This procedure covers the removal and replacement of a single piston in a 2015-2020 Ford F-150 5.0L Coyote V8, requiring engine disassembly including cylinder head removal.

Warnings

Tools required

Parts

• Piston assembly with rings (specify bank and cylinder number) × 1 — Use OEM specification
• Connecting rod bearing set (for affected cylinder) × 1 — Use OEM specification
• Cylinder head gasket (bank containing affected cylinder) × 1 — Use OEM specification
• Cylinder head bolts (TTY - do not reuse) × 10 — Use OEM specification
• Connecting rod bolts (TTY - do not reuse) × 2 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Valve cover gasket (for affected bank) × 1 — Use OEM specification
• Timing chain cover gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil filter × 1 — FL-910S or equivalent
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets (if disturbed) × 1 — Use OEM specification
• RTV silicone sealant (Motorcraft TA-31) × 1 — TA-31

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect battery negative terminal and wait 10 minutes
3. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
4. Drain engine coolant completely into appropriate container
5. Drain engine oil and remove oil filter
6. Remove engine cover and air intake system
7. Remove radiator hoses and position radiator aside or remove completely for access
8. Support engine with hoist or support fixture from above
9. Take detailed photos of all wiring harness routing, vacuum lines, and component positions for reassembly reference
10. Label all connectors and hoses with tape and marker before disconnecting

Procedure

1. 1

   Remove intake manifold assembly
   Disconnect all electrical connectors from fuel injectors, throttle body, and sensors. Remove fuel rail with injectors as an assembly. Disconnect all vacuum lines and PCV hoses. Unbolt intake manifold and carefully lift away. Clean all gasket surfaces thoroughly with gasket scraper and brake cleaner.
   Torque spec

   Electrical Connector Bolts8 Nm (6 lb-ft)
2. 2

   Remove valve cover and accessory components
   Remove valve cover from the cylinder bank containing the affected piston. Remove ignition coils from all cylinders on that bank. If removing left bank head, remove alternator and power steering pump. If removing right bank head, remove A/C compressor (do not disconnect lines - secure aside). Label and photograph spark plug wire or coil positions.
   Torque spec

   Cover Bolts20 Nm (15 lb-ft)

   Mounting Bolts60 Nm (44 lb-ft)
3. 3

   Remove timing chain cover and position timing components
   Remove crankshaft pulley using appropriate puller. Remove all timing chain cover bolts and carefully separate cover from engine block. Verify timing marks on camshaft and crankshaft sprockets align with TDC marks. Install timing chain holding tool to prevent chain from jumping time during cylinder head removal. Photograph timing mark positions.
   ⚠Do not rotate crankshaft or camshafts once timing components are loosened or engine timing will be lost.
   Torque spec

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

   Remove camshafts from affected cylinder head
   Remove camshaft bearing caps in reverse of tightening sequence (consult service manual for exact sequence). Loosen each cap gradually in multiple passes to prevent camshaft distortion. Lift camshafts straight up and store in clean area. Keep all bearing caps in order with their respective positions marked. Inspect cam lobes and journals for damage.
5. 5

   Remove cylinder head
   Remove exhaust manifold from affected bank if necessary for clearance. Loosen cylinder head bolts in reverse of tightening sequence using multiple passes. Remove all head bolts and lift cylinder head straight up off engine block. Place on clean padded surface. Mark cylinder head bank position (left or right). Inspect head gasket for failure pattern and document damage.
   ⚠Cylinder head weighs approximately 50 pounds. Use proper lifting technique or get assistance to avoid injury or dropping the head.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
6. 6

   Remove oil pan
   Raise and support vehicle on jack stands. Remove oil pan bolts in crisscross pattern. Carefully separate oil pan from engine block using plastic pry tool if needed. Remove old gasket material from both mating surfaces. Clean surfaces thoroughly with brake cleaner and inspect for damage.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)
7. 7

   Remove cylinder ridge and prepare bore
   Rotate crankshaft to position the affected piston at bottom dead center. Use ridge reamer to remove carbon ridge at top of cylinder bore. Work carefully to avoid gouging cylinder wall. Clean all carbon and debris from cylinder with clean rag and brake cleaner. Inspect cylinder wall for scoring or damage.
   ⚠Failure to remove ridge will result in piston ring breakage during removal or installation.
8. 8

   Remove connecting rod cap and piston assembly
   Mark connecting rod and cap with cylinder number and orientation using permanent marker or punch marks. Remove connecting rod cap bolts completely and separate cap from rod. Push piston and rod assembly up and out through top of cylinder bore. Be careful not to damage crankshaft journal during removal. Inspect rod bearing for wear pattern and damage.
   ℹ️Keep connecting rod cap matched with its rod. These are machined as a matched set and are not interchangeable.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
9. 9

   Measure cylinder bore and crankshaft journal
   Using cylinder bore gauge or telescoping gauge with micrometer, measure cylinder bore diameter at top, middle, and bottom in two perpendicular directions. Record all measurements. Maximum taper allowed is 0.0010 inch, maximum out-of-round is 0.0015 inch. Measure crankshaft rod journal diameter with micrometer. Compare all measurements to service specifications. If out of specification, cylinder will require machining.
10. 10

