Long Block Replacement

Complete removal and replacement of the 302ci V8 long block assembly, including transfer of all external components from the old engine to the new long block.

Warnings

Tools required

Parts

• 302ci V8 long block assembly × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Fel-Pro MS90032 or equivalent
• Exhaust manifold gaskets × 1 — Fel-Pro 1405 or equivalent
• Oil pan gasket × 1 — Fel-Pro OS30300R or equivalent
• Timing cover gasket × 1 — Fel-Pro TCS45031 or equivalent
• Valve cover gaskets × 1 — Fel-Pro VS12812R or equivalent
• Water pump gasket × 1 — Fel-Pro 35452 or equivalent
• Thermostat housing gasket × 1 — Use OEM specification
• Oil filter × 1 — Motorcraft FL-1A or equivalent
• Spark plugs × 8 — Autolite 25 or equivalent
• Engine oil × 5 — 10W-30 or 10W-40 conventional
• Oil pan drain plug gasket × 1 — Use OEM specification
• RTV silicone sealant × 1 — High-temp red RTV
• Anti-seize compound × 1 — Use OEM specification
• Thread locker (medium strength) × 1 — Loctite 242 or equivalent

Fluids

• 10W-30 or 10W-40 conventional engine oil — 5 qt
• Ethylene glycol green 50/50 coolant — 15 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable, then positive battery cable
3. Remove hood by marking hinge positions and unbolting from hinges with assistant (4 bolts total)
4. Drain engine oil completely into drain pan
5. Drain cooling system by opening radiator petcock and removing radiator cap
6. Relieve fuel system pressure by loosening fuel line at carburetor slowly
7. Place fender covers to protect vehicle paint
8. Take photographs of all connections, routing, and component positions for reference during reassembly
9. Label all electrical connectors, vacuum lines, and hoses with masking tape and marker

Procedure

1. 1

   Remove air cleaner and carburetor components
   Remove air cleaner assembly by disconnecting breather hoses and removing wing nut. Disconnect throttle linkage, kickdown linkage (if automatic transmission), choke cable, and all vacuum lines from carburetor. Tag each vacuum line with its port location. Remove distributor cap and set aside with spark plug wires attached. Mark distributor housing position relative to the engine block and note rotor orientation for reference during reinstallation.
2. 2

   Disconnect fuel and coolant lines
   Disconnect fuel line at fuel pump inlet. Cap or plug fuel line to prevent spillage. Disconnect heater hoses at engine block and water pump. Disconnect upper and lower radiator hoses at engine. Disconnect coolant bypass hose if equipped. Remove radiator shroud bolts (if equipped with shroud) and remove shroud. Remove radiator upper mounting bolts/brackets and lift radiator up and out, clearing lower supports.
3. 3

   Remove alternator and accessory drives
   Disconnect alternator wiring at alternator (2 connections). Loosen alternator adjustment bolt and pivot bolt. Remove drive belt. Remove alternator mounting bolts and remove alternator. If equipped with power steering, disconnect pressure and return lines at pump, loosen pump adjustment and pivot bolts, remove drive belt, and remove power steering pump (set aside without disconnecting hoses if possible). If equipped with A/C, remove compressor mounting bolts and secure compressor to frame with wire without disconnecting refrigerant lines.
4. 4

   Disconnect exhaust system
   Working underneath vehicle on jack stands, disconnect exhaust pipes at exhaust manifold flanges. Remove 4 exhaust flange nuts per side (8 nuts total). Separate exhaust pipes from manifolds and support exhaust system with wire or blocks to prevent damage.
5. 5

   Disconnect engine electrical connections
   Disconnect coil primary wire. Disconnect oil pressure sender wire. Disconnect coolant temperature sender wire. Disconnect starter solenoid wiring at starter. Remove starter mounting bolts (2 bolts) and remove starter. Disconnect any remaining electrical connections to engine (backup light switch if manual transmission, neutral safety switch if automatic).
6. 6

   Separate transmission from engine
   Support transmission with transmission jack or floor jack with wood block. Remove transmission-to-engine bellhousing bolts (typically 4-6 bolts depending on transmission type). If automatic transmission, mark torque converter position relative to flywheel through starter opening, then remove torque converter-to-flywheel bolts (4 bolts) by rotating crankshaft with breaker bar on harmonic balancer bolt. Ensure torque converter is fully seated in transmission and will not pull out with engine.
7. 7

