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Cylinder Head And Gasket Replacement: Installation

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Set crankshaft to 60° before top-dead-center (TDC) to prevent valves to piston contact.
  1. Transfer all components (intake manifold, plugs, etc.) if new cylinder head is being installed.
    Fig 1: Removing Cylinder Head From Block
    G01039243Courtesy of GENERAL MOTORS CORP.
  2. Set crankshaft to 60° before top dead center.
    Fig 2: Setting Crankshaft To 60° Before Top Dead Center
    G01039244Courtesy of GENERAL MOTORS CORP.
  3. Install cylinder head gasket placing OPEN facing up.
    Fig 3: Installing Cylinder Head Gasket
    G01039245Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  Always use new cylinder head bolts.

  4. With assistance, install cylinder head, aligning it onto cylinder head dowels.
  5. Lightly apply clean engine oil to threads and to bottom side of flange of head bolts. Allow oil to drain before installing.
  6. Install and torque cylinder head bolts in sequence.

    Torque: 

    Cylinder Head Bolts: 30 N.m (22 ft-lbs) + 155° 

    Fig 4: Cylinder Head Tightening Sequence
    G01039246Courtesy of GENERAL MOTORS CORP.
  7. Coat front cylinder head crankcase bolts with Permatex Threadlocker Blue P/N 21485278 or equivalent.

    Torque: 

    Cylinder Head Front Chaincase Bolts: 35 N.m (26 ft-lbs) 

    Fig 5: Coating Front Cylinder Head Crankcase Bolts
    G01039247Courtesy of GENERAL MOTORS CORP.
  8. Position exhaust camshaft with offset slot to 2 o'clock position.
    Fig 6: Positioning Exhaust Camshaft
    G01039248Courtesy of GENERAL MOTORS CORP.
  9. Position intake camshaft with offset slot to 11 o'clock position.
    Fig 7: Position Intake Camshaft
    G01039249Courtesy of GENERAL MOTORS CORP.
  10. Install timing chain drive sprocket to crankshaft.
  11. Using dampener, rotate crank so that mark on timing chain drive sprocket is at 5 o'clock position.
    Fig 8: Installing Timing Chain Drive Sprocket To Crankshaft
    G01039250Courtesy of GENERAL MOTORS CORP.
  12. Assemble chain to intake camshaft sprocket aligning copper link to INT diamond timing mark on camshaft sprocket.
    Fig 9: Aligning Camshaft Sprocket
    G01039251Courtesy of GENERAL MOTORS CORP.
    NOTE: When lowering timing chain into cylinder head, rotate assembly 90° to allow chain to fall between cylinder block bosses, then rotate assembly back so that camshaft sprocket is facing forward.
  13. Lower assembly through chain housing opening on top of cylinder head. Use care to make sure that chain goes around both sides of cylinder block bosses.
    Fig 10: Installing Timing Chain
    G01039252Courtesy of GENERAL MOTORS CORP.
    NOTE: The crankshaft sprocket timing mark will be at approximately 5 o'clock position.
  14. Route chain around crankshaft sprocket and align silver link to timing mark.
    Fig 11: Routing Chain Around Crankshaft Sprocket
    G01039253Courtesy of GENERAL MOTORS CORP.
    NOTE: The camshaft sprocket bolts are torque-to-yield bolts and are not reusable. They must be replaced when removed.
  15. Install intake camshaft sprocket with chain in proper position to camshaft. Rotate intake camshaft using a 24 mm wrench on flats on camshaft until camshaft aligns with sprocket.
  16. Install new intake camshaft sprocket bolt and finger tighten.

    IMPORTANT:  With timing chain aligned to crankshaft sprocket mark, the crankshaft can be rotated slightly to eliminate slack from the fixed side of timing chain. Be sure that marks are properly aligned.

    Fig 12: Installing New Intake Camshaft Sprocket Bolt
    G01039254Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  Make sure crankshaft marks and camshaft marks aligns with colored links.

