Cylinder Head - Installation

Cylinder Head Assembly:

Cylinder Head Assembly Legend:

Install or Connect

Tool Required:
J 34673 Straight Edge

1. New cylinder head gasket to cylinder block.
- Carefully place cylinder head on cylinder head gasket.
- Coat the threads and underside of head on each cylinder head bolt with engine oil.

Cylinder Head Bolt Tightening Sequence:

2. Ten bolts to cylinder head in sequence shown in the illustration, placing the 90 mm (3.54-inches) bolts on the intake manifold side and 108 mm (4.25-inches) bolts on the exhaust manifold side.

NOTICE: Cylinder head bolts must be tightened in several passes and in the sequence shown in the illustration. If the bolts are not tightened in this fashion, damage may occur to the cylinder head.

Tighten
- Cylinder head bolts to 29 N.m (22 lb.ft.).

- Once the cylinder head bolts are tightened to specifications. they must be tightened again using the following procedure:
- Mark the front of each cylinder head bolt with paint.
- Tighten each cylinder head bolt 90° using the sequence shown in the illustration.
- Tighten each cylinder head bolt an additional 90° in the sequence shown in the illustration.
- Check that the paint mark has been turned 180° from the front.
3. Intake and exhaust camshaft.
4. Engine coolant inlet pipe to vehicle; secure with two nuts.

Tighten
- Engine coolant inlet pipe nuts to 15 N.m (11 lb. ft.).

5. Hose to engine coolant inlet pipe; secure with hose clamp.
6. Guide tube to vehicle: secure with one bolt.

Tighten
- Guide tube bolt to 9.5 N.m (84 lb. in.).

7. Oil level indicator to guide tube.
8. Generator mounting bracket to vehicle: secure with three bolts.

Tighten
- Generator mounting bracket bolts to 26 N.m (19 lb. ft.).

9. Front engine hanger: secure with one bolt.

Tighten
- Front engine hanger bolt to 27 N.m (20 lb. ft.).

10. Timing belt.
11. Engine mount.

Engine Mount Bolt Identification:

A. Engine mount to vehicle while gently relocating A/C pipe to gain clearance (if equipped); secure with four bolts.

Tighten
- "A" bolts to 64 N.m (47 lb. ft.).
- "B" bolt to 25 N.m (18 lb. ft.).

B. Rubber insulator to engine mount; secure with one bolt.

Tighten
- Rubber insulator-to-engine mount bolt to 25 N.m (18 lb. ft.).

C. Engine mount reinforcement bracket to vehicle; secure with one nut and one bolt.

Tighten
- Engine mount reinforcement bracket bolt and nut to 25 N.m (18 lb. ft.).

D. Two-piece A/C pipe bracket (if equipped) to engine mount; secure with one bolt and one screw.

Tighten
- A/C pipe bracket bolt to 10 N.m (89 lb. in.).

E. Two nuts to engine mount studs.

Tighten
- Engine mount stud nuts to 52 N.m (38 lb. ft.).

F. Remove floor jack.
G. Cruise control actuator bracket to vehicle (if equipped); secure with three bolts.

Tighten
- Cruise control actuator bolts to 10 N.m (89 lb.in.).

H. Move cruise control actuator into place (if equipped); secure with three bolts.

Tighten
- Cruise control actuator bolts to 10 N.m (89 lb.in.).

I. Clip cruise control actuator cover onto actuator (if equipped).

- Using a J 34673 and feeler gage, check distortion of intake manifold face in both diagonal directions. If distortion exceeds 0.10 mm (0.0039-inch), the face must be resurfaced. If the distortion cannot be brought within limits, then a new intake manifold must be used.
12. Intake manifold with a new gasket; secure with seven bolts, two nuts and ground strap.

NOTICE: Tighten each intake manifold bolt and nut in several passes to eliminate the possibility of warping the intake manifold.

Tighten
- Intake manifold bolts and nuts to 19 N.m (14 lb. ft.).

13. Engine wire harness.
A. Engine wire harness retainer; secure with three nuts.

Tighten
- Engine wire harness retainer nuts 10 N.m (89 lb. in.).

B. Engine wire ground strap; secure with one bolt.

Tighten
- Engine wire ground strap bolt to 10 N.m (89 lb. in.).

