REMOVAL & INSTALLATION
140 cid (2.3L) Engine
- Drain the cooling system.
- Remove the air cleaner.
- Remove the valve cover.
On cars with air conditioning, remove the mounting bolts and the drive belt, and position the compressor out of the way. Remove the compressor upper mounting bracket from the cylinder head.
- Remove the intake and exhaust manifolds from the cylinder head.
- Remove the camshaft drive belt cover. Note the location of the belt cover attaching screws that have rubber grommets.
- Loosen the drive belt tensioner and remove the belt.
- Remove the water outlet elbow from the cylinder head with the hose attached.
- Remove the cylinder head attaching bolts.
- Remove the cylinder head from the engine.
- Clean all gasket material and carbon from the top of the cylinder block and pistons and from the bottom of the cylinder head.
- Position a new cylinder head gasket on the engine and place the head on the engine.
If you encounter difficulty in positioning the cylinder head on the engine block, it may be necessary to install guide studs in the block to correctly align the head and the block. To fabricate guide studs, obtain two new cylinder head bolts and cut their heads off with a hack saw. Install the bolts in the holes in the engine block which correspond with cylinder head bolt holes Nos. 3 and 4, as identified in the cylinder head bolt tightening sequence illustration. Then, install the head gasket and head over the bolts. Install the cylinder head attaching bolts, replacing the studs with the original head bolts.
- Using a torque wrench, tighten the head bolts in the sequence shown in the illustration.
- Install the camshaft drive belt.
- Install the camshaft drive belt cover and its attaching bolts. Make sure the rubber grommets are installed on the bolts. Tighten the bolts to 73-158 inch lbs.
- Install the water outlet elbow and a new gasket on the engine and tighten the attaching bolts to 146-182 inch lbs.
- Install the intake and exhaust manifolds. Refer to the procedures for intake and exhaust manifold installation.
- Assemble the rest of the components in the reverse order of the removal procedure.
- Drain the cooling system, remove the air cleaner and disconnect the negative battery cable.
On cars with air conditioning, remove the mounting bolts and the drive belt, and position the compressor out of the way of the left cylinder head. Remove the compressor upper mounting bracket from the cylinder head.
- Disconnect the exhaust pipe from the manifold, lower the exhaust pipe and remove the flange gasket.
- Disconnect the fuel and vacuum lines from the carburetor. Disconnect the intake manifold line at the intake manifold.
- Disconnect the accelerator linkage and retracting spring at the carburetor. Disconnect the transmission kickdown linkage, if equipped.
- Disconnect the carburetor spacer outlet line at the spacer. Disconnect the radiator upper hose and the heater hose at the water outlet elbow. Disconnect the radiator lower hose and the heater hose at the water pump.
- Disconnect the vacuum control line at the distributor. Disconnect the fuel line from the inlet side of the filter.
- Disconnect and label the spark plug wires, then remove the plugs. Disconnect the temperature sending unit wire.
- Remove the rocker arm cover.
- Remove the rocker arm shaft attaching bolts, then the rocker arm and shaft assembly. Remove the valve pushrods, and keep them in order for installation in their original positions.
- Remove the remaining cylinder head bolts and lift off the cylinder head. Do not pry under the cylinder head, as damage to the mating surfaces can easily occur.
To help in installation of cylinder head, two 6 in. X 7 / 16 -14 bolts with their heads cut off (and the head end slightly tapered and slotted, for installation and removal with a screwdriver) will reduce the possibility of damage during head replacement.
- Clean the cylinder head and block surfaces. Be sure of flatness and no surface damage.
- Apply cylinder head gasket sealer to both sides of the new gasket and slide the gasket down over the two guide studs in the cylinder block.
Apply gasket sealer only to steel shim head gaskets. Steel/asbestos composite head gaskets are to be installed without any sealer.
- Carefully lower the cylinder head over the guide studs. Place the exhaust pipe flange on the manifold studs along with a new gasket.
- Coat the threads of the end bolts for the right side of the cylinder head with a small amount of water-resistant sealer. Install, but do not tighten, two head bolts at opposite ends to hold the head gasket in place. Remove the guide studs and install the remaining bolts.
- Cylinder head tightening should proceed in three steps and in a prescribed order. Tighten the bolts to 55 ft. lbs., then give them a second tightening to 65 ft. lbs. The final step is to 75 ft. lbs., at which they should remain undisturbed.
- Lubricate both ends of the pushrods and install them in their original locations.
- Apply lubricant to the rocker arm pads and the valve stem tips, then position the rocker arm shaft assembly on the head. Be sure the oil holes in the shaft are in the down position.
- Tighten all the rocker shaft retaining bolts to 30-35 ft. lbs. and do a preliminary valve adjustment (make sure there are no tight valve adjustments).
- Attach the exhaust pipe.
- Reconnect the heater and radiator hoses.
- Reposition the distributor vacuum line, the carburetor gas line and the intake manifold vacuum line on the engine. Attach them to their respective connections and refasten the battery cable to the cylinder head.
- Connect the accelerator rod and retracting spring. Connect the choke control cable and adjust the choke. Connect the transmission kickdown linkage.
