Cylinder Head Assembly: Service and Repair

Fig. 7 Installing brass plug into cylinder head:

External coolant loss from the rear lower corner of the left cylinder head and front lower corner of the right cylinder head is the result of a sealing condition around the core clean-out hole in the cylinder head. This condition can be corrected by installing a brass plug kit (part No. 14077197), consisting of two brass plugs and one driver. To install plugs, remove cylinder head as outlined below, then proceed as follows:

1. Clean inside edge of plug hole, Fig. 7, with a wire brush and suitable solvent.
2. Apply suitable sealant to sides of brass plug and hole.
3. Install plug slowly and squarely using an arbor press and plug driver, until plug is flush with head surface. If the plug deforms or pulls away from side of hole, lightly tap sides of plug to move back into contact with side of hole while sealant is still wet.
4. Remove all old sealant from cylinder head bolt holes in block using an M12 [ERROR-1] 1.75 tap.
5. Clean block mating surfaces and remove any sheared brass or excessive sealant from cylinder head.
6. Install cylinder head as outlined below.

Fig. 8 Cylinder head bolt tightening sequence:

REMOVAL/INSTALLATION
Right Side
1. Remove intake manifold. Refer to INTAKE MANIFOLD REPLACE.
2. Remove injection lines.
3. If equipped with cruise control, remove cruise control transducer.
4. If equipped with A/C, remove upper fan shroud and A/C compressor belt.
5. Raise vehicle, then disconnect exhaust pipe at manifold flange.
6. If equipped with A/C, remove A/C compressor brace from exhaust manifold.
7. Disconnect glow plug wires and lower vehicle.
8. If equipped with A/C, discharge system, disconnect A/C compressor suction and discharge lines, then remove A/C compressor from brackets and remove.
9. Loosen dipstick tube front bracket and remove from stud.
10. Remove upper bracket from oil fill tube.
11. Remove wire loom bracket, rocker cover bolts and rocker cover.
12. Remove rocker arm assemblies, then remove pushrods. Prior to removing pushrods, mark upper end as an aid during reassembly. Failure to identify pushrods could result in incorrect installation, leading to premature wear or damage.
13. Drain cooling system, then remove air cleaner resonator and bracket.
14. Remove transmission fill tube bracket nut and position tube aside.
15. Disconnect heater, radiator and bypass hoses at coolant crossover, then remove crossover.
16. Remove generator upper bracket.
17. Remove cylinder head bolts.
18. Remove transmission dipstick at rear of head and remove tube.
19. Remove cylinder head.
20. Reverse procedure to install, noting the following:
a. Position cylinder head gasket over dowel pins. Do not use any sealer on cylinder head gasket, as sealer is ``printed'' onto gaskets during manufacture, and any additional sealer will increase the possibility of leakage.
b. Coat cylinder head bolts with sealing compound 1052080, or equivalent.
c. Install left rear cylinder head bolt through bolt hole and carefully guide cylinder head onto block.
d. Tighten cylinder head bolts in 3 steps, using sequence shown in Fig. 8. Refer to ``Tightening Specifications'' chart for torque specifications.

Left Side
1. Remove intake manifold. Refer to ``Intake Manifold, Replace.''
2. Remove fuel injection lines from injection pump.
3. If equipped with cruise control, remove cruise control transducer.
4. If equipped with A/C, remove upper fan shroud and A/C compressor belt.
5. Raise vehicle, then disconnect exhaust pipe at manifold flange.
6. If equipped with A/C, remove A/C compressor brace from exhaust manifold.
7. Remove exhaust manifold.
8. Remove power steering pump lower adjusting bolts.
9. Disconnect glow plug wiring and temperature switch.
10. Remove injection lines from nozzles, then cap all openings. Lower vehicle.
11. If equipped with A/C, discharge system, disconnect A/C compressor suction and discharge lines, then remove A/C compressor.
12. Remove power steering pump upper attaching bolt and position pump aside.
13. Remove stud from dipstick tube front bracket, then remove oil filler tube upper bracket.
14. Remove glow plug controller and bracket, then remove glow plug relay.
15. Disconnect T.V. cable.
16. Disconnect oil pressure switch and loom, then remove loom bracket.
17. Remove vacuum line clip attaching bolt from head.
18. Remove rocker cover bolts, then disconnect fuel return line bracket.
19. Remove rocker cover, then remove rocker arm assemblies and pushrods. Prior to removing pushrods, mark upper end as an aid during reassembly. Failure to identify pushrods could result in incorrect installation, leading to premature wear or damage.
20. Drain cooling system, then remove air cleaner resonator and bracket.
21. Remove transmission fill tube bracket nut, then position tube aside.
22. Disconnect heater, radiator and bypass hoses at coolant crossover, then remove crossover.
23. Remove generator upper mounting bracket.
24. Remove cylinder head bolts, then the cylinder head.
25. Reverse procedure to install, noting the following:
a. Position cylinder head gasket over dowel pins. Do not use any sealer on cylinder head gasket, as sealer is ``printed'' onto gaskets during manufacture, and any additional sealer will increase the possibility of leakage.
b. Coat cylinder head bolts with sealing compound 1052080, or equivalent.
c. Install left rear cylinder head bolt through bolt hole and carefully guide cylinder head onto block.
d. Tighten cylinder head bolts in 3 steps, using sequence shown in Fig. 8. Refer to TIGHTENING SPECIFICATIONS under SPECIFICATIONS chart for torque specifications.