Cylinder Head Assembly: Service and Repair

*** UPDATED BY TSB# 0284668 FEB 1984; TSB# 0284669 FEB 1984; TSB# 0987992 SEPT 1987; TSB# 0987994 SEPT 1987; TSB#0987995 SEPT 1987

1. Disconnect battery ground cable.
2. Drain coolant and remove upper radiator hose.
3. Remove crankcase ventilation hoses from valve cover.
4. Disconnect wires from distributor and temperature transmitter.
5. Remove warm-up regulator and auxiliary air valve from cylinder head.
6. Rotate crankshaft until flywheel (0) mark is aligned with line on clutch cover and mark on camshaft sprocket is aligned with mark on bearing cap.
7. Remove valve cover retaining bolts and cover. Design of distributor driving dog allows the valve cover to be removed only when cylinder 1 or 4 is at TDC.
8. Install a jack under transmission case. Remove stay between right engine mount and cylinder head and rotate it to one side.
9. Jack the engine up slightly and support it on a piece of wood between the crossmember and transmission case.
10. Remove exhaust and intake manifold from cylinder head, and support as needed.
11. Remove camshaft sprocket bolts, then remove sprocket from camshaft. Place sprocket with chain hanging from it between the chain guide and tensioner.
12. Remove the two bolts from the timing cover.
13. Using an E16 TORX socket, P/N 30-13-992, remove cylinder head bolts and lift off cylinder head.
14. Reverse procedure to install, noting the following:

Fig. 2 Flywheel Timing Mark Alignment:

a. Rotate crankshaft so that (0) mark on flywheel is aligned with pointer, Fig. 2.

Camshaft timing mark alignment.:

b. Temporarily install camshaft sprocket and rotate camshaft so that mark on sprocket is aligned with mark on bearing cap, Fig. 3.
c. Lock positions of camshaft and crankshaft. Do not allow either shaft to rotate until timing chain is properly installed. If engine rotates with shafts not synchronized, engine will be damaged.
d. Position timing chain on camshaft sprocket, place chain between guide and tensioner, and install cylinder head.

Fig. 4 Cylinder head bolt tightening sequence:

e. Torque cylinder head bolts in sequence shown, Fig. 4, first torquing bolts to 43 ft.lbs. (60 Nm), then to 65 ft. lbs. (90 Nm). If the head gasket is the new style, P/N 75-85-037 (8 valve) or P/N 75-61-301 (16 valve), proceed directly to step g. If other gaskets are used, perform step f, then step g.
f. Warm engine to operating temperature, then allow to cool for 30 minutes.
g. Back off each head bolt 1/2 turn, retorque to specifications in sequence shown, Fig. 4, then tighten each bolt an additional 1/4 turn in sequence.