#### REFINISHING & REPAIRING

Many of the procedures given for refinishing and repairing the cylinder head components must be performed by a machine shop. Certain steps, if the inspected part is not worn, can be performed yourself inexpensively. However, you spent a lot of time and effort so far, why risk trying to save a couple bucks if you might have to do it all over again?

##### Valves

Any valves that were not replaced should be refaced and the tips ground flat. Unless you have access to a valve grinding machine, this should be done by a machine shop. If the valves are in extremely good condition, as well as the valve seats and guides, they may be lapped in without performing machine work.

It is a recommended practice to lap the valves even after machine work has been performed and/or new valves have been purchased. This insures a positive seal between the valve and seat.

###### LAPPING THE VALVES

NOTE: Before lapping the valves to the seats, read the rest of the cylinder head section to insure that any related parts are in acceptable enough condition to continue.

NOTE: Before any valve seat machining and/or lapping can be performed, the guides must be within factory recommended specifications.

1. Invert the cylinder head.
2. Lightly lubricate the valve stems and insert them into the cylinder head in their numbered order.
3. Raise the valve from the seat and apply a small amount of fine lapping compound to the seat.
4. Moisten the suction head of a hand-lapping tool and attach it to the head of the valve.
5. Rotate the tool between the palms of both hands, changing the position of the valve on the valve seat and lifting the tool often to prevent grooving.
6. Lap the valve until a smooth, polished circle is evident on the valve and seat.
7. Remove the tool and the valve. Wipe away all traces of the grinding compound and store the valve to maintain its lapped location.

   WARNING
   Do not get the valves out of order after they have been lapped. They must be put back with the same valve seat with which they were lapped.

##### Springs, Retainers and Valve Locks

There is no repair or refinishing possible with the springs, retainers and valve locks. If they are found to be worn or defective, they must be replaced with new (or known good) parts.

##### Cylinder Head

Most refinishing procedures dealing with the cylinder head must be performed by a machine shop. Read the sections below and review your inspection data to determine whether or not machining is necessary.

###### VALVE GUIDE

NOTE: If any machining or replacements are made to the valve guides, the seats must be machined.

Unless the valve guides need machining or replacing, the only service to perform is to thoroughly clean them of any dirt or oil residue.

There are only two types of valve guides used on automobile engines: the replaceable-type (all aluminum heads) and the cast-in integral-type (most cast iron heads). There are four recommended methods for repairing worn guides.

- Knurling
- Inserts
- Reaming oversize
- Replacing

Knurling is a process in which metal is displaced and raised, thereby reducing clearance, giving a true center, and providing oil control. It is the least expensive way of repairing the valve guides. However, it is not necessarily the best, and in some cases, a knurled valve guide will not stand up for more than a short time. It requires a special knurlizer and precision reaming tools to obtain proper clearances. It would not be cost effective to purchase these tools, unless you plan on rebuilding several of the same cylinder head.

Installing a guide insert involves machining the guide to accept a bronze insert. One style is the coil-type which is installed into a threaded guide. Another is the thin-walled insert where the guide is reamed oversize to accept a split-sleeve insert. After the insert is installed, a special tool is then run through the guide to expand the insert, locking it to the guide. The insert is then reamed to the standard size for proper valve clearance.

Reaming for oversize valves restores normal clearances and provides a true valve seat. Most cast-in type guides can be reamed to accept an valve with an oversize stem. The cost factor for this can become quite high as you will need to purchase the reamer and new, oversize stem valves for all guides which were reamed. Oversizes are generally 0.003 to 0.030 inch (0.076 to 0.762mm), with 0.015 inch (0.381mm) being the most common.

To replace cast-in type valve guides, they must be drilled out, then reamed to accept replacement guides. This must be done on a fixture which will allow centering and leveling off of the original valve seat or guide, otherwise a serious guide-to-seat misalignment may occur making it impossible to properly machine the seat.

Replaceable-type guides are pressed into the cylinder head. A hammer and a stepped drift or punch may be used to install and remove the guides. Before removing the guides, measure the protrusion on the spring side of the head and record it for installation. Use the stepped drift to hammer out the old guide from the combustion chamber side of the head. When installing, determine whether or not the guide also seals a water jacket in the head, and if it does, use the recommended sealing agent. If there is no water jacket, grease the valve guide and its bore. Use the stepped drift, and hammer the new guide into the cylinder head from the spring side of the cylinder head. A stack of washers the same thickness as the measured protrusion may help the installation process.

###### VALVE SEATS

NOTE: Before any valve seat machining can be performed, the guides must be within factory recommended specifications.

NOTE: If any machining or replacements were made to the valve guides, the seats must be machined.

If the seats are in good condition, the valves can be lapped to the seats, and the cylinder head assembled. See the valves section for instructions on lapping.

If the valve seats are worn, cracked or damaged, they must be serviced by a machine shop. The valve seat must be perfectly centered to the valve guide, which requires very accurate machining.

###### CYLINDER HEAD SURFACE

If the cylinder head is warped, it must be machined flat. If the warpage is extremely severe, the head may need to be replaced. In some instances, it may be possible to straighten a warped head enough to allow machining. In either case, contact a professional machine shop for service.

NOTE: Any OHC cylinder head that shows excessive warpage should have the camshaft bearing journals align bored after the cylinder head has been resurfaced.

WARNING
Failure to align bore the camshaft bearing journals could result in severe engine damage including but not limited to: valve and piston damage, connecting rod damage, camshaft and/or crankshaft breakage.

###### CRACKS AND PHYSICAL DAMAGE

Certain cracks can be repaired in both cast iron and aluminum heads. For cast iron, a tapered threaded insert is installed along the length of the crack. Aluminum can also use the tapered inserts, however welding is the preferred method. Some physical damage can be repaired through brazing or welding. Contact a machine shop to get expert advice for your particular dilemma.