Cylinder Head Assembly: Service and Repair

Removal

1. Remove timing belt as previously described.
2. Remove camshaft sprocket and front cover.
3. Remove exhaust manifold, air cleaner, rocker cover and distributor.
4. Remove cylinder head with intake manifold, noting the following:
a. Bolts should be loosened in two or three stages.

Fig. 3 Cylinder head bolt loosening sequence:

b. Head warpage or cracking may result from removing in incorrect order, Fig. 3.
5. Remove intake manifold from cylinder head.

Installation

1. Install cylinder head with new gasket, noting the following:
a. Be sure to install washers between cylinder head and bolts.

Fig. 18 Cylinder head bolt identification:

b. There are three kinds of cylinder head bolts of varying lengths, Fig. 18. Bolts A are 3.74 inches (95 mm), bolt B is 4.33 inches (110 mm) and bolts C are 3.15 inch (80 mm).

Fig. 17 Cylinder head bolt tightening sequence:

2. Apply oil to threaded portion and seat surface of cylinder head bolts and tighten cylinder head bolts as follows, Fig. 17.
a. Torque all bolts to 22 ft. lbs.
b. Torque all bolts to 51 ft. lbs.
c. Loosen all bolts completely.
d. Torque all bolts to 22 ft. lbs.
e. Torque all bolts to 51-54 ft. lbs. or, if angle wrench is available, turn bolts A, Fig. 18, 45° clockwise, bolt B 55° clockwise and bolts C 40° clockwise.
3. Install timing belt and adjust belt tension.
4. Install rocker shaft with rocker arms, noting the following:
a. Apply engine oil to rocker shaft and interior of rocker arm.
b. Ensure punched mark on rocker shaft faces toward front side and oil holes in rocker shaft face downward.
c. Ensure cutout in center retainer of rocker shaft faces toward exhaust manifold side.
5. Tighten rocker shaft bolts, noting the following:
a. Ensure valve clearance adjusting screws are fully loosened.
b. Tighten bolts gradually, in two or three steps, from center outward.
6. Install new bolt stopper on Nos. 1 and 5 bolts.

Fig. 19 Valve identification:

7. Adjust valve clearance as follows:
a. Set No. 1 cylinder in TDC on its compression stroke and adjust valve clearance 1, 2, 3 and 6, Fig. 19.
b. Set No. 4 cylinder in TDC on its compression stroke and adjust valve clearance 4, 5, 7 and 8.
8. Install exhaust manifold.
9. Install distributor.
10. Install rocker cover, dust covers, water pump and crankshaft pulleys and the drive belts.