   Remove engine mount fasteners
   Remove engine mount-to-frame bracket bolts on both sides (2 bolts per side, 4 bolts total). Leave engine mounts attached to engine for now as they will support engine weight on hoist.
8. 8

   Attach engine hoist and remove engine
   Position engine hoist over engine bay. Attach lifting chain or engine leveler to intake manifold using intake manifold bolts (typically front and rear positions). Ensure lifting points are secure and balanced. Take up slack in hoist chain until engine weight is just supported. Double-check all connections are disconnected. Slowly lift engine while tilting slightly to clear transmission input shaft or torque converter. Guide engine forward and up, clearing radiator support and fenders. Once clear, lift engine high enough to move hoist away from vehicle.
9. 9

   Transfer external components to engine stand
   If using engine stand, mount old engine to stand using bellhousing bolt holes. If not using stand, support engine securely on blocks. This allows easier component removal and installation.
10. 10

    Remove and transfer intake manifold
    Remove valve covers (4 bolts per cover). Remove intake manifold bolts in reverse of tightening sequence (typically 12 bolts total working from outside to center). Lift intake manifold from engine. Remove and discard old gaskets. Clean all gasket surfaces thoroughly on intake manifold using gasket scraper. Inspect intake manifold for cracks or damage. Install new intake manifold gaskets on new long block following gasket manufacturer instructions. Position intake manifold on new engine and install bolts finger-tight. Torque intake manifold bolts in proper sequence (center outward) 18.0 lb-ft (25.0 Nm). Verified detail (Ford 302 (Windsor) valve covers typically use 4 bolts per cover, not 6. Six-bolt valve covers are characteristic of some other engines. This should be verified — Windsor 302 valve covers are commonly 4-bolt.): Remove valve covers (typically 4 bolts per cover on the 302 Windsor; verify count).
11. 11

    Transfer exhaust manifolds
    Remove exhaust manifold bolts from old engine (8 bolts per manifold, 16 bolts total). Remove exhaust manifolds and discard old gaskets. Clean exhaust manifold gasket surfaces and inspect manifolds for cracks. Install new exhaust manifold gaskets on new long block. Position exhaust manifolds and install bolts with anti-seize compound on threads. Torque exhaust manifold bolts as torque specifications become available, working from center outward.
12. 12

    Transfer timing cover and water pump
    Remove water pump bolts from old engine (4 bolts) and remove water pump. Remove timing cover bolts (approximately 6-8 bolts) and remove timing cover from old engine. Remove and discard old gaskets. Inspect water pump and timing cover for damage or wear. Clean all gasket surfaces thoroughly. Install new timing cover gasket on new long block with RTV sealant at oil pan-to-block junction. Install timing cover and torque bolts 18.0 lb-ft (25.0 Nm). Install new water pump gasket, position water pump, and torque bolts 18.0 lb-ft (25.0 Nm).
13. 13

    Transfer harmonic balancer and pulleys
    Use harmonic balancer puller to remove harmonic balancer from old engine crankshaft. Remove pulley bolts if pulleys are separate. Clean harmonic balancer hub and inspect for damage. Apply thin layer of engine oil to new long block crankshaft snout. Install harmonic balancer on new engine using harmonic balancer installation tool or by carefully tapping with soft mallet while threading center bolt. Torque harmonic balancer bolt as specifications become available. Install pulleys.
14. 14

    Transfer fuel pump and distributor
    Remove fuel pump bolts (2 bolts) and fuel pump from old engine. Remove distributor hold-down clamp bolt and remove distributor from old engine, noting gear engagement depth. Install new fuel pump gasket on new long block with RTV sealant. Install fuel pump and torque bolts 18.0 lb-ft (25.0 Nm). Rotate new engine crankshaft to position number 1 cylinder at TDC on compression stroke (timing mark at 0 degrees, rotor pointing to number 1 cylinder position). Install distributor with rotor in same orientation as noted during removal, engaging distributor gear with camshaft gear.
15. 15

