Cylinder Head Assembly: Service and Repair

*** UPDATED BY TSB #90-12B-9

Removal
1. Disconnect battery ground cable.
2. Remove lower radiator hose and drain coolant from engine.
3. Disconnect heater hose from fitting located under intake manifold.
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 & gasket.
9. Remove all accessory drive belts from engine.
10. Remove distributor cap and spark plug wires as an assembly.
11. Disconnect EGR tube from EGR valve. Disconnect choke cap wire.
12. Remove rocker arm fulcrum attaching bolts.
13. Remove fulcrum, rocker arms and push rods.
NOTE: The location of each rocker arm, push rod and fulcrum should be identified. When reassembled, each component should be installed in its original position.
14. Disconnect fuel supply and return lines from rubber connector.
15. Disconnect accelerator cable and speed control cable, if equipped.
16. Loosen thermactor pump belt pulley.
17. Raise and support vehicle.
18. Disconnect exhaust system from exhaust pipe. Lower vehicle.

Fig. 8 Cylinder Head Bolt Tightening Sequence:

19. Remove cylinder head bolts, cylinder head and gasket with thermactor pump, exhaust and intake manifolds attached. Do not lay cylinder head flat. Damage to spark plugs or gasket surfaces may result.

Installation
1. Clean all gasket material from mating surface on cylinder head and block.
2. Position cylinder head gasket on the cylinder block.
NOTE: Before installing the cylinder head, thread two cylinder alignment studs T84P-6065-A or equivalent trough head bolt holes in the gasket and into the block at opposite corners of the block.
3. Install cylinder head over the cylinder head alignment studs T84P-6065-A or equivalent onto the cylinder block. Start and run down several head bolts until snug. Remove guide studs and install cylinder head bolts. Refer to Engine Tightening Specifications for torque values and Fig. 5, for tightening sequence.
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 fulcrum attaching bolts, fulcrum rocker arms and push rods.
NOTE:Caution must be made to insure that the rocker arms, push rods, and fulcrums are installed into their original position.
10. Install rocker arm cover gasket and cover.
11. Install spark plug boots, wires and distributor cap as an assembly.
12. Connect all accessory drive belts.
13. Connect EGR tube at the EGR valve.
14. Connect required vacuum lines.
15. Connect air cleaner assembly.
16. Connect cooling fan switch at plastic connector.
17. Connect upper radiator hose at the cylinder block.
18. Connect the heater hose at the fitting located under the intake manifold.
19. Fill cooling system.
20. Connect battery ground cable.
21. Start engine; check for vacuum, coolant and oil leaks.
22.. After engine has reached operating temperature, check and, if necessary, add coolant.