Valve Job - Complete

Complete valve job including cylinder head removal, valve grinding/replacement, valve seat machining, valve guide service, and cylinder head reinstallation with timing system service.

Warnings

Tools required

Parts

• Cylinder head gasket set (both banks) × 1 — Use OEM specification
• Valve cover gaskets with grommets (both sides) × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets (both sides) × 2 — Use OEM specification
• Cylinder head bolts (TTY - do not reuse) × 20 — Use OEM specification
• Valve stem seals (16 intake, 16 exhaust) × 32 — Use OEM specification
• Intake and exhaust valves (if replacing) × 32 — Use OEM specification
• Valve keeper sets × 32 — Use OEM specification
• Timing chain tensioner gaskets × 2 — Use OEM specification
• Camshaft position sensor O-rings × 4 — Use OEM specification
• VCT solenoid seals × 4 — Use OEM specification
• Spark plugs × 8 — Motorcraft SP-515 or equivalent
• Anti-seize compound × 1 — High-temperature rated

Fluids

• Motorcraft 5W-20 Synthetic Blend — 7.5 qt
• Motorcraft Orange Coolant — 16 qt

Preparation

1. Disconnect negative battery cable and wait 10 minutes for airbag system capacitors to discharge
2. Drain engine coolant completely into appropriate container
3. Drain engine oil and remove oil filter
4. Remove engine cover and air intake system including air box and intake tube
5. Remove both valve covers after disconnecting ignition coils and harness connections
6. Disconnect all electrical connectors from cylinder heads including VCT solenoids, camshaft position sensors, and coolant temperature sensors
7. Remove spark plugs from all cylinders and label by cylinder number
8. Remove accessory drive belt and mark rotation direction
9. Support engine from below with jack and wood block, then remove upper engine mounting hardware
10. Remove power steering pump and set aside without disconnecting lines
11. Label and disconnect all vacuum lines, coolant hoses, and fuel lines from intake manifold
12. Relieve fuel system pressure before disconnecting fuel lines

Procedure

1. 1

   Remove intake manifold assembly
   Disconnect throttle body electrical connector and coolant hoses. Remove all intake manifold bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift intake manifold assembly from engine, ensuring all gasket material stays with manifold or is removed from cylinder heads. Clean all gasket surfaces with non-metallic scraper.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
2. 2

   Remove exhaust manifolds from both banks
   Working from below vehicle as needed, remove exhaust manifold nuts from both cylinder banks. Start removal from coolest point (outer ends) working toward center. Keep manifolds with hardware for reassembly. Inspect studs for damage and replace if necessary.
   ⚠Exhaust studs are prone to breaking on high-mileage engines. Apply penetrating oil and allow to soak before removal.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
3. 3

   Remove timing cover and position camshafts
   Remove crankshaft pulley and harmonic balancer. Remove all timing cover bolts following removal sequence. Carefully pry timing cover away from engine block using designated pry points only. Rotate engine to TDC on cylinder #1 (camshaft flats facing up). Mark timing chain position on both cam phasers and crankshaft sprocket with paint pen. Take clear reference photos showing all timing marks and chain positions.
   ⚠️Document exact timing chain and phaser positions. Incorrect timing will cause valve-to-piston contact and engine destruction.
   Torque spec

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

   Remove timing chains and camshaft components
   Compress both timing chain tensioners using tensioner compression tool and lock with pins or clips. Remove tensioner bolts. Hold camshafts using wrench flats and remove camshaft sprocket bolts. Remove both VCT cam phasers with timing chains attached. Keep left and right bank components separate and labeled. Remove camshaft bearing cap bolts in reverse sequence (outward from center). Carefully lift camshafts from cylinder heads, keeping them identified by bank and position (intake/exhaust).
   ⚠Do not rotate crankshaft with camshafts removed. Mark camshaft positions and keep all bearing caps in order.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)

   Camshaft Cap Bolts14 Nm (10 lb-ft)
5. 5

   Remove cylinder heads
   Remove all cylinder head bolts in proper reverse sequence (consult service manual for exact pattern, typically outside-to-inside spiral). Discard all cylinder head bolts as they are TTY and cannot be reused. Carefully lift cylinder heads straight up from engine block using lifting eyes or appropriate equipment. Place heads on clean padded surface with combustion chambers facing up. Remove and discard cylinder head gaskets. Do not allow debris to fall into engine cylinders - stuff clean shop rags into cylinder bores.
   ⚠️Cylinder head bolts are torque-to-yield and MUST be replaced with new bolts. Never reuse removed head bolts.
   Torque spec

