Cylinder Head - Installation

Tool Required - J 34673 Straight Edge, or equivalent.

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





4. Ten bolts to cylinder head in sequence shown, 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. Tighten cylinder head bolts to 29 Nm (22 ft. lbs.).

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

5. 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 degrees using the sequence shown above.
- Tighten each cylinder head bolt an additional 90 degrees in the sequence.
- Check that the paint mark has been turned 180 degrees from the front.
6. Intake and exhaust camshaft.
7. Engine coolant inlet pipe to vehicle; secure with two nuts. Tighten engine coolant inlet pipe nuts to 15 Nm (11 ft. lbs.).
8. Hose to engine coolant inlet pipe; secure with hose clamp.
9. Guide tube to vehicle; secure with one bolt. Tighten guide tube bolt to 9.5 Nm (84 inch lbs.).
10. Clip crankshaft position sensor electrical connector on guide tube.
11. Oil level indicator to guide tube.
12. Generator mounting bracket to vehicle; secure with three bolts. Tighten generator mounting bracket bolts to 26 Nm (19 ft. lbs.).
13. Front engine hanger; secure with one bolt. Tighten front engine hanger bolt to 27 Nm (20 ft. lbs.). (If equipped)
14. Timing belt.
15. Engine mount.





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 Nm (47 ft. lbs.).
- B bolt to 25 Nm (18 ft. lbs.).
b. Rubber insulator to engine mount; secure with one bolt. Tighten rubber insulator-to-engine mount bolt to 25 Nm (18 ft. lbs.).
c. Engine mount reinforcement bracket to vehicle; secure with one nut and one bolt. Tighten engine mount reinforcement bracket bolt and nut to 25 Nm (18 ft. lbs.).
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 Nm (89 inch lbs.).
e. Two nuts to engine mount studs. Tighten engine mount stud nuts to 52 Nm (38 ft. lbs.).
f. Remove floor jack.
g. Cruise control actuator bracket to vehicle (if equipped); secure with three bolts. Tighten cruise control actuator bolts to 10 Nm (89 inch lbs.).
h. Move cruise control actuator into place (if equipped); secure with three bolts. Tighten cruise control actuator bolts to 10 Nm (89 inch lbs.).
i. Clip cruise control actuator cover onto actuator (if equipped).
16. Using a straight edge 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.





17. Intake manifold with two new gaskets; secure with seven bolts, four nuts and ground strap. Tighten
- Intake manifold nut (A) to 13 Nm (9 ft. lbs.).
- Intake manifold bolts and nuts (B) to 19 Nm (14 ft. lbs.).

