Cylinder Head Assembly: Service and Repair
RemovalNOTE: 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 and the crankcase. Remove the hood. Remove the throttle body inlet tubes. Remove air conditioner compressor and condenser.
2. Disconnect the battery ground cable. Disconnect the heater hose from the water pump and coolant outlet housing. Disconnect the flexible fuel line from the fuel pump.
3. Remove the radiator.
4. Remove the cooling fan, viscous fan drive, water pump pulley, and fan drive belt.
5. Disconnect the accelerator cable at the throttle body. Remove the cable retracting spring.
On a vehicle with power brakes, disconnect the vacuum line at the intake manifold.
On a vehicle with an automatic transmission, disconnect the transmission kickdown cable at the throttle body.
6. Disconnect the exhaust manifold from the muffler inlet pipe. Disconnect the body ground strap and the battery ground cable at the engine.
7. Disconnect the Electronic Engine Control (EEC) harness from all sensors (if so equipped).
8. Disconnect the engine wiring harness at the ignition coil, coolant temperature sending unit and oil pressure sending unit. Position the harness out of the way.
9. Remove the alternator mounting bolts and position the alternator out of the way, leaving the wires attached.
On a vehicle with power steering, remove the power steering pump from the mounting brackets and position it right side up and to one side, leaving the lines attached. If equipped with an air compressor, bleed the air system and disconnect the two air pressure lines at the compressor.
10. Remove the coil bracket attaching bolts and position the coil out of the way.
11. Remove the valve rocker arm cover. Loosen the rocker arm bolts so that the rocker arms can be rotated to one side.
12. Remove the valve push rods in sequence and identify them so that they can be installed in their original position.
13. Disconnect the spark plug wires at the spark plugs using Spark Plug Wire Remover or equivalent.
14. 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 67-75 N-m (50-55 ft-lbs).
^ 2nd step-tighten all bolts to 82-88 N-m (60-65 ft-lbs).
^ 3rd step-tighten all bolts to 94-115 N-m (70-85 ft-lbs).
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 and 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 7.9-11.9 N-m (70-105 in-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 Positive Crankcase Ventilation (PCV) valve in the valve rocker arm cover.
12. Install the exhaust manifold-to-muffler inlet pipe lockwashers and nuts. Tighten the nuts to 34-52 N-m (25-38 ft-lbs).
13. Connect the engine ground strap and the battery ground cable.
14. Connect EEC harness to all sensors, if so equipped.
15. On a vehicle with an automatic transmission, connect the kickdown cable to the throttle body.
Connect the accelerator linkage to the carburetor and install the retracting spring. Connect the choke cable to the carburetor and hand throttle, if so equipped.
On a vehicle with power brakes, connect the brake vacuum line to the intake manifold.
16. Connect the coil primary wire, oil pressure and coolant temperature sending unit wires, flexible fuel line, heater hoses and the battery positive cable.
17. Install the alternator on the mounting bracket.
On a vehicle with power steering, install the power steering pump on the mounting brackets.
18. Install the water pump pulley, viscous fan drive, Right Hand threads on fan clutch, cooling fan and drive belt. Tighten the fan bolts to 17-24 N-m (12-18 ft-lbs).
Adjust tension of all drive belts. Tighten the alternator, power steering pump, and air compressor mounting bolts.
19. Install the radiator. Connect the radiator lower hose to the water pump and the radiator upper hose to the coolant outlet housing. Connect the air compressor lines. If removed, install air conditioner compressor and condenser.
On a vehicle with an automatic transmission, connect the oil cooler lines.
20. If applicable, install and adjust the hood.
21. Fill and bleed the cooling system. Fill the crankcase. Operate the engine at fast idle and check all hose connections and gaskets for leaks.
22. Perform EEC Quick Test to check the function of the EEC system, if so equipped.
23. On a vehicle with standard transmission, adjust the clutch pedal free travel.
On a vehicle with an automatic transmission, adjust the transmission control linkage. Check the fluid level and add as required to bring it to the proper level on the oil indicator.
24. Install the throttle body intake tubes.