Cylinder Head Assembly: Service and Repair

1. Relieve fuel pressure, then 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 engine 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, rocker arm fulcrum retaining bolts,fulcrum, rocker arms and pushrods.

NOTE: The location of each rocker arm, push rod and fulcrum should be identified, so each component can be installed in its original position.

9. Remove all accessory drive belts from engine.
10. Remove distributor cap, spark plug wires and retainers as an assembly.
11. Disconnect EGR tube from EGR valve.
12. Disconnect fuel supply and return lines from rubber connector.
13. Disconnect accelerator cable and speed control cable, if equipped.
14. Raise and support vehicle.
15. Disconnect exhaust system from exhaust pipe. Lower vehicle.
16. Remove cylinder head bolts, cylinder head and gasket with thermactor pump, exhaust and intake manifolds attached.

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

Fig. 8 Cylinder Head Bolt Tightening Sequence:

13. Reverse procedure to install. Torque cylinder head bolts in sequence shown in two steps: first to 52-59 ft lb, then to 70-76 ft lb.