Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable.
2. Drain engine cooling system.
3. Disconnect accelerator cable and kickdown cable, if equipped, from throttle body.
4. Disconnect all engine cylinder head vacuum, fuel and cooling hoses, marking for assembly reference.
5. Disconnect all engine cylinder head electrical connectors, marking for assembly reference.
6. Relieve pressure in fuel system.
7. Disconnect fuel feed pipe from throttle body assembly and the return line from the fuel pressure regulator.
8. Remove radiator cooling fan, fan shroud, water pump drive belt and water pump pulley. Refer to Cooling System / Water Pump / Service and Repair for pump removal procedure. Service and Repair
9. Remove crankshaft pulley, timing belt outer cover and timing belt. Refer to Timing Components / Timing Belt / Service and Repair for timing belt removal procedure. Service and Repair
10. Disconnect oil pressure switch electrical lead from retaining clamp.
11. Disconnect oxygen sensor electrical connector.
12. Remove center exhaust pipe from exhaust manifold.
13. On models equipped with air conditioning, remove A/C compressor adjusting arm from cylinder head.
14. Remove valve cover as described under "Valve Cover, Replace."
15. Remove cylinder head bolts.
16. Using an appropriate lifting device, remove cylinder head with distributor, exhaust manifold, intake manifold and carburetor assembly from cylinder block.

Fig. 6 Valve Keeper Removal.:

17. If valves and springs are to be removed, proceed as follows:
a. Using valve spring compressor tool Nos. J8062 and J37979, or equivalents, compress valve springs and remove valve keepers, Fig. 6.
b. Release valve lifter tool and remove valve spring retainers and valve springs.
c. Remove valves from cylinder head. Before removing valves from head, ensure there are no burrs on valve stem from spring removal procedure.
d. Using valve guide oil seal removal tool No. J37281-A, or equivalent, remove valve stem oil seals and valve spring seats.
e. Drive out valve guides using valve guide removal tool No. J34833, or equivalent, toward the valve spring side. Ream valve guide holes using valve guide reamer tool No. J34832, or equivalent, to remove any burrs and to ensure hole is perfectly round.
18. Reverse procedure to install, noting the following:

Fig. 7 Valve Guide Installation.:

a. If removed, install valve guides by heating cylinder head uniformly at a temperature of 176-212 degrees F to prevent head distortion. Using valve guide installation tool No. J34834, or equivalent, drive valve guide into cylinder head leaving a 0.55 inch protrusion above the cylinder head, Fig. 7. Ream valve guide bore after installation into the cylinder head using valve guide reamer tool No. J34831, or equivalent.
b. If removed, install new valve stem oil seals and install them with oil seal installation tool No. J34835, or equivalent.

Fig. 8 Valve Spring Installation.:

c. Install valve springs with small pitch end on valve seat side, Fig. 8.
d. Install new cylinder head gasket with the side marked "TOP" facing upward toward the crankshaft pulley.
e. Lightly oil cylinder head bolts with oil.

Cylinder Head Bolt Tightening Sequence:

f. Using sequence shown in Fig. 9, torque cylinder head bolts in three to four passes to 54 ft. lbs.
g. Check for any fuel, coolant or exhaust leakage.
h. On models equipped with A/C, evacuate and charge A/C system.