Cylinder Head Assembly: Service and Repair

Fig. 2 Cylinder head installation & bolt torque sequence:

1985-86

1. Disconnect battery ground cable, drain cooling system and remove air cleaner.
2. Remove A/C compressor, if equipped, and secure aside.
3. Disconnect wires from spark plugs and disconnect PCV hose and plug wires from rocker cover.
4. Remove EGR valve.
5. Disconnect vacuum line hold down at thermostat housing and vacuum hoses from throttle body and studs on intake manifold.
6. Remove bolts securing rocker cover and the cover.
7. Disconnect necessary electrical connectors and harness clips, and secure wiring harness aside.
8. Disconnect accelerator, TV and cruise control cables, as equipped, from throttle levers and brackets.
9. Disconnect bypass and heater hoses from intake manifold, and remove upper radiator hose.
10. Remove alternator brace and A/C compressor bracket, disconnect A/C line hold down, then remove alternator and secure aside.
11. Disconnect exhaust pipe from manifold.
12. Disconnect fuel line bracket near filter and remove dipstick tube.
13. Disconnect fuel and vacuum hoses at fuel filter.To avoid possibility of fire or injury, allow fuel system pressure to bleed off before servicing fuel system components.
14. Remove cylinder head bolts, noting position for installation.
15. Disconnect harness bracket and ground from rear of head and remove coil bracket.
16. Remove brace between engine block and intake manifold.
17. Remove rocker arms and pushrods, keeping components in order for assembly.
18. Remove cylinder head as an assembly with intake and exhaust manifolds.
19. Thoroughly clean gasket from head and block mating surfaces.
20. Install new head gasket, then the cylinder head, ensuring that both gasket and head are seated over dowel pins in block.
21. Reverse procedure to install, noting the following:
a. Ensure cylinder head attaching bolts are clean and dry, then apply suitable sealer to threads of bolts 9 and 10, Fig. 2.
b. Apply engine oil to undersides of remaining bolts, then install bolts and torque to 18 ft. lbs. in sequence shown in Fig. 2.
c. Repeat sequence torquing all bolts except No. 9 to 22 ft. lbs. Torque bolt No. 9 to 30 ft. lbs.
d. Repeat sequence, tightening all bolts except No. 9 120~ (2 flats). Tighten bolt No. 9 90~ (1/4 turn).