Valve Job - Complete

Complete valve job for the 302ci V8 including cylinder head removal, valve grinding/lapping, guide and seat inspection/refacing, spring replacement, and head reinstallation with new gaskets.

Warnings

Tools required

Parts

• Cylinder head gasket set × 1 — Fel-Pro HS7733PT or equivalent
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Valve stem seals (umbrella type) × 16 — Use OEM specification
• Intake valves (if replacing) × 8 — Use OEM specification
• Exhaust valves (if replacing) × 8 — Use OEM specification
• Valve springs (if replacing) × 16 — Use OEM specification
• Valve spring retainers × 16 — Use OEM specification
• Valve keepers × 32 — Use OEM specification
• Pushrod guide plates (if equipped) × 2 — Use OEM specification
• Rocker arm studs (if damaged) × 1 — Use OEM specification
• Carburetor base gasket × 1 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Copper head gasket sealant × 1 — Permatex Copper Spray-A-Gasket
• RTV silicone gasket maker × 1 — Use OEM specification
• Thread sealant × 1 — Permatex High Temp Thread Sealant

Fluids

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

Preparation

1. Position vehicle on level ground and engage parking brake
2. Disconnect negative battery cable
3. Drain cooling system completely into suitable container by opening radiator petcock and removing lower radiator hose
4. Drain engine oil and replace drain plug
5. Label all vacuum lines, electrical connections, and spark plug wires with tape and marker for reinstallation
6. Take reference photos of all hose routing, accessory positions, and connections before disassembly
7. Obtain factory service manual torque specifications for cylinder head bolts, rocker arm studs, intake manifold, and exhaust manifold bolts
8. Verify availability of machine shop services for valve seat cutting, guide replacement, and head resurfacing if needed

Procedure

1. 1

   Remove air cleaner, carburetor, and intake manifold
   Remove air cleaner assembly and disconnect fuel line from carburetor (have rag ready for residual fuel). Disconnect throttle linkage, choke cable, vacuum advance line, and all vacuum hoses from carburetor. Remove carburetor mounting nuts and lift carburetor away. Disconnect distributor vacuum advance line and all remaining intake manifold connections. Remove intake manifold bolts (12 total) in reverse order of tightening sequence (work from center outward). Carefully lift intake manifold from engine, watching for coolant spillage from passages. Remove and discard intake manifold gaskets.
2. 2

   Remove exhaust manifolds
   Disconnect exhaust pipes from exhaust manifolds at flange connections. Remove exhaust manifold bolts from both sides (8 bolts per manifold). On driver side, manifold may require manipulation around steering linkage. Lift exhaust manifolds away and set aside. Discard exhaust manifold gaskets.
3. 3

   Remove valve covers and rocker arm assemblies
   Remove valve cover bolts (6 bolts per side) and lift valve covers off. If stuck, gently tap with rubber mallet - do not pry against gasket surface. Remove rocker arm stud nuts while keeping rocker arms, pushrods, and fulcrum seats organized by position. Label or arrange components in order (cylinder 1-8, intake/exhaust). Lift rocker arms and fulcrum seats off studs. Carefully remove pushrods and store in numbered rack or cardboard template maintaining exact position identification. Inspect pushrod ends for wear and roll each on flat surface to check for straightness.
4. 4

   Remove cylinder heads
   Remove cylinder head bolts in reverse sequence of installation pattern (work from ends toward center in crisscross pattern). The 302 uses 14 head bolts per cylinder head. Once all bolts are removed, break cylinder head seal by gently tapping with rubber mallet. Never pry between head and block as this will damage sealing surfaces. Lift cylinder heads straight up and off dowel pins. Place heads on padded surface or head stand. Remove and discard cylinder head gaskets. Cover open cylinder bores with clean shop towels to prevent debris entry.
5. 5

   Disassemble valvetrain from cylinder heads
   Mount cylinder head securely on head stand or padded workbench. Using valve spring compressor, compress first valve spring until keepers are accessible. Use magnet to carefully remove both keepers from valve stem groove. Slowly release spring compressor tension. Remove retainer, spring, and umbrella-type valve stem seal. Slide valve out from combustion chamber side. Place valve in numbered holder corresponding to its cylinder and position (intake/exhaust). Repeat for all 16 valves per head, maintaining strict organization. Inspect each valve for burning, pitting, or warping of head. Inspect valve stems for scoring or wear. Measure valve stem diameter with micrometer - standard intake stem diameter is 0.3416-0.3423", exhaust is 0.3411-0.3418".
6. 6