C. Fan thermostat switch electrical connector.
D. Knock Sensor (KS) electrical connector.
E. Engine wire cover to engine; secure with two bolts.

Tighten
- Engine wire cover bolts to 10 N.m (89 lb. in.).

F. Oil pressure switch electrical connector.
G. A/C compressor electrical connector (if equipped).

14. Fuel rail with injectors.
A. Four insulators and two spacers to cylinder head.
B. New grommet to each injector.
C. Apply gasoline to each new O-ring and place O-rings on injectors.
D. Injectors to fuel rail.
E. Fuel rail with injectors to intake manifold; secure with two bolts, do not tighten fully.

Inspect
- Injectors for smooth rotation. If injectors do not rotate smoothly, the probable cause is incorrectly seated O-rings. Replace O-rings and recheck. Position injector electrical connector upward.

Tighten
- Fuel rail bolts to 15 N.m (11 lb. ft.).

F. Injector electrical connectors.
G. Two gaskets, fuel inlet pipe to fuel rail; secure with union bolt.

Tighten
- Tighten bolt to 29 N.m (22 lb. ft.).

15. Intake chamber.
A. Intake chamber with new gasket; secure with two nuts and three bolts.

Tighten
- Intake chamber cover nuts and bolts to 19 N.m (14 lb. ft.).

B. Vacuum hose to pressure regulator.

16. Two positive crankcase ventilation (PCV) hoses to cylinder head cover; secure with hose clamps.
17. New gasket and intake chamber cover; secure with three bolts and two nuts.

Tighten
- Intake chamber cover bolts and nuts to 19 N.m (14 lb. ft.).

18. Fuel inlet hose clamp bolt.

Tighten
- Fuel inlet hose clamp bolt to 10 N.m (89 lb. in.).

19. Throttle body (TB) to intake manifold.
A. New gasket and TB; secure with two nuts and two bolts.

Tighten
- Throttle body (TB) bolts and nuts to 23 Nm (17 lb. ft.).

B. Throttle position (TP) sensor electrical connector.
C. Accelerator bracket; secure with two bolts.

Tighten
- Accelerator bracket bolts to 15 N.m (11 lb. ft.).

20. Slide vacuum modulator onto bracket and connect vacuum hoses (California specification vehicles).
21. Two new gaskets and exhaust gas recirculation (EGR) valve; secure with two bolts and two nuts (California specification vehicles).

Tighten
- EGR valve-to-intake manifold bolts and nuts to 13 Nm (115 lb. in.).
- EGR valve-to-cylinder head bolts to 59 N.m (43 lb. ft.).

22. Air pipe to intake manifold; secure with one bolt and one nut.

Tighten
- Air pipe-to-intake manifold bolt and nut to 9 N.m (80 lb. in.).

23. Fuel return hose to pressure regulator.
24. Intake manifold brace; secure with three bolts.

Tighten
- Intake manifold brace bolts (12 mm bolt head) to 19 N.m (14 lb. ft.).
- Intake manifold brace bolt (14 mm bolt head) to 39 N.m (29 lb. ft.).

25. Engine wire clamp.
26. EGR solenoid vacuum (SV) valve (California specification vehicles).
A. EGR SV valve; secure with one mounting bolt.

Tighten
- EGR SV valve mounting bolt to 13 N.m (115 lb. in.).

B. Vacuum hose to EGR SV valve.
C. EGR SV valve and EGR temperature sensor electrical connectors.
27. Air conditioning (A/C) solenoid vacuum (SV) valve electrical connector.
28. The following hoses to the intake chamber:
- Air hose to air pipe.
- A/C vacuum hoses to A/C SV valve (if equipped).
- Brake booster vacuum hose.
- Vacuum sensor hose to fuel filter.
29. Engine wire harness to right side fender.
30. A/C triple pressure switch electrical connector (if equipped).
31. Manifold absolute pressure (MAP) sensor electrical connector.
32. Ground strap electrical connector.
33. Left-side engine hanger to engine; secure with one nut.

Tighten
- Left-side engine hanger nut to 28 N.m (21 lb. ft.).

Clean
- Remaining gasket material from cylinder head and thermostat housing contact surfaces.

34. Thermostat housing.
A. Apply RTV silicone sealer GM P/N 1052917, or equivalent, to the thermostat housing. Avoid excessive application; also avoid getting sealer into oil passages. Thermostat housing must be installed within 15 minutes after sealer application.
B. Thermostat housing to vehicle; secure with one bolt and two nuts.