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

   Disassemble valvetrain from cylinder heads
   Using valve spring compressor, compress each valve spring and remove valve keepers (use magnetic tool to prevent dropping). Release spring pressure and remove valve spring retainer and valve spring. Remove valve stem seal. Pull valve from combustion chamber side of head. Keep all valves in order by cylinder and position (intake/exhaust) using numbered valve holder tray. Repeat for all 32 valves across both cylinder heads. Inspect each valve for burning, pitting, or damage to face and stem.
   ⚠Keep all valves organized by position. Valve keepers are small and easily lost - work over clean surface or magnetic tray.
7. 7

   Inspect and measure cylinder head components
   Check cylinder head deck surface flatness using precision straight edge and feeler gauge across multiple angles. Maximum allowable warpage is 0.003 inches. Measure valve guide inside diameter using small bore gauge or inside micrometer at top, middle, and bottom of each guide. Measure valve stem diameter at multiple points. Calculate stem-to-guide clearance (should be 0.0008-0.0027 inches for intake, 0.0018-0.0037 inches for exhaust). Inspect valve seats for pitting, burning, or uneven wear. Check valve springs for squareness and proper free length.
   ⚠Heads exceeding 0.003 inch flatness specification require resurfacing. Excessive resurfacing will alter compression ratio and valve geometry.
8. 8

   Machine valve seats and resurface cylinder heads
   Send cylinder heads to qualified machine shop or perform seat machining using proper equipment. Valve seat angles for Coyote engine: 45-degree face angle with 30-degree top cut and 60-degree throat cut. Seat width should be 0.060-0.080 inches after machining. If cylinder heads require resurfacing due to warpage, remove minimum material necessary. Replace valve guides if clearances are excessive. After machining, thoroughly clean cylinder heads with hot soapy water, blow dry with compressed air, then oil all machined surfaces to prevent rust.
   ⚠Valve seat concentricity is critical. Seats must run true to valve guide within 0.002 inches TIR (total indicated runoff).
9. 9

   Grind or replace valves and lap to seats
   Grind valve faces to 45.5-degree angle (0.5 degrees different from seat creates interference angle for better seal). If valves show burning, severe pitting, or stem wear beyond specification, replace with new valves. After face grinding, lap each valve to its corresponding seat using valve lapping compound and lapping tool. Apply thin layer of coarse compound, lap with rotary motion until even gray band appears on both seat and valve face, then finish with fine compound. Clean all compound residue thoroughly with solvent. Verify seal by applying layout dye to valve face - seating area should show complete contact around entire circumference.
   ℹ️Each valve should be lapped to the specific seat it will be installed in. Do not mix valve positions after lapping.
10. 10

    Reassemble valvetrain with new seals
    Lubricate valve stems with clean engine oil. Install each valve into its corresponding guide from combustion chamber side. Place new valve spring over valve (verify correct orientation if spring has different pitch ends - closer coils go toward head). Install new valve stem seal over valve stem and seat firmly onto valve guide using appropriate seal installation tool. Place spring retainer over spring. Compress spring with valve spring compressor and install valve keepers in valve stem groove. Carefully release spring pressure ensuring keepers are properly seated. Tap valve stem tip lightly with plastic mallet to verify keepers are locked. Repeat for all 32 valves in both cylinder heads.
    ⚠Ensure valve keepers are fully seated in stem grooves. Improperly seated keepers will release under engine operation causing catastrophic valve drop.
11. 11

    Prepare engine block and install cylinder heads
    Remove shop rags from cylinders. Clean cylinder head gasket surfaces on engine block using non-metallic scraper - surface must be completely clean and free of old gasket material, RTV, or debris. Clean engine block deck surface with solvent and lint-free cloth. Verify block deck flatness if heads were resurfaced. Install new cylinder head gaskets on block - note orientation markings (FRONT, LEFT/RIGHT bank indicators). Carefully position cylinder heads onto block, aligning dowel pins. Install NEW cylinder head bolts finger-tight in all positions.
    ⚠️Use only NEW cylinder head bolts. Old TTY bolts will fail causing head gasket failure or bolt breakage.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
12. 12

    Torque cylinder head bolts in sequence
    Following manufacturer's tightening sequence (consult service manual for exact pattern - typically starts at center and spirals outward), torque all head bolts to 48 ft-lbs (65 Nm) in sequence. Then perform additional tightening using angle gauge: rotate each bolt an additional 90 degrees in same sequence, then a final 90 degrees (total 180 degrees additional rotation after initial torque). Verify all bolts have been angle-tightened by marking bolt heads with paint pen before starting angle tightening.
    ⚠Follow exact torque sequence and angle tightening procedure. Skipping sequence or angles will result in head gasket failure.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
13. 13

