Cylinder Head Assembly: Service and Repair
Cylinder Head Assembly
Removal (Right Side)
1. Remove intake manifold as previously outlined.
2. Disconnect AIR hose from exhaust check valve.
3. Remove two rear A/C compressor braces.
4. Remove lower A/C compressor mounting bolt.
5. Remove A/C compressor bracket nuts at water pump.
6. Slide A/C compressor mounting bracket forward and disconnect wires at compressor.
7. Remove upper A/C compressor mounting bolt and remove compressor.
8. Remove rocker cover bolts.
9. Bend bracket at rear of head and remove rocker cover.
10. Disconnect AIR hose at converter pipe check valve.
11. Remove spark plugs
12. Remove temperature sending unit.
13. Disconnect AIR pipe at exhaust manifold.
14. Raise vehicle.
15. Remove two rear exhaust manifold bolts.
16. Disconnect exhaust pipe at manifold.
17. Lower vehicle.
18. Remove remaining manifold bolts.
19. Remove remaining manifold bolts.
20. Remove exhaust manifold
21. Disconnect spark plug wire holder at rear of head.
22. Loosen rocker arm nuts and remove push rods.
23. Remove head bolts.
24. Remove cylinder head.
Removal (Left Side)
1. Remove intake manifold as previously outlined.
2. Remove alternator bolts and lay aside.
3. Remove rocker cover bolts.
4. Disconnect spark plug wires at spark plugs.
5. Bend bracket at rear of head and remove rocker cover.
6. Disconnect AIR hose at exhaust check valve.
7. Raise vehicle.
8. Disconnect exhaust pipe at manifold.
9. Lower vehicle.
10. Remove exhaust manifold.
11. Remove upper AIR pump bracket with power steering reservoir.
12. Disconnect plug wire holder at back of head.
13. Disconnect ground wire at back of head.
14. Disconnect wire at temperature sending unit.
15. Remove push rods.
16. Remove head bolts.
17. Remove cylinder head.
Disassembly
1. With cylinder head removed, remove valve rocker arm nuts, balls and rocker arms (if not previously done).
2. Using Tool J-15062 compress the valve springs and remove stem keys. Release the compressor tool and remove rotator or spring caps, oil shedders, springs and damper assembly, then remove oil seals and valve spring shims.
3. Remove valves from cylinder head and place them in a rack in their proper sequence so that they can be assembled in their original positions.
Cleaning
1. Clean all carbon from combustion chambers and valve ports using Tool J-8089.
2. Thoroughly clean the valve guides using Tool J-8101.
3. Clean all carbon and sludge from push rods, rocker arms and push rod guides.
4. Clean valve stems and heads on a buffing wheel.
5. Clean carbon deposits from head gasket mating surface.
Inspection
1. Inspect the cylinder head for cracks in the exhaust ports, combustion chambers, or external cracks to the water chamber.
2. Inspect the valves for burned heads, cracked faces or damaged stems.
- Excessive valve stem to bore clearance will cause excessive oil consumption and may cause valve breakage. Insufficient clearance will result in noisy and sticky functioning of the valve and disturb engine smoothness.
3. Measure valve stem clearance as follows:
a. Clamp a dial indicator on one side of the cylinder head rocker arm cover gasket rail.
b. Locate the indicator so that movement of the valve stem from side to side (crosswise to the head) will cause a direct movement of the indicator stem. The indicator stem must contact the side of the valve stem just above the valve guide.
c. Drop the valve head about 1/16" off the valve seat.
d. Move the stem of the valve from side to side using light pressure to obtain a clearance reading. If clearance exceeds specifications, it will be necessary to ream valve guides for oversize valves.
- Service valves are available in standard .003", .015" and .030" oversize.
4. Check valve spring tension with Tool J-8056 spring tester. Springs should be compressed to the specified height and checked against the specifications chart. Springs should be replaced if not within 10 lbs. (44 N) of the specified load (without dampers).
5. Inspect rocker arm studs for wear or damage.
Assembly
1. Insert a valve in the proper port.
2. Assemble the valve spring and related parts as follows:
a. Set the valve spring shim, valve spring, damper assembly, oil shedder and valve cap or rotator in place.
b. Compress the spring with Tool J-8062.
c. Install oil seal in the lower groove of the stem, making sure that the seals flat and not twisted.
d. Install the valve and release the compressor tool making sure that the valve stems seat properly in the upper groove of the valve stem. Grease may be used to hold the locks in place while releasing the compressor tool.
3. Install the remaining valves.
4. Check each valve stem oil seal by placing Valve Seal Leak Detector (Tool J-23994) over the end of the valve stem and against the cap (or rotator). Operate the vacuum pump and make sure no air leaks past the seal.
5. Check the installed height of the valve springs, using a narrow thin scale. A cutaway scale will help. Measure from the top of the sum or the spring seat tot he top of the oil shedder. If this is found to exceed the specified height, install a valve spring seat shim approximately 1/16" (1.6 mm) thick. At no time should the spring be shimmed to give an installed height under the minimum specified.
Installation
- The gasket surfaces on both the head and the block must be clean of any foreign matter and free of nicks or heavy scratches. Cylinder bolt threads in the block and threads on the cylinder head bolts must be clean, as dirt will affect bolt torque.
1. On engine using a STEEL gasket, coat both sides of a new gasket with a good sealer. Spread the sealer thin and even. One method of applying the sealer that will assure the proper coat is with the use of a paint roller. Too much sealer may hold the gasket away from the head or block.
2. Place the gasket in position over the dowel pins with the bead up.
3. Carefully guide the cylinder head into place over the dowel pins and gasket.
4. Coat threads of cylinder head bolts with sealing compound, #1052080 or equivalent, and install bolts finger tight.
5. Tighten each cylinder head bolt a little at a time until the specified torque is reached.
6. Install exhaust manifolds as previously outlined.
7. Install intake manifold as previously outlined.
8. Install and adjust valve mechanism as previously outlined.