Cylinder Head Assembly: Service and Repair

REMOVAL

1. Disconnect battery ground cable, drain coolant and disconnect hoses from thermostat housing.
2. Remove air cleaner, then the rocker cover as follows:
a. Remove PCV hose, shut-off valve and PCV valve.
b. Disconnect necessary vacuum and AIR hoses, noting position for assembly.
c. Remove rocker cover nuts and the cover, breaking RTV seal with suitable putty knife or cutter. Do not pry on cover until seal has been completely broken, and only pry cover at locations marked, or cover will be damaged.
3. Remove rocker arm, bridge and pivot assemblies, then the pushrods, keeping all components in order for assembly. Loosen retaining bolts alternately, 1 turn at a time, to avoid damaging bridges.
4. On all models, remove intake manifolds refer to INTAKE MANIFOLD.
5. Remove exhaust manifold refer to EXHAUST MANIFOLD.
6. Disconnect spark plug wires, temperature sensor lead and battery ground strap.
7. Remove cylinder head bolts, cylinder head and gasket.

Fig. 2 Cylinder Head Tightening Sequence:

INSTALLATION

1. Thoroughly clean gasket mating surfaces.
2. Fabricate two alignment dowels from a pair of the longest used head bolts as follows:
a. Cut bolt head off just below the hex head.
b. Cut a slot in the top of the bolt to allow removal with a screwdriver.
3. Install fabricated dowels in cylinder block bolt holes No. 8 and No. 10.
4. Position cylinder head gasket, with numbers facing upward, on cylinder block.
5. Install cylinder head.
6. Apply a suitable sealant to threads of No. 7 head bolt.
7. Install all except No. 8 and No. 10 head bolts.
8. Remove fabricated dowels and install No. 8 and No. 10 head bolts.
9. Torque head bolts in sequence shown in Fig. 2, as follows:
a. Torque bolts 1-10 to 22 ft. lbs.
b. Retorque bolts 1-10 to 45 ft. lbs.
c. Retorque all bolts to 45 ft. lbs.
d. Retorque bolts 1-6 to 110 ft. lbs., bolt 7 to 100 ft. lbs. and bolts 8-10 to 110 ft. lbs.
10. Reverse removal procedure to finalize installation.