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

Warnings

Tools required

Parts

• Cylinder head gasket set × 1 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Intake valves (if replacement needed) × 12 — Use OEM specification
• Exhaust valves (if replacement needed) × 12 — Use OEM specification
• Valve stem seals × 24 — Use OEM specification
• Valve keepers × 48 — Use OEM specification
• Camshaft seal × 4 — Use OEM specification
• Timing chain tensioner × 2 — Use OEM specification
• Cylinder head bolts (TTY) × 20 — Use OEM specification
• Anti-seize compound × 1 — High-temp nickel or copper

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt
• Motorcraft Orange Coolant — 13 qt

Preparation

1. Disconnect negative battery cable and wait 10 minutes for system capacitors to discharge
2. Drain engine coolant completely into appropriate container and dispose per local regulations
3. Drain engine oil and remove oil filter
4. Remove engine cover and air intake system
5. Remove intercooler and charge air cooler piping
6. Disconnect and remove both turbochargers with oil and coolant lines
7. Label and disconnect all electrical connectors, vacuum lines, and fuel lines from cylinder heads
8. Remove accessory drive belt and mark rotation direction
9. Remove power steering pump and A/C compressor (leave hoses attached and secure aside)
10. Position vehicle on level surface with wheel chocks applied

Procedure

1. 1

   Remove valve covers and intake manifold
   Remove ignition coils and spark plugs, labeling cylinder positions. Unbolt and remove both valve covers. Disconnect throttle body and fuel rails. Remove intake manifold assembly, carefully cleaning any gasket debris from mating surfaces without gouging aluminum.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

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

   Remove exhaust manifolds
   Disconnect oxygen sensors and unbolt exhaust manifolds from both cylinder heads. Note that manifolds may be seized to studs. Apply penetrating oil if necessary and allow to soak. Remove manifolds and set aside.
   Torque spec

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

   Set engine to TDC and lock timing
   Rotate crankshaft clockwise to Top Dead Center for cylinder #1 using crankshaft bolt. Verify timing marks on camshaft sprockets align with cylinder head reference marks. Install timing chain locking tools to prevent chain movement. Mark chain-to-sprocket relationship with paint marker on all four camshaft sprockets.
   ⚠Verify TDC position three times before proceeding. Incorrect positioning will result in valve damage during reassembly.
4. 4

   Remove timing cover and timing chains
   Remove front timing cover bolts in reverse sequence. Carefully pry cover away from block without damaging sealing surfaces. Remove timing chain tensioners by compressing and inserting retaining pin. Hold each camshaft with wrench on hex section and remove camshaft sprocket bolts. Remove timing chains, sprockets, and guides as an assembly for each cylinder bank. Keep left and right bank components separated.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Camshaft Sprocket Bolt80 Nm (59 lb-ft)
5. 5

   Remove camshafts
   Loosen camshaft cap bolts in reverse sequence (outward from center) in multiple passes to prevent warping. Remove camshaft caps, keeping them in order with cylinder bank identification. Carefully lift out intake and exhaust camshafts for each bank. Inspect camshaft journals and lobes for wear or scoring.
   ⚠Do not pry on camshafts. If stuck, gently tap cap bolt bosses with plastic mallet.
   Torque spec

   Camshaft Cap Bolts14 Nm (10 lb-ft)
6. 6

   Remove cylinder heads
   Loosen cylinder head bolts in reverse of tightening sequence in multiple passes. Remove all head bolts and discard (TTY bolts cannot be reused). Using proper lifting fixture, carefully remove cylinder heads from block. Place heads on padded surface with valves facing up. Stuff clean rags into cylinder bores to prevent debris entry.
   ⚠Cylinder heads weigh approximately 40 pounds each. Use proper lifting technique or assistance.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
7. 7

   Disassemble valvetrain components
   Using valve spring compressor, compress each valve spring and remove valve keepers. Release spring tension and remove retainers, springs, and seals. Remove all 12 valves from each head, keeping them in order if reusing. Remove rocker arms if not already done. Place all components in labeled containers organized by cylinder and position.
   ⚠️Valve springs are under high tension. Ensure compressor is properly seated before removing keepers. Wear safety glasses.
8. 8

   Clean and inspect cylinder heads
   Thoroughly clean cylinder heads, removing all carbon deposits from combustion chambers and valve seats. Use appropriate solvent and brushes, avoiding wire wheels on aluminum surfaces. Inspect heads for cracks, especially between valve seats and in combustion chambers. Send heads for professional magnaflux inspection and pressure testing. Check head flatness with straightedge and feeler gauge - maximum warpage is 0.003 inch. Have heads resurfaced if necessary.
   ℹ️Professional machine shop inspection is mandatory. Hidden cracks will cause coolant or compression loss after reassembly.
9. 9