  17. Install adjustable timing chain guide through opening at top of cylinder head and install chain guide bolt.

    Torque: 

    Timing Chain Guide (Adjustable) Bolt: 10 N.m (89 in-lbs) 

    Fig 13: Installing Adjustable Timing Chain Guide
    G01039255Courtesy of GENERAL MOTORS CORP.
  18. Install exhaust camshaft sprocket loosely on exhaust camshaft with timing mark on sprocket aligned with silver link.
  19. Install new camshaft sprocket bolt loosely.
    Fig 14: Installing New Camshaft Sprocket Bolt
    G01039256Courtesy of GENERAL MOTORS CORP.
  20. Align exhaust camshaft sprocket with chain in proper position to camshaft. Rotate exhaust clockwise using a 24 mm wrench on flats on camshaft until camshaft aligns with sprocket.
    Fig 15: Aligning Exhaust Camshaft
    G01039257Courtesy of GENERAL MOTORS CORP.
  21. Verify that all colored links are aligned with appropriate intake (1), crankshaft sprocket (2), and exhaust marks.
  22. Verify crankshaft sprocket timing mark is at 5 o'clock.
  23. If marks are not correct you must repeat timing procedure.
    Fig 16: Verifying Intake, Crankshaft Sprocket and Exhaust Alignment Marks
    G01039258Courtesy of GENERAL MOTORS CORP.
  24. Install fixed timing chain guide and bolts.

    Torque: 

    Timing Chain (Fixed) Bolts: 10 N.m (89 in-lbs) 

    Fig 17: Installing Fixed Timing Chain Guide And Bolts
    G01039259Courtesy of GENERAL MOTORS CORP.
  25. Apply thread sealant Permatex® Thread Pipe Sealant (or equivalent) compound to thread. Install fixed guide bolt access hole plug.

    Torque: 

    Timing Chain Guide Bolt Access Hole Plug: 40 N.m (30 ft-lbs) 

    Fig 18: Installing Timing Chain Bolt Access Hole Plug
    G01039260Courtesy of GENERAL MOTORS CORP.
  26. Install upper timing chain guide and bolts.

    Torque: 

    Timing Chain Guide (Upper) Bolts: 10 N.m (89 in-lbs) 

    Fig 19: Installing Upper Timing Chain Guide And Bolts
    G01039261Courtesy of GENERAL MOTORS CORP.
    NOTE: Use a 24 mm wrench to support the camshaft while applying torque to camshaft sprocket bolt. Do not torque camshaft bolts against timing chain, as it may damage timing chain.
  27. Tighten intake and exhaust camshaft sprocket bolts while holding camshaft with 24 mm wrench.

    Torque: 

    Camshaft Sprocket Bolts: 85 N.m (63 ft-lbs)+ 30° 

    Fig 20: Tightening Intake And Exhaust Camshaft Sprockets Bolts
    G01039262Courtesy of GENERAL MOTORS CORP.
    NOTE: There is 1st and 2nd tensioner and guide assembly. A 2nd design tensioner assembly (knotched style) should be used only with a 2nd design adjustable guide.
  28. Measure timing chain tensioner assembly from end to end. A new tensioner should be supplied in a fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in.) (a) from end-to-end. A tensioner in the active state will measure 85 mm (3.35 in.) (a) from end-to-end. If the tensioner is not in a compressed state, perform the following steps:
    Fig 21: Measuring Timing Chain Tensioner
    G01039263Courtesy of GENERAL MOTORS CORP.
    1. 28.1 Hole the flat end of tensioner piston with Timing Chain Tensioner Unloader J45027.
    2. 28.2 Using timing chain tensioner unloader J45027, rotate piston clockwise slightly at which resistance will be felt and will collapse and lock in.
    3. 28.3 At this point tensioner should measure approximately 72 mm (2.83 in.) (a) from end-to-end. If tensioner does not read 72 mm, repeat this procedure.
  29. Remove all thread material from timing chain tensioner hole.
    Fig 22: Removing All Thread Material From Timing Chain Tensioner Hole
    G01039264Courtesy of GENERAL MOTORS CORP.
  30. Install timing chain tensioner.