   Clean and inspect cylinder heads
   Thoroughly clean all carbon deposits from combustion chambers using wire brush and gasket scraper. Clean valve seats with appropriate solvent. Remove all gasket material from head deck surface using gasket scraper - be careful not to gouge aluminum or cast iron surfaces. Clean all oil and coolant passages with rifle brush and solvent. Blow out all passages with compressed air. Inspect cylinder head deck surface with precision straightedge and feeler gauge at multiple angles (lengthwise, crosswise, diagonal). Check for warpage - maximum allowable is 0.003" per 6" span, 0.006" total. If warpage exceeds specification, head must be resurfaced by machine shop. Inspect valve seats for pitting, burning, or cracking. Check valve guides for wear using small hole gauge or guide worn gauge - standard intake guide diameter is 0.3433-0.3443", exhaust is 0.3433-0.3443". Guide wear exceeding 0.005" requires replacement.
7. 7

   Machine shop services or manual valve seat work
   If performing professional valve job, transport heads to machine shop for valve seat refacing (three-angle or five-angle cut), valve guide replacement if needed, and head resurfacing to restore flat deck surface. Specify valve seat angles for 302 Windsor: intake seats 45° with 30° top cut and 60° throat cut, exhaust seats 45° with 30° top cut and 60° throat cut. If performing in-shop work, use valve seat cutter set to reface seats to proper angles, checking concentricity with pilot. Seat width should be 0.060-0.080" for intake, 0.070-0.097" for exhaust. Measure valve guide inside diameter after any machining.
8. 8

   Grind and lap valves
   Inspect valves for burning, pitting, or excessive wear. If valve face is damaged beyond light refacing, replace valve. Using valve grinding machine or hand grinding tool with appropriate stones, grind valve faces to 44° for both intake and exhaust valves (45° seat with 44° face gives a 1° interference angle for optimal sealing). Grind only enough to achieve clean, continuous surface. Margin at edge of valve face must be minimum 0.030" - if margin is less, replace valve. After grinding, apply thin coat of fine valve lapping compound to valve face. Insert valve into correct guide and use lapping tool with back-and-forth rotating motion (not continuous rotation) for 30-60 seconds until consistent grey ring appears on both seat and valve face. Clean all compound thoroughly with solvent. Apply Prussian blue to valve face, insert in guide, rotate 1/4 turn, and lift out - blue transfer should show continuous contact band 0.060-0.080" wide on intake seat, 0.070-0.097" wide on exhaust seat. Repeat lapping if contact pattern is incomplete.
9. 9

   Measure and verify valve spring specifications
   Inspect all valve springs for cracks, corrosion, or damaged ends. Measure free length of each spring - standard specification is approximately 2.04" for 302 Windsor valve springs. Measure spring pressure with spring tester if available - closed pressure should be 71-79 lbs at 1.58-1.62" installed height, open pressure 190-210 lbs at 1.20" lift. Springs not meeting specification must be replaced. Check spring squareness by standing on flat surface against square - out of square more than 1/16" requires replacement. If any springs are questionable or engine has high mileage, replace complete spring set for consistent valve control.
10. 10

    Reassemble valvetrain in cylinder heads
    Lightly oil valve stems with assembly lube or engine oil. Install each valve into its original guide from combustion chamber side. Slide new umbrella-type valve stem seal over valve stem and down onto guide. Install valve spring over valve stem with tightly wound coils or damper end toward head. Place retainer over spring. Using valve spring compressor, compress spring until retainer groove is fully exposed below retainer. Install both keepers into valve stem groove, ensuring they seat completely in groove and engage retainer. Slowly release compressor tension while guiding keepers into place. After release, tap valve stem tip lightly with plastic hammer to ensure keepers are fully seated. Verify keepers are locked by attempting to lift retainer - it should not move. Repeat for all 16 valves per head. After assembly, verify valve spring installed height (distance from spring seat on head to underside of retainer) - should be 1.58-1.62". If height exceeds maximum, valve or seat has been ground too much and requires correction.
11. 11

    Prepare block deck surface and check piston height
    Remove shop towels from cylinder bores. Thoroughly clean cylinder head deck surfaces on engine block using gasket scraper and solvent. Remove all old gasket material and carbon buildup. Clean with degreaser and wipe with lint-free cloth. Inspect deck surface for damage or corrosion. Rotate crankshaft to bring piston 1 to top dead center. Using piston stop tool or dial indicator, verify piston does not protrude above deck surface (should be 0.015-0.030" below deck on standard 302). Check all pistons. If any piston protrudes above deck or deck surface is damaged, consult machine shop before proceeding. Install cylinder head dowel pins if removed.
12. 12

