Cylinder Head Assembly: Service and Repair

REMOVAL
1. Disconnect battery ground cable.
2. Drain cooling system, then remove air cleaner assembly.
3. Remove heater hose to rocker arm cover retaining screw.
4. Remove distributor cap and spark plug wires, then the spark plugs.
5. Disconnect vacuum hoses as necessary.
6. Remove dipstick and rocker arm cover.
7. Remove intake manifold retaining bolts.
8. Remove alternator belt and alternator bracket-to-cylinder head bolts.
9. Remove upper radiator hose.
10. Remove timing belt cover. On vehicles with power steering, remove power steering pump bracket bolts.
11. Loosen cam idler retaining bolts, then position idler in the unloaded position and tighten bolts.
12. Remove timing belt.
13. Remove heated air intake pipe and exhaust manifold bolts.
14. Remove timing belt idler, the two bracket bolts and idler spring from cylinder head.
15. Disconnect oil pressure sending unit lead wire.
16. Remove cylinder head bolts and cylinder head.
17. Thoroughly clean all gasket surfaces, then blow oil out of the cylinder head bolt block holes.

Fig. 3 Cylinder head bolt tightening sequence. 4-122 & 4-140 carbureted engines:

Fig. 4 Cylinder head bolt tightening sequence. 4-140 EFI engine:

INSTALLATION
1. Position cylinder head gasket onto engine block.
2. Clean rocker arm cover (cam cover).
3. Using suitable contact cement, install rocker cover gasket onto rocker cover.
4. Install cylinder head attaching bolts and torque in sequence and to specifications, Figs. 3 and 4.
5. Connect oil sending unit electrical connector(s).
6. Install cam belt (timing belt) idler spring stop onto cylinder head.
7. Position cam belt idler onto cylinder head and install attaching bolts.
8. Install exhaust manifold attaching bolts and/or stud bolts.
9. Install heat air intake pipe to exhaust manifold.
10. Align distributor rotor with number one plug location in the distributor cap.
11. Align cam gear with pointer.
12. Align crank pulley (TDC) with pointer on cam belt cover.
13. Position cam belt onto cam and auxiliary pulleys.
14. Loosen idler retaining bolts, rotate engine and check timing alignment.
15. Adjust belt tensioner, then tighten bolts.
16. Install cam belt cover attaching bolts.
17. Install upper radiator hose onto engine and radiator assembly, then tighten retaining clamps.
18. Position alternator bracket onto cylinder head and install retainers.
19. Position drive belt onto pulley and adjust belt tension.
20. Position intake manifold to head and install attaching bolts.
21. Install rocker arm cover and attaching bolts.
22. Install spark plugs and dipstick.
23. Connect all vacuum hoses and spark plug wires.
24. Install air cleaner assembly.