Cylinder Head Replacement
Cylinder Head Replacement^ Tools Required
- J36660-A Torque Angle Meter
- J28467-360 Engine Support Fixture
- J26467-380 Engine Lift Hook
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain cooling system.
3. Remove the intake manifold.
4. Install the generator stud-ended bolt.
5. Remove the exhaust manifold.
6. Install the J28467-360 and J28467-380 in order to support the engine.
7. Remove the ignition coil and the module assembly to the camshaft housing bolts. Remove the assembly by pulling it straight up.
8. Disconnect the camshaft Position sensor connector.
9. Remove the power steering pump.
10. Remove the fuel rail from the cylinder head.
11. Use the following procedure in order to remove the fuel rail from the cylinder head:
12. Disconnect the timing chain housing at the intake camshaft housing. Do not remove it from the vehicle.
13. Disconnect the electrical connection from the oil pressure switch.
14. Remove the intake camshaft housing.
15. Remove the exhaust camshaft housing.
16. Disconnect the radiator inlet (upper) hose from the coolant outlet.
17. Remove the coolant temperature sensor connectors.
18. Reverse the tightening sequence shown in order to remove the cylinder head to block bolts.
19. Remove cylinder head and gasket.
Notice: Engine damage may result if an abrasive paper, pad, or motorized wire brush is used to clean any engine gasket surfaces.
Important:
^ Use a razor blade gasket scraper in order to clean the cylinder head and the cylinder block gasket surfaces. Do not gouge or scratch the gasket surfaces or the combustion chamber surfaces. Use a new razor blade for each cylinder head and the cylinder block.
^ Hold the gasket scraper so the blade is as parallel to the gasket surface as possible.
^ The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket.
^ Do not use any other method or technique to clean the gasket surfaces.
^ Do not use a tap to clean the cylinder head bolt holes. Use a nylon bristle brush.
20. Clean the old sealer/lube and dirt from the bolt, the studs, and the bolt holes.
Clean the bolt holes with a nylon bristle brush.
Caution: Wear safety glasses when using compressed air in order to prevent eye injury.
21. When cleaning the cylinder head long bolt holes, use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.
22. Clean the following components:
^ The cylinder head bolts.
^ The cylinder head.
^ Remove all the varnish, the soot, and the carbon to the bare metal.
^ Do not use a wire brush on any gasket sealing surface.
^ The valve guides
^ The threaded holes
^ The remains of sealer from the plug holes
Important:
^ Do not remove the spark plugs from an aluminum cylinder head until the cylinder head has cooled.
^ Clean the dirt and debris from the spark plug recess area.
^ If the spark plug opening threads are damaged and not restorable with a Thread Chaser, use the thread inserts in order to repair the threads.
23. Remove the spark plugs.
24. Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by an improper use of tools.
Replace any suspected bolts.
25. Clean and inspect cylinder head.
Installation Procedure
1. If removed, install spark plugs.
2. Install cylinder head gasket.
3. Install cylinder head.
4. Install cylinder head bolts.
Notice: Refer to Fastener Notice in Service Precautions.
5. Tighten
5.1. Tighten bolts 1 through 8 to 65 Nm (40 ft. lbs.).
5.2. Tighten bolts 9 and 10 to 40 Nm (30 ft. lbs.).
5.3. Then turn all bolts an additional 90 degrees in sequence, using the J36660-A.
6. Connect coolant temperature sensor connector.
7. Install intake camshaft housing.
8. The exhaust camshaft housing.
9. Install the timing chain housing and the timing chain.
10. Install the fuel rail to the cylinder head.
11. Install the vacuum line to the fuel pressure regulator.
12. Install the camshaft Position sensor connector.
Important: When reinstalling the power steering pump apply a 3 mm bead of GM P/N 12346586 sealer or the equivalent to the joint at the end of the camshaft housing halves before installation of the power steering pump and the pump face seal.
13. Install the power steering pump assembly.
14. Install the electrical connection from the oil pressure switch.
15. Reinstall any spark plug boot connector assembly that stuck to a spark plug back onto the ignition coil and module assembly.
16. Locate the ignition coil and the module assembly over the spark plugs and push straight down.
17. Clean any loose lubricant that is present on the ignition coil and the module assembly to the camshaft housing bolts.
18. Apply the Pipe Sealant GM P/N 1052080 or the equivalent onto the ignition coil and the module cover assembly to the camshaft housing bolts.
Tighten the bolts to 15 Nm (11 ft. lbs.) + 30 degrees.
19. Install the electrical connector to the ignition coil and the module assembly.
20. Remove the J28467-360 and the stud-ended generator bolt.
21. Install the intake manifold.
22. Connect the coolant temperature sensor connectors.
23. Connect the upper radiator hose to the coolant outlet.
24. Connect the following electrical connectors:
^ The MAP sensor
^ The IAT sensor
^ The purge solenoid
^ The fuel injectors
25. Install the exhaust manifold.
26. Install the resonator and air cleaner duct.
27. Fill the cooling system.
28. Connect the negative battery cable.