Cylinder Head Replacement
Cylinder Head Replacement^ Tools Required
- J 36660-A Torque Angle Meter
- J 8614-01 Pinion Flange Holder
Removal Procedure
1. Remove the left engine splash shield.
2. Remove the right engine splash shield.
3. Drain the engine oil.
4. Remove the engine cover.
Caution: Refer to Battery Disconnect Caution in Service Precautions.
5. Disconnect the battery ground cable.
6. Remove the air cleaner assembly.
7. Disconnect the accelerator cable.
8. Relieve the fuel pressure.
9. Remove the serpentine drive belt.
10. Remove the alternator.
11. Remove the timing chain and sprockets.
12. Remove the exhaust pipe.
13. Remove the exhaust manifold bracket nut and bolts.
14. Remove the ignition coils.
15. Remove the spark plugs.
16. Disconnect the positive crankcase ventilation (PCV) hoses from the cylinder head cover.
17. Remove the throttle body.
18. Remove the fuel injectors.
19. Remove 1 bolt and 1 nut from the accelerator cable bracket.
20. Disconnect the ECT sensor and camshaft position sensor electrical connectors.
21. Disconnect the VVT and the VVTL electrical connectors.
22. Disconnect the oil pressure switch and 2 ground electrical connectors.
23. Remove 2 bolts from the engine wire harness bracket.
24. Remove the intake manifold insulator.
25. Remove the intake manifold.
26. Remove the camshaft position sensor.
27. Remove the ECT sensor.
28. Remove the PCV valve and grommet.
29. Remove the intake camshaft.
30. Remove the exhaust camshaft.
31. Remove the bolt for the oil control valve.
32. Remove the bolt, gasket and oil control valve filter.
33. Disconnect the upper radiator hose from the water house union.
34. Disconnect the heater hose from the water hose union.
35. Remove the following items in sequence:
35.1. The cylinder head bolts
35.2. The cylinder head washers
36. Remove the water bypass to cylinder block bolt.
37. Remove the cylinder head.
38. Remove the following items.
^ The upper exhaust manifold heat insulator bolts (1) and heat insulator.
^ The exhaust manifold nuts (2) and bolts (3).
^ The exhaust manifold (4) and gasket.
^ The lower exhaust manifold heat insulator bolts (5) and heat insulator.
39. Remove the cylinder head gasket (1).
40. Clean the cylinder block mating surfaces.
41. Clean the cylinder head mating surface.
42. Clean the timing chain cover mating surface.
Installation Procedure
1. Install the following items.
^ The lower exhaust manifold heat insulator and heat insulator bolts (5).
^ The exhaust manifold gasket and exhaust manifold (4).
^ The exhaust manifold nuts (2) and bolts (3).
^ The upper exhaust manifold heat insulator and heat insulator bolts (1).
Notice: This engine uses special torque to yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage.
2. Clean the threads in the cylinder block.
3. Apply sealant GM P/N 12346240 (Canadian P/N 10953493), or an equivalent, to the head gasket.
4. Install the new cylinder head gasket on the cylinder block.
5. Install the cylinder head on the cylinder block.
Notice: This bolt is designed to permanently stretch when tightened. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt that is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The system or the components may be damaged.
6. Install the cylinder head bolts and washers into the cylinder head.
Notice: Refer to Fastener Notice in Service Precautions.
7. Progressively torque the cylinder head bolts using two steps in the sequence shown.
7.1. 1st Pass
^ Tighten the cylinder head bolts to 35 Nm (26 ft. lbs.).
7.2. Mark the front of the cylinder head bolts with paint.
7.3. 2nd Pass
After reaching the torque of 35 Nm (26 ft. lbs.). Use a J 36660-A and tighten the cylinder head bolts an additional 180°.
8. Connect the heater hose to the water hose union.
9. Connect the upper radiator hose from the water house union.
10. Install the bolt gasket and oil control valve filter.
11. Install the bolt for the oil control valve.
12. Install the exhaust camshaft.
13. Install the intake camshaft.
14. Install the PCV valve and grommet.
15. Install the ECT sensor.
16. Install the camshaft position sensor.
17. Install the intake manifold.
18. Install the intake manifold insulator.
19. Install 2 bolts to the engine wire harness bracket.
20. Connect the oil pressure switch and two ground electrical connectors.
21. Connect the VVT and the VVTL electrical connectors.
22. Connect the ECT sensor and camshaft position sensor electrical connectors.
23. Install 2 bolts from the accelerator cable bracket.
^ Tighten the accelerator cable bolts to 13 Nm (10 ft. lbs.).
24. Install the fuel injectors.
25. Install the throttle body.
26. Connect the Positive Crankcase Ventilation (PCV) hoses to the cylinder head cover.
27. Install the spark plugs.
28. Install the ignition coils.
29. Install the exhaust manifold bracket.
^ Tighten the exhaust manifold bracket nut and bolts to 50 Nm (15 ft. lbs.).
30. Install the exhaust pipe.
^ Tighten the exhaust pipe to 43 Nm (32 ft. lbs.).
31. Install the timing chain and sprockets.
32. Install the right engine splash shield.
33. Install the left engine splash shield.
34. Install the generator.
35. Install the serpentine drive belt.
36. Connect the accelerator cable.
37. Install the air cleaner assembly.
38. Install the engine cover.
39. Refill the engine oil.
40. Refill the cooling system.