Cylinder Head Assembly: Service and Repair

Cylinder Head Removal, Installation, And Tightening Sequence.:

REMOVAL
1. Disconnect battery ground cable.
2. Remove lower radiator hose and drain coolant from engine.
3. Disconnect heater hose at heater inlet tube and disconnect heater inlet tube at water outlet connector.
4. Disconnect upper radiator hose from cylinder head.
5. Disconnect electric cooling fan switch from electrical connector.
6. Remove air cleaner assembly from engine.
7. Mark and disconnect all vacuum hoses from cylinder head.
8. Remove rocker arm cover.
9. Remove all accessory drive belts from engine.
10. Remove distributor cap and spark plug wires as an assembly.
11. If applicable, disconnect EGR tube from EGR valve. Disconnect choke cap wire.
12. Disconnect fuel supply and return lines. Observe safety precautions for fuel under pressure.
13. Disconnect accelerator cable and speed control cable, if equipped.
14. Loosen thermactor pump belt pulley, if so equipped.
15. Raise and support vehicle.
16. Disconnect exhaust system from exhaust pipe. Lower vehicle.
17. Remove cylinder head bolts, cylinder head and gasket with thermactor pump, exhaust and intake manifolds attached.

NOTE: Do not lay cylinder head flat. Damage to spark plugs or gasket surfaces may result.

INSTALLATION
1. Clean all gasket material from mating surfaces on cylinder head and block.
2. Position cylinder head gasket on cylinder block.

NOTE: Before installing cylinder head, thread two cylinder head alignment studs through head bolt holes in gasket and into the block at opposite corners of block.

3. Install cylinder head alignment studs onto cylinder block. Start and run down several head bolts until snug. Remove guide studs and install new cylinder head bolts. Tighten all bolts in sequence (shown in figure) in two steps: First to 70-80 Nm (52-59 ft lb), and then 95-103 Nm (70-76 ft lb).
4. Raise vehicle.
5. Connect exhaust system at exhaust pipe and hose to metal tube.
6. Lower vehicle.
7. Connect accelerator cable and speed control cable, if so equipped.
8. Connect fuel supply and return lines.
9. Install distributor cap and spark plug wires as an assembly.
10. Connect accessory drive belts.
11. Install rocker arm cover.
12. Connect required vacuum hoses.
13. Install air cleaner assembly.
14. Connect upper radiator hoses.
15. Connect heater hose to heater inlet tube and heater inlet tube to water outlet connector.
16. Fill cooling system.
17. Connect battery ground cable.
18. Start engine, check for vacuum, coolant, and oil leaks.
19. After engine has reached operating temperature, check and, if necessary, add coolant.