    Install camshafts and bearing caps
    Lubricate all camshaft journals and lobes with engine assembly lube or clean engine oil. Position camshafts in cylinder heads with timing flats facing upward (TDC position). Install camshaft bearing caps in correct positions and orientation (caps are numbered and marked for position). Install camshaft cap bolts and tighten in sequence from center outward. First pass: 5 ft-lbs, second pass: 10 ft-lbs (14 Nm) final torque. Verify camshafts rotate freely by hand after installation.
    ⚠Camshaft bearing caps must be installed in exact original positions. Mixing positions will cause binding and bearing damage.
    Torque spec

    Camshaft Cap Bolts14 Nm (10 lb-ft)
14. 14

    Install timing chains and set camshaft timing
    Verify crankshaft is still at TDC position. Install VCT cam phasers onto camshafts with timing chains positioned exactly per reference photos and paint marks made during disassembly. Hold camshafts with wrench on hex flats and install camshaft sprocket bolts, torquing to 59 ft-lbs (80 Nm). Install timing chain tensioners with compression pins still installed and torque tensioner bolts to 18 ft-lbs (25 Nm). Verify all timing marks align correctly with camshaft flats facing up. Remove tensioner compression pins allowing tensioners to apply chain tension. Rotate engine by hand two complete revolutions and recheck all timing marks - they must return to exact alignment.
    ⚠️Timing must be absolutely correct. Verify timing marks alignment after rotating engine two full turns. Incorrect timing causes valve-to-piston contact.
    Torque spec

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
15. 15

    Install timing cover and remaining components
    Clean timing cover and engine block surfaces. Install new timing cover gasket (use small amount of RTV at block-to-head joints only if specified). Position timing cover and install all bolts following tightening sequence, torquing 8mm timing cover bolts to 18 ft-lbs (25 Nm). Install harmonic balancer and crankshaft pulley. Install exhaust manifolds to both cylinder heads using new gaskets, applying anti-seize to stud threads, torquing nuts to 22 ft-lbs (30 Nm) working from hot (center) to cold (outer ends). Install intake manifold with new gaskets, torquing bolts in sequence to 18 ft-lbs (25 Nm). Reconnect all coolant hoses, vacuum lines, fuel lines, and electrical connectors.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
16. 16

    Install valve covers and complete reassembly
    Install new valve cover gaskets with grommets in valve covers. Apply small dab of RTV at front camshaft cap corners if specified. Position valve covers and install bolts, torquing in sequence from center outward to 7 ft-lbs (10 Nm). Install new spark plugs (do not overtighten - follow spark plug manufacturer torque spec). Reconnect ignition coils. Install power steering pump and accessory drive belt. Reinstall engine cover and air intake system. Reconnect battery negative cable.
    Torque spec

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

    Fill fluids and perform initial start
    Fill cooling system with 16 quarts Motorcraft Orange Coolant (50/50 mixture). Install new oil filter and fill engine with 7.5 quarts Motorcraft 5W-20 Synthetic Blend oil. Check all fluid levels. Before starting engine, crank engine with fuel pump fuse removed and throttle wide open for 10 seconds to build oil pressure (verify oil pressure light goes off). Reinstall fuel pump fuse. Start engine and verify oil pressure immediately. Allow engine to idle and monitor for leaks, unusual noises, or warning lights. Engine may run rough briefly while air purges from fuel system.
    ⚠Monitor oil pressure closely during first start. If oil pressure warning light stays on, shut down immediately and investigate.

Reassembly

1. Reverse removal procedure for all disconnected components not covered in steps
2. Bleed cooling system by running engine to operating temperature with heater on full hot, adding coolant as needed until system is full and no air pockets remain
3. Check and adjust all accessory belt tensions
4. Verify all electrical connectors are fully seated and locked

Verification

• Start engine and verify smooth idle with no unusual noises, ticking, or rattling
• Verify oil pressure reaches normal range (40-70 psi at idle when warm)
• Check for any coolant, oil, or fuel leaks around cylinder heads, timing cover, intake manifold, and valve covers
• Verify no check engine light or diagnostic trouble codes present
• Road test vehicle under various load conditions to verify proper engine performance and power delivery
• After 500 miles, re-check cylinder head bolt torque (though TTY bolts should not require re-torquing, verify no loosening has occurred)
• Monitor oil consumption and coolant level over first 1000 miles to verify proper valve seal function and head gasket seal

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