    Install cylinder head gaskets and heads
    Verify cylinder head bolt holes in block are clean and dry. Chase threads with tap if necessary. Place new cylinder head gaskets on block with "TOP" or "UP" marking facing upward. Align gaskets with dowel pins and coolant passages. Apply light coat of copper gasket sealant spray to both sides of gasket per manufacturer instructions (some gaskets require no sealant - verify). Carefully lower cylinder heads onto block, aligning with dowel pins. Do not slide heads after placement as this can damage gasket. Install cylinder head bolts with light coat of engine oil on threads and under bolt heads (or use thread sealant on threads entering water jacket per service manual). Hand-tighten all 10 bolts per head. Torque cylinder head bolts in proper sequence (start at center, work outward in spiral pattern) to factory specification in three stages: first to 30 ft-lbs, second to 50 ft-lbs, third to final specification of 65-72 ft-lbs for standard bolts. Follow exact torque sequence from service manual.
13. 13

    Install pushrods and rocker arm assemblies
    Apply assembly lube or moly paste to both ends of each pushrod. Install pushrods into their original positions, ensuring lower end fully seats in lifter cup. Place fulcrum seats on rocker arm studs. Install rocker arms with valve stem contact side toward valves. Thread rocker arm stud nuts onto studs finger tight. Rotate engine by hand to position cylinder 1 on compression stroke (both valves closed, timing mark at TDC). Tighten cylinder 1 rocker arm nuts while rotating pushrod with fingers - when all lash is removed (slight drag on pushrod rotation), tighten nut an additional 3/4 to 1 turn to achieve proper preload. Repeat procedure for each cylinder in firing order sequence (1-5-4-2-6-3-7-8), rotating engine 90° of crankshaft rotation between cylinders. After all rockers are adjusted, verify adjustment by checking for 0.001-0.003" clearance with feeler gauge when lifter is on base circle of cam.
14. 14

    Install exhaust manifolds
    Place new exhaust manifold gaskets on cylinder head exhaust ports. Position exhaust manifolds and install bolts with anti-seize compound on threads. Tighten exhaust manifold bolts to factory specification (typically 12-18 ft-lbs) working from center bolts outward. Connect exhaust pipes to exhaust manifold flanges with new gaskets and tighten flange nuts securely.
15. 15

    Install intake manifold
    Clean intake manifold mating surfaces thoroughly. Apply thin bead of RTV silicone to front and rear block rails where intake manifold seals meet cylinder heads (4 corner junctions). Place intake manifold end seals in position. Place intake manifold gaskets on cylinder heads with alignment pins or tabs properly positioned. Carefully lower intake manifold into position, ensuring gaskets remain aligned. Install all 12 intake manifold bolts with light oil on threads. Torque intake manifold bolts in proper sequence (start at center, work outward) in two stages: first pass to 5-10 ft-lbs, final pass to 23-25 ft-lbs. Install carburetor with new base gasket, reconnect all linkages, fuel line, and vacuum connections per reference photos.
16. 16

    Install valve covers and restore accessories
    Clean valve cover gasket surfaces. Install new valve cover gaskets with appropriate sealant if required. Position valve covers and install bolts, tightening evenly in crisscross pattern to 3-5 ft-lbs (do not overtighten or gasket will leak). Reconnect all vacuum lines, electrical connections, and spark plug wires per labels and photos. Reconnect all cooling system hoses. Refill cooling system with 15 quarts of 50/50 ethylene glycol coolant mixture. Fill engine with 5 quarts of 10W-30 or 10W-40 conventional engine oil. Reconnect negative battery cable.

Reassembly

1. Double-check all fastener torque values against factory service manual specifications
2. Verify all vacuum lines, electrical connections, and hoses are reconnected per reference photos
3. Check that all accessories (alternator, power steering pump, A/C compressor if equipped) are properly mounted and belt tensioned
4. Verify carburetor linkage operates smoothly through full range without binding
5. Confirm cooling system is filled to proper level and all hose clamps are tight

Verification

• Perform initial engine start and allow to idle - watch for oil pressure to register within 30 seconds
• Listen for unusual valve noise, ticking, or knocking - properly adjusted valvetrain should operate quietly
• Inspect all gasket areas for leaks while engine warms to operating temperature
• Check for coolant leaks at head gaskets, intake manifold, and thermostat housing
• Verify engine reaches normal operating temperature (180-195°F) and thermostat opens
• After engine reaches operating temperature, shut down and allow to cool for 15 minutes, then re-torque cylinder head bolts to specification (some gaskets require re-torque, verify with gasket manufacturer instructions)
• After 500 miles of operation, re-check valve lash adjustment and intake manifold torque
• Monitor oil consumption and coolant level for first 1000 miles - new valve seals may require slight break-in period

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