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

18. Engine wire harness.
a. Engine wire harness retainer; secure with one bolt and two nuts. Tighten engine wire harness retainer bolts and nuts 10 Nm (89 inch lbs.).
b. Engine wire ground strap; secure with one bolt. Tighten engine wire ground strap bolt to 10 Nm (89 inch lbs.).
. Fan thermostat switch electrical connector.
d. Engine wire cover to engine; secure with two bolts. Tighten engine wire cover bolts to 10 Nm (89 inch lbs.).
e. Oil pressure switch electrical connector.
f. A/C compressor electrical connector (if equipped).
19. 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 Nm (11 ft. lbs.).
f. Injector electrical connectors.
g. Two gaskets, fuel inlet pipe to fuel rail; secure with union bolt. Tighten union bolt to 29 Nm (22 ft. lbs.).
20. Intake chamber cover.
a. Intake chamber cover with new gasket; secure with two nuts and three bolts. Tighten intake chamber cover nuts and bolts to 19 Nm (14 ft. lbs.).
b. Vacuum hose to pressure regulator.
21. Two Positive Crankcase Ventilation (PCV) hoses to cylinder head cover; secure with hose clamps.
22. Throttle Body (TB) to intake manifold.
a. New gasket and TB; secure with two nuts and two bolts. Tighten TB bolts and nuts to 22 Nm (16 ft. lbs.).
b. Throttle Position (TP) sensor electrical connector.
c. Accelerator bracket; secure with two bolts. Tighten accelerator bracket bolts to 11 Nm (98 inch lbs.).
23. One new gasket and Exhaust Gas Re-circulation (EGR) valve; secure with two nuts. Tighten EGR valve-to-intake manifold nuts to 13 Nm (115 inch lbs.).
24. Air pipe to intake manifold; secure with one bolt, one nut and fuel inlet hose clamp bolt. Tighten air pipe-to-intake manifold bolt and nut to 9 Nm (80 inch lbs.).
25. Fuel return hose to pressure regulator.
26. Intake manifold brace; secure with two bolts. Tighten
- Intake manifold brace bolts (12 mm bolt head) to 19 Nm (14 ft. lbs.).
- Intake manifold brace bolt (14 mm bolt head) to 39 Nm (29 ft. lbs.).
27. Engine wire clamp.
28. EGR solenoid vacuum (SV) valve and vacuum modulator.
a. EGR SV valve, vacuum modulator and vacuum hose assembly. Tighten EGR SV valve mounting bolt to 13 Nm (115 inch lbs.).
b. Hose to EGR SV valve pipe.
c. EGR SV valve electrical connector.
29. Air Conditioning (A/C) SV valve electrical connector.
30. 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.
31. Engine wire harness to right-side fender.
32. A/C triple pressure switch electrical connector (if equipped).
33. Manifold Absolute Pressure (MAP) sensor electrical connector
34. Ground strap electrical connector.
35. Left-side engine hanger to engine; secure with one bolt. Tighten left-side engine hanger bolt to 28 Nm (21 ft. lbs.). Clean remaining gasket material from cylinder head and thermostat housing contact surfaces.
36. 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 Nm (14 ft. lbs.).
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.
37. 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.
38. Engine coolant outlet housing to vehicle; secure with two bolts. Tighten engine coolant outlet housing bolts to 20 Nm (14 ft. lbs.).
39. Upper radiator hose to engine coolant outlet housing.
40. Exhaust manifold.
a. Using a straight edge 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. Tighten exhaust manifold nuts to 34 Nm (25 ft. lbs.).

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

c. Exhaust manifold brace; secure with three bolts. Tighten exhaust manifold brace bolts to 59 Nm (43 ft. lbs.).
d. Upper heat insulator; secure with five bolts. Tighten upper heat insulator bolts to 17 Nm (12 ft. lbs.).
41. Front exhaust pipe.
a. Front exhaust pipe to vehicle; secure with two nuts at front exhaust pipe-to-exhaust manifold mating flange. Tighten front exhaust pipe-to-exhaust manifold nuts to 62 Nm (46 ft. lbs.).
b. Electrical connector to oxygen sensor (02S1) at front exhaust pipe.
c. Two bolts to front exhaust pipe-to-TWC mating flange. Tighten front exhaust pipe-to-TWC mating flange bolts to 43 Nm (32 ft. lbs.).
d. Front exhaust pipe support to front exhaust pipe; secure with two bolts. Tighten front exhaust pipe support bolts to 19 Nm (14 ft. lbs.).
42. Distributor. See Powertrain Management.
43. Generator. See Starting and Charging.
44. Air cleaner (ACL) cover.
45. ACL hose to cover; secure with clamp bolt.
46. Intake air temperature (IAT) sensor electrical connector to ACL cap.
47. Vacuum hose to the EVAP canister.
48. 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 Nm (11 ft. lbs.).
49. 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 Nm (11 ft. lbs.).
50. Raise and suitably support vehicle.
51. Right-side engine splash shield; secure with six bolts. Tighten right-side engine splash shield bolts to 10 Nm (89 inch lbs.).
52. Lower vehicle.
53. Fill radiator with engine coolant. See Cooling System.
54. Negative (-) battery cable.
55. Start engine and check for engine coolant leaks, fuel leaks, oil leaks and exhaust gas leaks.
56. Adjust ignition timing. See Powertrain Management.
57. Perform road test and check for any abnormal noises, smooth operation, correct shift points and slippage.
58. Check for leaks a second time.