    Transfer remaining external components
    Transfer oil pressure sender, coolant temperature sender, motor mounts, flywheel (if manual transmission, mark position and remove 6 bolts), and any remaining brackets or accessories from old engine to new long block. Install new valve cover gaskets and install valve covers with bolts torqued 7.0 lb-ft (10.0 Nm). Install new spark plugs gapped to specification (typically 0.034 inches for a 1972 302 with conventional point-type ignition; verify against underhood decal or service manual).
16. 16

    Install engine into vehicle
    Attach engine hoist to new engine assembly using same lifting points. Lift engine and position over engine bay. Carefully lower engine into position, tilting as necessary to clear radiator support and align with transmission. Guide engine rearward to engage transmission input shaft (manual) or align with torque converter (automatic). Ensure torque converter pilot is seated and bolt holes align with the flexplate if automatic transmission. Continue lowering until engine mounts align with frame brackets.
17. 17

    Secure engine and transmission
    Install engine mount-to-frame bracket bolts and torque 63.0 lb-ft (85.0 Nm). Remove transmission jack support. Install bellhousing-to-engine bolts and torque 63.0 lb-ft (85.0 Nm). If automatic transmission, install torque converter-to-flywheel bolts through starter opening, rotating crankshaft to access each bolt. Torque 63.0 lb-ft (85.0 Nm). Install starter and torque mounting bolts 63.0 lb-ft (85.0 Nm). Verified detail (Torque specification for 1972 F-100 302 V8 engine mount-to-frame bracket bolts): 55.0 lb-ft (75.0 Nm) Verified detail (Torque specification for 1972 F-100 302 V8 starter mounting bolts): 37.0 lb-ft (50.0 Nm)
18. 18

    Reconnect exhaust and accessories
    Connect exhaust pipes to exhaust manifolds using new exhaust flange gaskets. Install exhaust flange nuts and torque as specifications become available. Install alternator, power steering pump (if equipped), and A/C compressor (if equipped) with drive belts adjusted to proper tension (1/2 inch deflection under thumb pressure at belt center). Reconnect all accessory wiring and hoses.
19. 19

    Reconnect coolant and fuel systems
    Install radiator and shroud. Connect upper and lower radiator hoses with new hose clamps. Connect heater hoses and coolant bypass hose. Connect fuel line to fuel pump. Install new oil filter. Fill engine with 5 quarts of 10W-30 or 10W-40 conventional engine oil. Fill cooling system with approximately 14-15 quarts of 50/50 conventional green ethylene glycol coolant (verify exact capacity from service manual).
20. 20

    Reconnect electrical and final connections
    Reconnect all electrical connections using labels applied during disassembly: coil primary wire, oil pressure sender, coolant temperature sender, alternator wiring, and any other tagged connections. Install distributor cap. Reconnect throttle linkage, transmission kickdown linkage (if automatic), and all vacuum lines to proper ports using reference photos and labels. Install air cleaner assembly.
21. 21

    Initial startup and break-in procedure
    Reconnect battery cables (positive first, then negative). Verify oil pressure immediately upon startup using mechanical gauge if possible. Set initial timing to approximately 6-8 degrees BTDC. Start engine and check immediately for oil pressure (should register within 10 seconds). Check for fuel, oil, and coolant leaks. Allow engine to reach operating temperature while monitoring coolant level and temperature gauge. Adjust idle speed and timing to factory specifications. Check and adjust valve lash if solid lifters are used. Recheck all fluid levels after engine reaches operating temperature.

Reassembly

1. All reassembly steps are included in the main procedure as this is a complete replacement job
2. Follow new engine manufacturer's break-in procedure if provided, typically including initial oil change at 500 miles and avoiding sustained high RPM or load for first 500 miles
3. Reinstall hood by aligning with marks made during removal and torquing bolts as specifications become available

Verification

• Verify oil pressure registers on gauge within 10 seconds of startup and maintains minimum 10 PSI at idle when warm
• Verify no oil, coolant, or fuel leaks at all connection points
• Verify engine reaches and maintains normal operating temperature (approximately 180-200°F)
• Verify all electrical accessories function properly (alternator charging, gauges reading correctly)
• Verify proper idle quality and throttle response
• Verify transmission engages properly in all gears
• Road test vehicle to verify proper engine performance under load
• Recheck all fluid levels after test drive and top off as necessary
• Recheck all critical bolt torques after engine reaches operating temperature and cools

More procedures for this vehicle