   Perform valve guide and seat service
   Measure valve stem-to-guide clearance. Replace worn guides using proper driver and piloted reamer. Cut or grind valve seats to proper angles (typically 45-degree seat with 30 and 60-degree relief cuts). Achieve proper seat width of 1.0-1.5mm. Lap new or resurfaced valves to seats using fine lapping compound. Clean thoroughly and verify seat contact pattern covers middle third of valve face. Test with Prussian blue marking compound.
   ℹ️This step requires specialized machining equipment and experience. Consider professional machine shop service if not equipped.
10. 10

    Reassemble valves into cylinder heads
    Install new valve stem seals on guides using proper installation tool. Lubricate valve stems with assembly lube or clean engine oil. Install valves into their original positions (or new valves if replaced). Install valve springs with closer-wound coils toward head. Compress springs and install new keepers, ensuring they seat properly in valve stem grooves. Tap valve stem tip lightly with plastic hammer to verify keeper seating.
    ⚠Verify keepers are fully seated in valve stem grooves before releasing spring compressor. Improper seating will cause valve failure.
11. 11

    Prepare block surface and install cylinder heads
    Remove rags from cylinders. Clean block deck surface thoroughly with gasket scraper and solvent. Verify deck surface is clean and dry. Inspect for damage or corrosion. Install new head gaskets on block with orientation marks facing up. Carefully lower cylinder heads onto block, aligning dowel pins. Install new TTY head bolts with light oil on threads. Tighten to 48 lb-ft in proper sequence, then tighten additional 90 degrees, then final 90 degrees in same sequence.
    ⚠Do not use any sealant on head gaskets. Follow torque sequence exactly as specified in Ford service manual.
    Torque spec

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

    Install camshafts and timing components
    Lubricate camshaft journals and lobes with assembly lube. Install camshafts in correct positions (intake/exhaust, left/right bank). Install camshaft caps in original positions with arrows pointing toward front of engine. Tighten cap bolts from center outward in multiple passes to 10 lb-ft. Install new camshaft seals. Position timing chains with marked links aligned to camshaft and crankshaft sprockets. Install sprockets and tighten bolts to 59 lb-ft while holding camshaft hex. Install timing chain guides and tensioners.
    ⚠️Verify all timing marks are perfectly aligned before releasing locking tools. Rotate engine two complete revolutions by hand and recheck all timing marks.
    Torque spec

    Camshaft Cap Bolts14 Nm (10 lb-ft)

    Camshaft Sprocket Bolt80 Nm (59 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
13. 13

    Install timing cover and remaining components
    Install new timing cover gasket and apply small bead of RTV sealant at block-to-oil pan junction points. Install timing cover and tighten bolts in sequence to 18 lb-ft. Install rocker arms with cam lobes pointing away from followers and tighten to 22 lb-ft. Install exhaust manifolds with new gaskets, applying anti-seize to studs, torque nuts to 22 lb-ft working from center outward. Install intake manifold with new gaskets, torque bolts to 18 lb-ft in sequence.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Rocker Arm Bolts30 Nm (22 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Intake Manifold Bolts25 Nm (18 lb-ft)
14. 14

    Install valve covers and finalize assembly
    Install new valve cover gaskets. Clean valve cover bolt holes and threads. Install valve covers and tighten bolts in sequence from center outward to 7 lb-ft. Install spark plugs and ignition coils. Reconnect all electrical connectors, vacuum lines, and fuel lines. Reinstall turbochargers with new gaskets. Install intercooler piping. Reinstall accessory drive components. Install new oil filter.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
15. 15

    Refill fluids and perform initial start
    Fill engine with 6 quarts of Motorcraft 0W-20 synthetic oil. Fill cooling system with 13 quarts of Motorcraft Orange coolant, bleeding air from system at bleeder valves. Reconnect battery. Prime fuel system by cycling ignition 3-4 times without starting. Start engine and observe for leaks. Allow engine to reach operating temperature while monitoring oil pressure and coolant temperature. Check for leaks at all gasket surfaces.
    ⚠Do not rev engine during initial start. Allow to idle for 20 minutes minimum. Listen for unusual noises indicating improper valve adjustment or timing.

Reassembly

1. Reassembly is covered in the main procedure steps above
2. Always use new gaskets and TTY bolts - never reuse
3. Follow all torque sequences exactly as specified in Ford service documentation
4. Apply thread sealant or anti-seize only where specifically noted

Verification

• Verify no coolant, oil, or fuel leaks at all gasket surfaces after initial warm-up
• Check engine oil level and top off if necessary after running
• Verify proper coolant level after burping system completely
• Listen for valve train noise - ticking or tapping indicates problem with valve lash or timing
• Perform compression test on all cylinders - readings should be within 10% of each other and meet Ford specifications
• Verify no check engine lights or fault codes related to camshaft or crankshaft position sensors
• Road test vehicle under light load and verify smooth operation across RPM range
• Recheck all fluid levels after 50-100 miles of operation
• Monitor for any oil consumption issues over first 500 miles

More procedures for this vehicle