Cylinder Head Assembly: Service and Repair

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. Remove air cleaner assembly.
6. Mark and disconnect all vacuum hoses from cylinder head.
7. Remove rocker arm cover.
8. Remove all accessory drive belts from engine.
9. Remove distributor cap and spark plug wires as an assembly.
10. Disconnect fuel supply and return lines from rubber connector.
11. Disconnect accelerator cable and speed control cable, if equipped.
12. Raise and support vehicle.
13. Disconnect exhaust system from exhaust pipe. Lower vehicle.
14. Remove cylinder head bolts.
15. Remove cylinder head and gasket with exhaust and intake manifolds attached.

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

INSTALLATION
1. Clean gasket material from cylinder head and block mating surfaces.
2. Position head gasket on block using sealer to retain gasket.

NOTE: Before installing cylinder head, install two alignment studs (T84P-6065-A or equivalent) through head gasket into opposite ends of the block.

3. Install cylinder head over alignment studs. Install head bolts and remove alignment studs.

Fig. 8 Cylinder Head Bolt Tightening Sequence:

4. Torque head bolts in sequence shown in two stages:

Stage 1 52-59 Ft. Lbs. (70-80 Nm)
Stage 2 70-76 Ft. Lbs. (95-103 Nm)

5. Raise and support vehicle. Install exhaust system to exhaust manifold and hose to metal tube. Lower vehicle.
6. Connect accelerator pedal and speed control cable (if equipped.)
7. Connect fuel supply and return lines.
8. Install distributor cap and plug wires as an assembly.
9. Reinstall accessory drive belts.
10. Install rocker arm cover.
11. Reconnect vacuum hoses.
12. Install air cleaner assembly.
13. Install upper radiator hose.
14. Connect heater hose to heater inlet tube and heater inlet tube to water outlet connector.
15. Fill cooling system with fresh coolant.
16. Connect battery ground cable.
17. Start engine, check for vacuum, coolant, and oil leaks.
18. After engine reaches operating temperature, re-check coolant level and add coolant if necessary.