Valve Job - Complete

Complete valve job including cylinder head removal, valve grinding/replacement, seat machining, spring replacement, and reassembly with new gaskets and seals.

Warnings

Tools required

Parts

• Cylinder head gaskets (left and right) × 2 — Use OEM specification
• Valve cover gaskets (left and right) × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Exhaust manifold gaskets (left and right) × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Valve stem seals (32 total) × 32 — Use OEM specification
• Cylinder head bolts (TTY) × 20 — Use OEM specification
• Valve springs (if replacement needed) × 32 — Use OEM specification
• Intake valves (if replacement needed) × 16 — Use OEM specification
• Exhaust valves (if replacement needed) × 16 — Use OEM specification
• Valve keepers × 64 — Use OEM specification
• Anti-seize compound × 1 — High-temperature rated
• RTV silicone gasket maker × 1 — Ford WSE-M4G323-A6 or equivalent

Fluids

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

Preparation

1. Disconnect negative battery cable and wait 10 minutes for airbag system deactivation
2. Drain engine coolant completely into appropriate container
3. Drain engine oil and remove oil filter
4. Remove engine cover and air intake system
5. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
6. Remove both valve covers with all ignition coils and spark plugs
7. Tag and disconnect all electrical connectors, vacuum lines, and coolant hoses from cylinder heads
8. Remove throttle body and complete intake manifold assembly
9. Remove both exhaust manifolds
10. Position cylinder 1 to TDC on compression stroke and mark all timing chain alignment positions with paint

Procedure

1. 1

   Remove Timing Chain and Components
   Remove front timing cover. Use timing chain tensioner compression tool to collapse both tensioners and secure with pins. Remove camshaft sprocket bolts while holding camshafts with hex wrench. Remove timing chain, sprockets, and guides. Keep all components organized by cylinder bank.
2. 2

   Remove Camshafts
   Mark each camshaft cap with cylinder number and intake/exhaust designation using permanent marker. Loosen camshaft cap bolts in reverse sequence (outside to center) in multiple passes. Remove caps and carefully lift out camshafts. Inspect camshaft journals and lobes for wear. Store camshafts in protective wrap to prevent damage.
3. 3

   Remove Cylinder Heads
   Remove cylinder head bolts in reverse of tightening sequence (outside to inside pattern). Discard all head bolts as they are TTY and cannot be reused. Carefully lift cylinder heads off block using lifting hooks or assistance. Place heads on clean padded surface. Do not pry between head and block surfaces.
4. 4

   Disassemble Valvetrain
   Using valve spring compressor, compress each valve spring and remove keepers with magnetic tool. Release compressor and remove retainers, springs, and valve stem seals. Remove valves and keep organized by cylinder number and intake/exhaust position. Inspect all components for wear, burning, or damage. Measure valve stem diameter and guide clearance.
   ⚠Valve keepers can fly out under spring pressure. Control spring compressor carefully and use magnetic retrieval tool.
5. 5

   Clean and Inspect Cylinder Heads
   Thoroughly clean combustion chambers, valve guides, and all gasket surfaces using plastic scraper and solvent. Do not use metal scrapers on aluminum surfaces. Clean all carbon deposits from valves using wire brush and solvent. Inspect valve seats for pitting, burning, or recession. Check cylinder head flatness using straightedge and feeler gauge at multiple points - maximum warpage specification is 0.003 inch. If warpage exceeds limit, head must be resurfaced at machine shop.
6. 6

   Machine Valve Seats and Grind Valves
   Take cylinder heads to qualified machine shop for valve seat cutting/grinding and valve face grinding. Specify three-angle valve job (intake and exhaust). Machine shop should cut seats to proper angles, grind valve faces to match, and lap valves to seats. Verify proper seat width (1.0-1.5mm for intake, 1.5-2.0mm for exhaust). Replace any valves with stems worn beyond specification or faces that cannot be properly ground.
   ℹ️This step requires professional machine shop equipment. Do not attempt valve seat cutting without proper training and tools.
7. 7

   Reassemble Valvetrain
   Lubricate valve stems with clean engine oil. Install valves into correct cylinder positions. Install new valve stem seals using seal installer tool - tap gently until seated. Install valve springs with closer-wound coils toward cylinder head. Compress springs and install keepers, ensuring they seat properly in valve stem grooves. After installation, tap valve stem lightly with plastic hammer to verify keeper engagement.
8. 8