- Reconnect the vacuum line at the distributor. Connect the fuel line at the fuel filter and the intake manifold vacuum line at the vacuum pump.
- Lightly lubricate the spark plug threads and install them. Connect spark plug wires and be sure the wires are all the way down in their sockets. Connect the temperature sending unit wire.
- Fill the cooling system. Run the engine to stabilize all engine part temperatures.
- Adjust engine idle speed.
- Coat one side of a new rocker cover gasket with oil-resistant sealer. Lay the treated side of the gasket on the cover and install the cover. Be sure the gasket seals evenly all around the cylinder head.
- Drain the cooling system.
- Remove the intake manifold and the carburetor as an assembly.
- Disconnect the spark plug wires, marking them as to placement. Position them out of the way of the cylinder head. Remove the spark plugs.
- Disconnect the exhaust pipes at the manifolds.
- Remove the rocker arm covers.
- On cars with air conditioning, remove the mounting bolts and the drive belt, and position the compressor out of the way of the left cylinder head. Remove the compressor upper mounting bracket from the cylinder head.
If the compressor refrigerant lines do not have enough slack to permit repositioning of the compressor without first disconnecting the refrigerant lines, the air conditioning system will have to be evacuated by a trained air conditioning serviceman. Under no circumstances should an untrained person attempt to disconnect the air conditioning refrigerant lines.
- In order to remove the left cylinder head on cars equipped with power steering, it may be necessary to either completely remove the steering pump and bracket from the vehicle, or tie the pump out of the way. If tying the pump aside, do so in such a way as to prevent the loss of its fluid.
- In order to remove the right cylinder head it may be necessary to remove the alternator mounting bracket bolt and spacer, the ignition coil, and the air cleaner inlet duct.
- In order to remove the left cylinder head on a car equipped with a Thermactor air pump system, disconnect the hose from the air manifold.
- If the right cylinder head is to be removed on a car equipped with a Thermactor system, remove the Thermactor air pump and its mounting bracket. Disconnect the hose from the air manifold.
- Loosen the rocker arm stud nuts enough to rotate the rocker arms to the side (in order to facilitate the removal of the pushrods.) Remove the pushrods in sequence, so that they may be installed in their original positions. Remove the exhaust valve stem caps, if equipped.
- Remove the cylinder head attaching bolts, noting their positions. Lift the cylinder head off the block. Remove and discard the old cylinder head gasket. Clean all mounting surfaces.
- Position the new cylinder head gasket over the dowels on the block. Position new gaskets on the muffler inlet pipes at the exhaust manifold flange.
- Position the cylinder head on the block, and install the head bolts, each in its original position. On engines on which the exhaust manifold has been removed from the head to facilitate removal, it is necessary to properly guide the exhaust manifold studs into the muffler inlet pipe flange when installing the head.
- Tighten the cylinder head retaining bolts first to 50 ft. lbs. then to 60 ft. lbs., and finally to the torque specification listed in the Torque Specifications chart. Tighten the exhaust manifold to cylinder head attaching bolts to specifications.
- Tighten the nuts on the exhaust manifold studs at the muffler inlet flanges to 18 ft. lbs.
- Clean and inspect the pushrods. Check the ends for nicks, grooves and wear, replace as necessary. Visually inspect the pushrods for straightness, and replace any bent ones. Do not attempt to straighten pushrods.
- Install the pushrods in their original positions. Apply Lubriplate® or a similar product to the valve stem tips and to the pushrod guides in the cylinder head. Install the exhaust valve stem caps.
- Apply Lubriplate® or a similar product to the fulcrum seats and sockets. Turn the rocker arms to their proper position and tighten the stud nuts enough to hold the rocker arms in position. Make sure that the lower ends of the pushrods have remained properly seated in the valve lifters. Tighten the stud nuts to 17-23 ft. lbs. in the order given under Valve Adjustment.
- Install the valve covers.
- Install the intake manifold and carburetor, following the procedure under "Intake Manifold Installation."
- Reinstall all other items removed.
MACHINE SHOP SERVICES
Certain rebuilding operations require special tools that may be too expensive or not feasible to buy for only occasional use. The answer to these problems is the local automotive machine shop. The machine shop can usually handle any job from drilling out and replacing a broken stud to any major rebuilding.
- Remove the cylinder head(s) from the car engine. Place the head(s) on a workbench and remove any manifolds that are still connected. Remove all rocker arm retaining parts and the rocker arms, if still installed. On 4-cylinder engines, remove the camshaft.
- Turn the cylinder head over so that the mounting surface is facing up and support it evenly on wooden blocks.
- Use a scraper and remove all of the gasket material stuck to the head mounting surface. Mount a wire carbon removal brush in an electric drill and clean away the carbon on the valves and head combustion chambers.
- Number the valve heads with a permanent felt-tip marker for cylinder location.
If the cylinder head is warped, resurfacing by a machine shop is required. Place a straightedge across the gasket surface of the head. Using feeler gauges, determine the clearance at the center and along the length between the head and straightedge. Measure clearance at the center and along the lengths of both diagonals. If warpage exceeds 0.003 inches in a six inch span, or 0.006 inches over the total length the cylinder head must be resurfaced. Do not grind more than 0.010 inch from the original cylinder head gasket surface.