    Install new piston rings
    Remove old piston from connecting rod if reusing rod with new piston assembly. Using ring expander tool, carefully install oil control ring assembly first (expander and rails), then second compression ring with identification mark facing up, then top compression ring with mark facing up. Verify ring end gaps using feeler gauge (insert ring square in cylinder bore). Top ring gap should be 0.010-0.020 inch, second ring 0.010-0.020 inch. Rotate rings so gaps are 120 degrees apart but not aligned with piston pin.
    ⚠Piston rings are brittle and will break if over-expanded. Use proper ring installation tool and work carefully.
11. 11

    Check bearing clearances and install new bearings
    Install new bearing inserts in connecting rod and cap (ensure locating tabs seat properly). Place Plastigauge strip on crankshaft journal parallel to crankshaft centerline. Install rod cap with bearings in correct orientation and torque to specification. Do NOT rotate crankshaft. Remove cap and measure Plastigauge width with gauge on package. Clearance should be 0.0010-0.0018 inch. If clearance is incorrect, verify bearing part numbers and journal diameter before proceeding.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
12. 12

    Install piston assembly into cylinder
    Coat piston rings, cylinder bore, piston skirt, and rod bearings with fresh engine oil. Install piston ring compressor around piston and compress rings fully. Rotate crankshaft to position affected rod journal at bottom dead center. Ensure piston orientation mark faces front of engine. Guide rod bolts with protective hose sections to prevent scoring crankshaft. Insert piston assembly into cylinder bore using wooden hammer handle to tap piston crown gently until it enters bore completely.
    ⚠Verify piston orientation before installation. Piston directional arrow or notch must face front of engine or severe damage will occur.
13. 13

    Torque connecting rod cap
    Position connecting rod over crankshaft journal and install rod cap in correct orientation (match marks aligned). Install new connecting rod bolts. Lubricate bolt threads and underside of bolt heads with clean engine oil. Torque bolts to 45 Nm (33 lb-ft), then tighten an additional 90 degrees using angle gauge. Verify rod moves freely on crankshaft journal by rotating crankshaft through full rotation.
    ⚠Connecting rod bolts are torque-to-yield and must be replaced. The final angle torque is critical for proper clamping force.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
14. 14

    Reinstall oil pan
    Apply thin continuous bead of RTV sealant to oil pan mating surface and around bolt holes. Install new oil pan gasket. Position oil pan to engine block within 5 minutes of applying sealant. Install all oil pan bolts finger tight, then torque in crisscross pattern starting from center to 12 Nm (9 lb-ft). Allow sealant to cure for at least 30 minutes before filling with oil.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)
15. 15

    Reinstall cylinder head
    Clean cylinder head and block mating surfaces completely with gasket scraper and brake cleaner. Ensure no coolant or oil remains in head bolt holes (blow out with compressed air). Install new head gasket with orientation marks facing up. Carefully position cylinder head onto block ensuring alignment dowels engage. Install new cylinder head bolts and torque in correct sequence to 65 Nm (48 lb-ft), then tighten additional 90 degrees, then additional 90 degrees (total 180 degrees angle torque after initial torque).
    ⚠Follow exact torque sequence from service manual. Incorrect sequence will cause head gasket failure and possible head warpage.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
16. 16

    Reinstall camshafts and timing components
    Lubricate all camshaft lobes and journals with assembly lube or fresh engine oil. Position camshafts in cylinder head ensuring timing marks are correctly aligned. Install bearing caps in correct positions and sequences. Torque bearing cap bolts in multiple passes per service manual specifications. Reinstall timing chain cover with new gasket, applying RTV to corners where gasket meets. Verify all timing marks remain aligned. Remove timing chain holding tool.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)
17. 17

    Reinstall remaining components
    Reinstall valve cover with new gasket. Reinstall intake manifold with new gaskets, torquing bolts in proper sequence. Reconnect all fuel lines, vacuum hoses, electrical connectors, and sensors per photos and labels. Reinstall all accessory components (alternator, A/C compressor, power steering pump). Reinstall ignition coils. Install new oil filter and fill engine with 7.5 quarts Motorcraft 0W-20 full synthetic oil. Install new oil drain plug crush washer and torque drain plug to specification.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

    Mounting Bolts60 Nm (44 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Refill cooling system with 16 quarts Motorcraft Orange Coolant following proper bleeding procedure for Coyote engine (burp at radiator cap location with engine running at temperature)
2. Reconnect battery negative terminal
3. Prime fuel system by cycling ignition on/off three times without cranking
4. Double-check all electrical connectors, hoses, and fluid levels before starting engine
5. Verify no tools or parts remain in engine bay

Verification

• Start engine and verify it runs smoothly without abnormal noises such as knocking, ticking, or rattling
• Check for oil leaks at oil pan, timing cover, valve cover, and cylinder head gasket areas while engine is running
• Check for coolant leaks at head gasket and all cooling system connections
• Monitor engine temperature to verify proper cooling system operation and thermostat function
• Allow engine to reach full operating temperature and verify no overheating occurs
• Perform test drive and monitor engine performance under load - check for smooth acceleration and proper power delivery
• Re-check oil level after test drive and top off if necessary
• Scan for diagnostic trouble codes with scan tool to verify no misfires or sensor issues
• After 500 miles of operation, re-check oil level and inspect for any leaks developing at gasket areas

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