Cylinder Head Assembly: Service and Repair

Fig. 4 Power Steering Pump Assembly:

Fig. 3 Alternator Assembly:

Fig. 9 Rocker Cover, Rocker Arm & Pushrod Assemblies:

(Figure 10) Cylinder Head Replacement:

TOOLS REQUIRED (or equivalents)
^ J-37088 Fuel line quick connect fittings.
^ J 36660 Torque angle meter.

REMOVAL
1. Disconnect battery ground cable and remove air cleaner assembly.
2. Relieve fuel system pressure, refer to Fuel Delivery and Air Induction / Service and Repair.
3. Drain cooling system and Remove TBI cover and coolant reservoir.
4. Raise and support vehicle, disconnect exhaust pipe from manifold.
5. Remove coolant hose from intake manifold, remove accelerator and T.V. cable bracket.
6. Lower the vehicle and disconnect vacuum lines at intake manifold and accelerator linkage at the TBI unit.
7. Disconnect all wiring to cylinder head and remove upper radiator hose from thermostat housing.
8. Remove serpentine belt, then belt tensioner.
9. Remove power steering pump as follows:
a. Disconnect return and pressure hoses from the pump.
b. Loosen drive belt tensioner. Separate belt from power steering pulley.
c. Remove three front pump retaining bolts, (figure 4). Bolts can be accessed through hole in the pulley.
d. Remove one retaining bolt from rear of the pump, then remove the pump.
10. Ensure engine compartment fuel line connections are clean, then using Connector Tool Set No. J-37088 disconnect fuel line quick connect fittings, plug all fittings.
11. Remove alternator and rear brace (figure 3).
12. Remove rocker arm cover (figure 9), then the rocker arms and pushrods.

NOTE: Keep rocker arms and pushrods in order so they can be reinstalled in position they were removed from.

13. Remove cylinder head attaching bolts, then the cylinder head and gasket, intake and exhaust manifolds, and TBI unit as an assembly.

INSTALLATION
1. Ensure cylinder head mating surfaces are thoroughly clean and install cylinder head, manifolds and TBI assembly with new gaskets. Torque in sequence shown in (figure 10) to the following specs:
a. Torque all bolts to 55 Nm (41 ft lbs) in sequence.
b. Next using J 36660 Torque angle meter tighten ALL bolts 45° in sequence.
c. Next tighten ALL bolts an additional 45° in sequence.
d. Then tighten LONG bolts (#1 figure 10) an additional 20° and the SHORT bolts (#2 figure 10) an additional 10°.
2. Install the rocker arms and torque to specifications (figure 9), then install the push rods and rocker cover.
3. Install the alternator and rear brace (figure 3).
4. Connect fuel lines and install power steering pump, then the serpentine belt.
5. Connect upper radiator hose, wiring, accelerator linkage to TBI unit and vacuum lines to intake manifold.
6. Raise vehicle and connect heater hose to intake, accelerator and T.V. cable bracket and exhaust pipe.
7. Lower vehicle and install TBI cover and coolant reservoir.
8. Fill cooling system and connect negative battery cable.

Inspect For
^ Fluid leaks
^ fluid levels