Tighten
- Thermostat housing nuts and bolt to 20 N.m (14 lb. ft.).

C. Two engine coolant bypass hoses to thermostat housing.
D. Evaporative emissions thermal vacuum valve (EVAP TVV) vacuum hoses to thermostat housing.
E. Engine coolant control valve inlet and outlet hoses to thermostat housing.
F. Lower radiator hose to thermostat housing.
G. Idle air control (IAC) valve electrical connector.
H. Engine coolant temperature (ECT) sensor electrical connector.
I. ECT sending unit electrical connector.

Clean
- Remaining sealer from cylinder head and engine coolant housing contact areas.

- Apply RTV silicone sealer GM P/N 1052917, or equivalent, to the engine coolant outlet housing. Avoid excessive application; also avoid getting sealer into oil passages. Engine coolant outlet housing must be installed within 15 minutes after sealer application.
35. Engine coolant outlet housing to vehicle; secure with two bolts.

Tighten
- Engine coolant outlet housing bolts to 15 N.m (11 lb. ft.).

36. Upper radiator hose to engine coolant outlet housing.
37. Exhaust manifold.
A. Using a J 34673 and feeler gage, check distortion of exhaust manifold face in both diagonal directions. If distortion exceeds 0.10 mm (0.0039-inch), the face must be resurfaced. If the distortion cannot be brought within limits, then a new exhaust manifold must be used.
B. Exhaust manifold with a new gasket; secure with five nuts.

NOTICE: Tighten each exhaust manifold nut in several passes to eliminate the possibility of warping the exhaust manifold.

Tighten
- Exhaust manifold nuts to 34 N.m (25 lb. ft.).

C. Exhaust manifold brace; secure with three bolts (two bolts on California specification vehicles).

Tighten
- Exhaust manifold brace bolts to 39 N.m (29 lb. ft.).

D. Upper heat insulator; secure with five bolts.

Tighten
- Upper heat insulator bolts to 9 N.m (80 lb. in.).

38. Front exhaust pipe.
A. New gasket and front exhaust pipe to muffler pipe; secure with two nuts.

Tighten
- Front exhaust pipe-to-muffler pipe nuts to 62 N.m (46 lb.ft.).

B. New gasket and front exhaust pipe to exhaust manifold (to warm up three way catalytic converter [WU TWC] on California specification vehicles); secure with two nuts.

Tighten
- Front exhaust pipe-to-exhaust manifold (WU TWC on California specification vehicles) nuts to 43 N.m (32 lb. ft.).

C. Front exhaust pipe to mounting bracket; secure with two bolts.

Tighten
- Front exhaust pipe-to-mounting bracket bolts to 19 N.m (14 lb. ft.).

D. Sub-oxygen sensor (SUB-O2S) (California specification vehicles).
E. Oxygen sensor (O2S).

39. Distributor.
40. Generator.
41. Air cleaner (ACL) cover.
42. ACL hose to cover; secure with clamp bolt.
43. Intake air temperature (IAT) sensor electrical connector to ACL cap.
44. Vacuum hose to the EVAP canister.
45. Throttle cable to bracket and TB; secure with lock nut and adjusting nut (automatic transaxle equipped vehicles).

Tighten
- Throttle cable-to-bracket lock nut and adjusting nut to 15 N.m (11 lb. ft.).

46. Accelerator cable to bracket and TB; secure with lock nut and adjusting nut.

Tighten
- Accelerator cable-to-throttle lever lock nut and adjusting nut to 15 N.m (11 lb. ft.).

- Raise and suitably support vehicle.
47. Right-side engine splash shield; secure with six bolts.

Tighten
- Right-side engine splash shield bolts to 10 N.m (89 lb. in.).

- Lower vehicle.
48. Fill radiator with engine coolant.
49. Negative (-) battery cable.

Tighten
- Negative (-) battery cable-to-negative (-) battery terminal retainer to 15 N.m (11 lb. ft.).

- Start engine and check for engine coolant leaks, fuel leaks, oil leaks and exhaust gas leaks.
- Adjust ignition timing.
- Perform road test and check for any abnormal noises, smooth operation, correct shift points and slippage.
- Check for leaks a second time.