   Prepare Block and Install Cylinder Heads
   Clean cylinder block deck surfaces thoroughly with plastic scraper and solvent. Ensure all coolant and oil passages are clear. Check block deck flatness with straightedge. Install alignment dowels if removed. Place new head gaskets on block with 'TOP' or 'FRONT' markings visible - do not use any sealant on MLS head gaskets. Carefully lower cylinder heads onto block, aligning with dowels. Install new TTY head bolts with light oil on threads and under bolt heads.
   ⚠Head gasket orientation is critical. Verify TOP and FRONT markings before installation.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
9. 9

   Torque Cylinder Head Bolts
   Tighten cylinder head bolts in proper sequence starting from center bolts and working outward. First pass: torque all bolts to 65 Nm (48 lb-ft). Second pass: tighten all bolts an additional 90 degrees using angle gauge. Third pass: tighten all bolts another 90 degrees (180 degrees total rotation after initial torque). Verify each bolt has been angle-torqued by marking bolt heads with paint pen before rotation.
   ⚠Torque-to-yield bolts must follow exact sequence and angle specification. Missing angle torque step will cause head gasket failure.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
10. 10

    Install Camshafts
    Lubricate all camshaft journals and lobes with assembly lube or clean engine oil. Verify camshaft timing marks are visible and positioned correctly. Install camshafts into correct positions (intake/exhaust, left/right bank). Install camshaft caps in exact original positions matching marked cylinder numbers. Tighten cap bolts in sequence from center outward in at least 3 progressive passes, final torque 14 Nm (10 lb-ft). Verify camshafts rotate freely by hand.
    Torque spec

    Camshaft Cap Bolts9 Nm (7 lb-ft)
11. 11

    Install Timing Components
    Install timing chain guides and install timing chain onto crankshaft sprocket. Route chain over both camshaft sprockets, aligning all timing marks per factory specifications (colored links align with cam sprocket marks). Install camshaft sprockets while holding camshaft hex with wrench, torque sprocket bolts to 80 Nm (59 lb-ft). Install timing chain tensioners with compression pins/clips inserted, then torque tensioner bolts to 25 Nm (18 lb-ft). Remove tensioner pins to activate tensioners. Rotate engine two complete revolutions by hand and verify all timing marks realign.
    ⚠️Incorrect timing chain installation will cause catastrophic engine damage. Verify all timing marks align before and after two complete crankshaft rotations.
    Torque spec

    Camshaft Sprocket Bolt121 Nm (89 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
12. 12

    Install Timing Cover and Exhaust Manifolds
    Clean timing cover and block mating surfaces. Apply small bead of RTV silicone at block-to-head corners. Install new timing cover gasket and install cover, tightening 8mm bolts in sequence to 25 Nm (18 lb-ft). Install exhaust manifolds with new gaskets, applying anti-seize to stud threads. Tighten exhaust manifold nuts working from hot (center) to cold (outer) positions, final torque 30 Nm (22 lb-ft).
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
13. 13

    Install Intake Manifold and Valve Covers
    Install new intake manifold gaskets and position intake manifold. Tighten intake manifold bolts in sequence from center outward to 25 Nm (18 lb-ft). Install new valve cover gaskets and position valve covers. Tighten valve cover bolts in sequence to 10 Nm (7 lb-ft). Reconnect all electrical connectors, vacuum lines, and coolant hoses. Install spark plugs and ignition coils.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Cover Bolts20 Nm (15 lb-ft)
14. 14

    Refill Fluids and Initial Start
    Install new oil filter and refill engine with 7.5 quarts Motorcraft 0W-20 full synthetic oil. Refill cooling system with 16 quarts Motorcraft Orange coolant, bleeding air from system. Reconnect battery. Disable fuel injection and crank engine for 30 seconds to build oil pressure. Enable fuel injection and start engine. Check for leaks at all gasket surfaces. Allow engine to reach operating temperature while monitoring for proper operation.
    ⚠Monitor oil pressure immediately on startup. Shut down if pressure does not build within 10 seconds.

Reassembly

1. Verify all timing marks aligned correctly after two full crankshaft rotations before installing timing cover
2. Double-check that all camshaft caps are installed in original marked positions
3. Ensure all electrical connectors are properly seated and vacuum lines routed correctly
4. Verify coolant system is fully bled of air after refilling

Verification

• Start engine and verify smooth idle with no unusual valve train noise or ticking
• Check for oil leaks at valve covers, cylinder head gaskets, and timing cover
• Check for coolant leaks at head gaskets and intake manifold
• Check for exhaust leaks at manifold gaskets
• Verify oil pressure reads normal at idle and under load
• Road test vehicle and verify proper engine performance with no misfires or loss of power
• Recheck all fluid levels after test drive and top off as needed
• After 500 miles, recheck valve cover bolt torque and inspect for any new leaks

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