Cylinder Head Assembly: Service and Repair

Removal

NOTE: If the cylinder head is to be replaced, transfer all valves, springs, spark plugs, etc., to the new cylinder head. Clean and inspect all parts, reface the valves and check valve guide clearances before assembling the used parts to the new cylinder head.

1. Drain the cooling system.
2. Remove the Positive Crankcase Ventilation (PCV) valve from the rocker arm cover. Disconnect the vent hose at the intake manifold.
3. Remove the radiator.
4. Disconnect and remove the carburetor fuel inlet line and the distributor vacuum line. Disconnect and label all vacuum lines from the carburetor.
5. Remove the accelerator cable retracting spring. Disconnect the accelerator cable at the carburetor.
On a vehicle with an automatic transmission, disconnect the kickdown cable at the carburetor.
6. Disconnect the radiator upper hose and heater hose at the coolant outlet elbow.
7. Disconnect the muffler inlet pipe from the exhaust manifold. Discard the inlet pipe gasket.
8. Remove the coil bracket attaching bolts and position the coil out of the way.
9. Remove the valve rocker arm cover. Loosen the rocker arm bolts so that the rocker arms can be rotated to one side.
10. Remove the valve push rods in sequence and identify them so that they can be installed in their original position.






11. Disconnect the spark plug wires at the spark plugs using Spark Plug Wire Remover or equivalent.






12. Remove the cylinder head bolts. Install the cylinder head lifting eyes using Engine Lifting Bracket, in the locations shown. Position a floor crane and attach the hoist and lifting sling to the lifting eyes using Rotunda Engine Sling and Rotunda Floor Crane or equivalents. Lift the cylinder head and intake and exhaust manifolds assemblies off the engine.

CAUTION: Do not pry between the head and block as the gasket surfaces may become damaged.


Installation
1. Clean the cylinder head and cylinder block gasket surfaces. Clean the exhaust manifold and muffler inlet pipe gasket surfaces.
2. If the cylinder head was removed for a cylinder head gasket replacement, check the flatness of the head and block gasket surfaces.
3. Position the gasket over the dowel pins on the cylinder block.
4. Install lifting eyes on the cylinder head and use a floor crane and lifting sling to lift the cylinder head over the cylinder block. Lower it carefully until it is properly positioned on the block and dowel pins. Remove the hoist and lifting eyes.
5. Coat the threads of the cylinder head bolts with engine oil. Install the bolts.
6. Tighten the bolts in numerical sequence. Bolts are tightened in 3 steps.
^ 1st step-tighten all bolts to 75 N-m (55 ft-lb).
^ 2nd step-tighten all bolts to 88 N-m (65 ft-lb).
^ 3rd step-tighten all bolts to 115 N-m (85 ft-lb).
When cylinder head bolts have been tightened it is not necessary to re-tighten the bolts after extended operation.
7. Apply Polyethylene Grease or equivalent to both ends of the push rods. Install the push rods in their original bores, positioning the lower end of the rods in the valve tappet sockets.
8. Apply Polyethylene Grease or equivalent to the rocker arm fulcrum seat and the fulcrum seat socket in the rocker arm. Position the rocker arms and tighten the rocker arm bolt just enough to hold the push rods in position. Check the valve clearance.
9. Clean the valve rocker arm cover. Place the new gasket in the cover making sure that the tabs of the gasket engage the notches provided in the cover. Position the cover, making sure that the gasket seats evenly around the cylinder head. Install the cover bolts and tighten in sequence (starting in the center) to 5-9 N-m (4-7 ft-lbs).
10. Connect the spark plug wires to the spark plugs.
11. Connect the crankcase vent hose to the inlet tube in the intake manifold. Install the PCV valve in the valve rocker arm cover.
12. Position the fuel inlet line and the distributor vacuum line on the engine. Connect the distributor vacuum line to the distributor and carburetor. Connect the carburetor fuel inlet line to the carburetor and fuel pump. Connect all vacuum lines to the carburetor.
13. Connect the accelerator cable to the carburetor. Install the accelerator cable and retracting spring.
14. On a vehicle with an automatic transmission, connect the kickdown cable to the carburetor.
15. Connect the radiator upper hose to the coolant outlet housing. Connect the heater hose to the coolant outlet housing, but do not tighten the clamp.
16. Fill and bleed the cooling system, then tighten the heater hose clamp.
17. Operate the engine until engine temperatures have stabilized. Adjust the engine idle speed to specification on engine decal. Check for fuel, oil, and coolant leaks.
18. Install the air cleaner.