to outside). Install timing chain guides. Route timing chains over camshaft sprockets aligning timing marks as noted during disassembly. Install camshaft phasers and torque bolts (remember left-hand threads on exhaust cam phasers). Release timing chain tensioners. Verify timing marks are correctly aligned at TDC #1.
    ⚠️Exhaust camshaft phaser bolts have LEFT-HAND THREADS. Turn counterclockwise to tighten.
    Torque spec

    Camshaft Cap Bolts20 Nm (15 lb-ft)
12. 12

    Install Exhaust Manifolds
    Install new exhaust manifold gaskets on cylinder heads. Position exhaust manifolds and install new nuts finger-tight. Torque exhaust manifold nuts to specification working from center outward in cross pattern. Install exhaust manifold heat shields. Connect exhaust Y-pipe to manifolds using new gaskets and hardware.
    Torque spec

    Exhaust Manifold Nuts42 Nm (31 lb-ft)
13. 13

    Install Front Timing Cover and Accessories
    Clean timing cover mating surfaces thoroughly. Apply thin bead of RTV silicone to block-to-oil pan seam and cylinder head corners as specified in service manual. Install new timing cover gasket and position cover onto engine. Install timing cover bolts to specification. Install water pump with new gasket. Install harmonic balancer ensuring keyway is aligned, torque to specification. Install accessory brackets, power steering pump, A/C compressor, and alternator.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

    Mounting Bolts60 Nm (44 lb-ft)
14. 14

    Install Valve Covers and Intake System
    Install new valve cover gaskets in covers. Apply small dab of RTV at cylinder head-to-timing cover corners. Position valve covers and install bolts to specification in sequence (inside to outside pattern). Install new spark plugs torqued to specification. Install ignition coils. Install new intake manifold gaskets. Position intake manifold and torque bolts to specification in proper sequence (inside to outside). Reconnect fuel rail, injectors, throttle body, and all vacuum/electrical connections.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

    Intake Manifold Bolts31 Nm (23 lb-ft)
15. 15

    Final Assembly and Fluid Fill
    Install new thermostat with new gasket. Reconnect all coolant hoses. Install radiator, cooling fans, and shroud. Install serpentine belt on all pulleys. Reconnect all electrical connectors and vacuum lines per photos/labels. Install new oil filter and fill engine with 7.5 quarts Motorcraft 0W-20 synthetic oil. Fill cooling system with 50/50 mixture of Motorcraft Orange coolant and distilled water (16 quarts total capacity). Use vacuum fill method if available to eliminate air pockets. Reconnect battery.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Double-check all coolant hose clamps are tight
3. Verify serpentine belt is properly routed on all pulleys and tensioner
4. Confirm all ground straps are reconnected
5. Check that no tools or parts were left in engine compartment

Verification

• Before starting engine, rotate crankshaft by hand two full revolutions to verify no interference and proper valve timing
• Check engine oil level and add if necessary to reach full mark on dipstick
• Start engine and immediately verify oil pressure indication on gauge/light
• Allow engine to warm to operating temperature while monitoring for leaks at head gaskets, valve covers, and coolant connections
• Check for any abnormal noises, misfires, or warning lights
• Bleed cooling system of air pockets by running engine with heater on high, adding coolant as needed until level stabilizes
• After engine reaches full operating temperature, shut off and allow to cool completely, then recheck coolant level and top off
• Perform test drive monitoring engine temperature, oil pressure, and performance
• After 500 miles, re-torque cylinder head bolts if manufacturer specifies (not typical on TTY bolts but verify in service bulletin)
• Check for any fluid leaks after test drive and recheck all fluid levels

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