Removal and Installation
REMOVAL1. Disconnect the battery negative cable.
2. Drain cooling system.
3. Remove the air cleaner resonator and duct work.
4. Remove the intake manifold-to-generator bracket support rod. Remove the generator.
5. Remove closed crankcase ventilation system.
6. Disconnect the evaporation control system.
7. Perform the Fuel System Pressure Release procedure. Disconnect the fuel supply line.
8. Disconnect accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
9. Remove distributor cap and wires.
10. Disconnect the coil wires.
11. Disconnect heat indicator sending unit wire.
12. Disconnect heater hoses and bypass hose.
13. Remove cylinder head covers and gaskets.
14. Remove intake manifold and throttle body as an assembly. Discard the flange side gaskets and the front and rear cross-over gaskets.
15. Remove exhaust manifolds.
16. Remove rocker arm assemblies and push rods. Identify to ensure installation in original locations.
17. Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylinder head gasket.
18. Remove spark plugs.
CLEANING
1. Clean all surfaces of cylinder block and cylinder heads.
2. Clean cylinder block front and rear gasket surfaces using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is any reason to suspect leakage. If out-of-flatness exceeds 0.00075 mm/mm (0.0001 in/in.) times the span length in any direction, either replace head or lightly machine the head surface.
FOR EXAMPLE:
-A 305 mm (12 inch) span is 0.102 mm (0.004 inch) out-of-flat. The allowable out-of flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm (0.009 inch). This amount of out-of-flat is acceptable.
The cylinder head surface finish should be 1.78 - 3.00 microns (70 - 125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
1. Clean all surfaces of cylinder block and cylinder heads.
2. Clean cylinder block front and rear gasket surfaces using a suitable solvent.
3. Position new cylinder head gaskets onto the cylinder block.
4. Position cylinder heads onto head gaskets and cylinder block.
5. Starting at top center, tighten all cylinder head bolts, in sequence (Fig. 6).
CAUTION: When tightening the rocker arm bolts, make sure the piston in that cylinder is NOT at TDC. Contact between the valves and piston could occur.
6. Install push rods and rocker arm assemblies in their original position. Tighten the bolts to 28 Nm (21 ft. lbs.) torque.
7. Install the intake manifold and throttle body assembly.
8. Install exhaust manifolds.
9. If required, adjust spark plugs to specifications. Install the plugs and tighten to 41 Nm (30 ft. lbs.) torque.
10. Install coil wire.
11. Connect heat indicator sending unit wire.
12. Connect the heater hoses and bypass hose.
13. Install distributor cap and wires.
14. Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables.
15. Install the fuel supply line.
16. Install the generator and drive belt. Tighten generator mounting bolt to 41 Nm (30 ft. lbs.) torque. Tighten the adjusting strap bolt to 23 Nm (200 inch lbs.) torque.
17. Install the intake manifold-to-generator bracket support rod. Tighten the bolts.
18. Place the cylinder head cover gaskets in position and install cylinder head covers.
19. Install closed crankcase ventilation system.
20. Connect the evaporation control system.
21. Install the air cleaner.
22. Fill cooling system.
23. Connect the negative cable to the battery.
24. Start engine check for leaks.