Cylinder Head Assembly: Service and Repair

1. Disconnect ground cables from both batteries.
2. Mark hood hinge locations and remove hood.
3. Drain cooling system.
4. Disconnect breather hose from valve cover, then remove intake and breather hoses from air cleaner and intake manifold.
5. Remove heater hose bracket-to-valve cover and exhaust manifold attaching nuts.
6. Disconnect heater hoses from thermostat housing and water pump, and position heater hose tube assembly aside.
7. Remove vacuum pump support brace from cylinder head and vacuum pump bracket.
8. Remove alternator and vacuum pump drive belt.
9. Remove A/C compressor and/or power steering pump drive belt, if equipped.
10. Disconnect brake booster vacuum hose, then remove vacuum pump.
11. Disconnect exhaust pipe from exhaust manifold.
12. Disconnect coolant thermoswitch and temperature sender electrical connectors.
13. Remove fuel injection lines. Cap lines and fittings.
14. Disconnect alternator, glow plug harness and dropping resistor electrical connectors and position aside.
15. Disconnect fuel lines from both sides of fuel line heater.
16. Remove fuel filter from mounting bracket and position aside with outlet line connected.
17. Loosen lower No. 3 intake port nut and ``Banjo'' bolt on injection pump, then disconnect lower fuel return line from intake manifold stud and upper fuel return line.
18. If equipped with power steering, remove rear power steering pump bracket attaching bolt.
19. Remove upper radiator hose from engine, then loosen clamp on water pump-to-thermostat housing bypass hose.
20. If equipped with A/C, remove A/C compressor from mounting bracket and position aside with refrigerant lines attached.
21. Remove valve cover and rocker arm shaft.
22. Remove cylinder head attaching bolts and the cylinder head.
23. Reverse procedure to install. Torque cylinder head attaching bolts to specifications in sequence shown, Fig. 5.