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6A1-16
1977 PONTIAC SERVICE MANUAL
Fig. 6 A 1 - 4 0 Exhaust Manifold Bolts
2" long. Number one and number four cylinder
attaching bolts are self-locking.
1. Position manifold to head and loosely install bolts.
2. Torque bolts to 30 lbs. ft. (Fig. 6A1-40).
3. Connect oil level dipstick to exhaust manifold.
4. Raise car on a hoist and connect exhaust pipe.
5. Install intake manifold.
CYLINDER HEAD ASSEMBLY
Removal
1. Raise hood and secure open.
2. Disconnect battery negative cable at battery.
3. Drain cooling system.
4. Remove engine front cover and camshaft cover.
5. Remove timing belt and camshaft timing sprocket.
6. Disconnect coolant hose at thermostat housing (water
outlet).
7. Remove cylinder head bolts; then, with the aid of an
assistant, remove manifolds and cylinder head assembly and
gasket. Place cylinder head on two blocks of wood to prevent
damage to valves.
Disassembly
1. Remove intake and exhaust manifolds.
2. Remove camshaft retainer and timing belt upper
cover.
3. Install camshaft removal Tool J 23591.
4. Remove camshaft, valve lifters, valve springs, valve
stem seals and valves.
5. Remove camshaft removal Tool J 23591.
6. Remove spark plugs.
7. Remove thermostat housing.
Cleaning
1. Clean all carbon from combustion chambers and valve
ports using Tool J 8089 (Fig. 6A1-41).
2. Thoroughly clean the valve guides using Tool J 8101
(Fig. 6A1-42).
3. Clean valve stems and heads on a buffing wheel.
Fig. 6A1-4 1 Cleaning Combustion Chamber
Fig. 6 A 1 - 4 2 Cleaning Valve Guide
4. Clean carbon deposits from head gasket mating
surface.
5. Remove valve spring dampers and clean in an
approved cleaning solvent.
Inspection
1. Inspect the cylinder head for cracks in the exhaust
ports or combustion chambers or external cracks to the water
chamber.
2. Inspect the valves for burned heads, cracked faces and
damaged stems.
NOTE: Excessive valve stem to bore clearance will cause
excessive oil consumption and may cause valve breakage.
Insufficient clearance will result in noisy and sticky
valves and rough engine idle.
3. Measure valve stem clearance (Fig. 6A1-43). 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. With the
head of the valve dropped off the valve seat approximately
1/16", 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.
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