    Torque: 

    Timing Chain Tensioner: 75 N.m (55 ft-lbs) 

  31. Timing chain tensioner is released by compressing it 2 mm (.079 in.) which will release locking mechanism in ratchet. Tensioner can be released by one of two methods:
    • If engine has less than 48,279 km (30,000 miles) tensioner can be released by starting engine. This method cannot be used on engine with over 30,000 miles or cam chain may jump teeth on cam sprockets.
    • If engine has over 48,279 km (30,000 miles) on it use a suitable tool with a rubber tip on the end. Feed tool down through cam drive to rest on cam chain, giving a sharp jolt diagonally downward to release tensioner.
      Fig 23: Installing Timing Chain Tensioner
      G01039265Courtesy of GENERAL MOTORS CORP.
  32. Raise vehicle if necessary.
  33. Install new front cover gasket.
  34. Install front cover assembly.
  35. Install front cover assembly bolts.

    Torque: 

    Front Cover-to-Block Bolts: 25 N.m (18 ft-lbs) 

  36. Install front cover water pump bolt.

    Torque: 

    Water Pump Bolts: 25 N.m (18 ft-lbs) 

    Fig 24: Installing Front Cover Assembly Bolts
    G01039266Courtesy of GENERAL MOTORS CORP.
  37. Lubricate front seal and sealing surface of pulley with clean motor oil.
  38. Install balancer pulley onto crankshaft indexing keyway. Use care to properly align flats on balancer pulley with flats on oil pump drive in front cover assembly.
  39. Install crankshaft damper pulley.
    Fig 25: Installing Crankshaft Damper Pulley
    G01039267Courtesy of GENERAL MOTORS CORP.
  40. Install new crankshaft balancer pulley bolt with washer assembly.
    Fig 26: Installing New Crankshaft Balancer Pulley Bolt
    G01039268Courtesy of GENERAL MOTORS CORP.
  41. Install crankshaft pulley holder J38122.

    Torque: 

    Crankshaft Pulley Bolt: 100 N.m (74 ft-lbs)+ 75° 

    Fig 27: Installing Crankshaft Pulley Holder
    G01039269Courtesy of GENERAL MOTORS CORP.
  42. Install accessory drive belt tensioner.

    Torque: 

    Drive Belt Tensioner Bolt: 50 N.m (37 ft-lbs) 

    Fig 28: Installing Accessory Drive Belt Tensioner
    G01039270Courtesy of GENERAL MOTORS CORP.
  43. Route belt around alternator and A/C compressor.
  44. Install accessory drive belt tool J39914 onto tensioner and unload spring tension from tensioner while positioning belt.
  45. Release tensioner and remove tool.
  46. Position manifold down pipe with gasket onto flange studs.
  47. Install exhaust manifold pipe to exhaust manifold nuts.

    Torque: 

    Exhaust Manifold Pipe to Exhaust Manifold Nuts: 30 N.m (22 ft-lbs) 

  48. Attach electrical harnesses at bottom intake manifold.
  49. Position oil level indicator into oil pan assembly.
  50. Install oil level indicator tube bolt.

    Torque: 

    Oil Level Indicator-to-Manifold Bolt: 10 N.m (89 in-lbs) 

  51. Remove oil drain plug and drain oil.

    Torque: 

    Oil Drain Plug: 25 N.m (18 ft-lbs) 

  52. Lower vehicle.
  53. Remove oil filter and install new oil filter.
  54. Fill engine with oil.

    Torque: 

    Oil Filter Cap: 25 N.m (18 ft-lbs) 

  55. Install right-hand engine bracket and bolts.

    Torque: 

    Engine Mount Bracket-to-Engine Bolts: 90 N.m (66 ft-lbs) 

    Fig 29: Installing Right-Hand Engine Bracket And Bolts
    G01039271Courtesy of GENERAL MOTORS CORP.
  56. Install right-hand engine mount onto body side rail studs.
  57. Install right hand engine mount to body nuts.

