Remove and Refit Cylinder Head
This module covers the complete process of removing a cylinder head, inspecting and preparing components, and refitting the head with correct sealing and torque practices. The course is structured in two hands‑on days, giving you the skills and experience to do the job confidently and correctly.
Day 1 – Removal, Inspection & Preparation
- Compression and leak‑down testing: We begin with compression and leak‑down tests to confirm any specific issues before disassembly.
- Ancillary removal: Carburettors, extractors and other attachments to the cylinder head are removed to allow full access.
- Cylinder head removal: Under instructor guidance, the cylinder head is safely unbolted and removed from the engine block.
- Component cleaning and inspection: All critical surfaces and passages (mating faces, coolant/oil galleries, bolt holes and threads) are thoroughly cleaned and examined for wear, damage, blockages or corrosion.
- Measurement and condition assessment: Accurate measurements are taken to check tolerances and determine whether machining, surface preparation, or part replacement is required as part of later work.
Day 2 – Measurement, Refitting & Final Checks
- Compression ratio calculation: We calculate the compression ratio by measuring the capacity of the compression and non‑compression strokes to verify correct sealing and geometry.
- Preparation of surfaces: Once the block and cylinder head faces have been verified as flat and clean, a new head gasket is selected and prepared in the correct orientation for reliable sealing.
- Head refitting: The cylinder head is refitted using dowels/locating pins where applicable, with head bolts cleaned, prepared and torqued in correct sequence and to manufacturer specifications.
- Engine start‑up: With the head refitted, the engine is started and run‑in monitored to confirm correct installation.
- Final integrity checks: Post‑assembly checks include inspection for oil or coolant leaks and confirmation that all passages are clean and unobstructed, ensuring proper sealing and operating condition.
There is a gap of 3 weeks between days 1 and 2. During that time the valve gear will be disassembled and machining carried out as part of Step 2. Cylinder-Head Rebuild class.
We keep these classes separate as refitting valve gear is a more complex task. Most enthusiasts will give the cylinder head to a specialist to rebuild.
Similarly, many enthusiasts are capable of replacing a cylinder head gasket but may want to learn how to rebuild the valve gear.
What’s Included
- Hands‑on removal of the cylinder head
- Pre‑removal testing (compression & leak down)
- Detailed cleaning and inspection of head and block mating surfaces
- Accurate measurement and tolerance assessment
- Head refitting with correct gasket orientation and torque sequence
- Post‑assembly start and inspection for sealing integrity
Course Details
- Participants: 2–4 per session
- Duration: 2 days (Day 1 + Day 2)
- Location: The Hub Workshop, Kings Park, NSW 2168
- Fee: $990 per participant. Under 16 half price with adult also attending
Ready to learn correct cylinder head removal and refit techniques?
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