    Torque: 

    Engine Mount-to-Body Nuts: 110 N.m (81 ft-lbs) 

  58. Install right-hand engine mount to engine mount bracket bolts.

    Torque: 

    Engine Mount-to-Engine Mount Bracket Bolts: 55 N.m (41 ft-lbs) 

  59. Remove support wood between engine cradle and oil pan.
  60. Install right engine inner splash shield.
  61. Install right wheel and hand-tighten wheel nuts.
  62. Tighten wheel nuts.
    Fig 30: Installing Right-Hand Engine Mount To Engine Mount Bracket Bolts
    G01039272Courtesy of GENERAL MOTORS CORP.

    Torque: 

    Wheel Nuts: 125 N.m (92 ft-lbs) 

  63. Visually inspect camshaft cover gasket for signs of leakage. Camshaft cover gasket is reusable if not damaged.
  64. Assemble camshaft cover and gasket using care to make sure that gasket is located in retaining groove on camshaft cover.
  65. Install cover on cylinder head and tighten bolts.

    Torque: 

    Camshaft Cover Bolts: 10 N.m (89 in-lbs) 

    Fig 31: Installing Cover On Cylinder Head
    G01039273Courtesy of GENERAL MOTORS CORP.
  66. Position engine harness and install fasteners at cam cover.
  67. Connect throttle body connector.
  68. Attach ECM ground and ECM connector.
  69. Connect fuel injector harness.
  70. Connect upper radiator hose.
  71. Connect brake booster hose at booster.
  72. Connect EVAP purge hose and connector.
  73. Connect oxygen sensors at exhaust manifold.
    Fig 32: Attaching ECM Ground And ECM Connector
    G01039274Courtesy of GENERAL MOTORS CORP.
  74. Re-position fuel line assembly.
    NOTE: An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging fuel rail assembly.
  75. Install transfer line fitting at fuel to fuel rail.

    Torque: 

    Transfer Line Fitting-to-Fuel Rail: 10 N.m (89 in-lbs) 

    Fig 33: Installing Transfer Line Fitting At Fuel To Fuel Rail
    G01039275Courtesy of GENERAL MOTORS CORP.
  76. Connect fuel rail bracket and bolt to cylinder head.

    Torque: 

    Fuel Line Bracket Bolt: 10 N.m (89 in-lbs) 

    Fig 34: Connecting Fuel Rail Bracket And Bolt
    G01039276Courtesy of GENERAL MOTORS CORP.
  77. Connect ground strap to camshaft cover assembly.

    Torque: 

    Camshaft Cover Ground Strap Bolts: 10 N.m (89 in-lbs) 

  78. Connect degas hose and attach to fuel rail.
  79. Connect coolant pipe bracket bolts to cylinder head.

    Torque: 

    Coolant Pipe Bracket Bolt: 10 N.m (89 in-lbs) 

    Fig 35: Connecting Ground Strap To Camshaft Cover Assembly
    G01039277Courtesy of GENERAL MOTORS CORP.
  80. Install spark plugs (if removed).

    Torque: 

    Spark Plugs: 20 N.m (15 ft-lbs) 

  81. Install ignition module assembly to cam cover and hand-tighten retaining bolts.

    Torque: 

    Ignition Module-to-Camshaft Cover Bolts: 8 N.m (71 in-lbs) 

    Fig 36: Installing Ignition Module Assembly
    G01039278Courtesy of GENERAL MOTORS CORP.
  82. Install air cleaner assembly and bolt.

    Torque: 

    Air Cleaner-to-Support Bracket Bolt: 10 N.m (89 in-lbs) 

  83. Install outlet resonator/duct assembly into position.
  84. Connect PCV fresh air vent hose assembly.
  85. Tighten clamp at throttle body assembly.
  86. Position outlet resonator/duct assembly up with support bracket and install push-pin.
  87. Tighten clamp at air cleaner assembly.
  88. Connect intake air temperature (IAT) sensor connector.
  89. Install coolant.
  90. Connect negative battery cable.
    Fig 37: Installing Outlet Resonator/Duct Assembly
    G01039279Courtesy of GENERAL MOTORS CORP.

    Torque: 

    Battery Terminal Bolt: 17 N.m (13 ft-lbs) 

  91. Start vehicle and inspect for leaks.
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