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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1023 (Engine Mechanical - 6.6L (Lb7) (Repair Instructions 1 Of 4)) >> Repair Instructions (On-Vehicle & Off Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Cylinder Head Replacement - Left >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If the injector sleeve is pulled from the cylinder head when removing the injector, the injector sleeve installation procedure is as follows:
      IMPORTANT: An injector sleeve with scoring or other damage must be replaced.
    1. Set the new injector sleeve gaskets (1) to the injector sleeve (2).
    2. Apply sealant (Locktite 272 or equivalent) to the lower sealing area of injector sleeve.
    2. Fig 1: View Of O-Rings & Fuel Injector Sleeve
    GM761232Courtesy of GENERAL MOTORS CORP.
    NOTE: The left and right cylinder head gaskets are not interchangeable. Improper placement of the cylinder head gasket will block coolant and oil passages. Blocked coolant and oil passages will cause severe engine damage.
  2. Install the left cylinder head gasket of the correct grade. Refer to Cylinder Head Gasket Selection Specifications .
  3. Install the left cylinder head.
    4. Fig 2: View Of Cylinder Head & Gasket (Left)
    GM660511Courtesy of GENERAL MOTORS CORP.
    NOTE: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install NEW cylinder head bolts.
  5. Tighten the cylinder head bolts in the following steps using the sequence shown.

    Tighten: 

    1. Tighten the M12 bolts a first pass to 50 N.m (37 lb ft).
    2. Tighten the M12 bolts a second pass to 80 N.m (59 lb ft).
    3. Tighten the M12 bolts a third pass to 60 degrees, using J 45059  .
    4. Tighten the M12 bolts a final pass to 60 degrees, using J 45059  .
    5. Tighten the M8 bolts to 25 N.m (18 lb ft).

    6. Fig 3: Cylinder Head Bolt Installation Sequence
    GM663831Courtesy of GENERAL MOTORS CORP.
  6. Install a NEW O-ring onto the fuel injector.
  7. Lubricate the O-ring with clean engine oil.
  8. Ensure the injector bore is clean and free from carbon.
  9. Install a new copper washer into the fuel injector bore in the cylinder head.
  10. Install the fuel injector locating pin.
  11. If you are reusing the injectors, clean the injector tip of carbon. Do not clean with a wire brush.
  12. Install the fuel injector with fuel injector retainer.
  13. Install the fuel injector retainer bolt.

    Tighten:  Tighten the bolt to 50 N.m (37 lb ft).

    14. Fig 4: View Of Fuel Injectors, Brackets & Injector Locating Pins
    GM660480Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel injector return pipe.
    15. Fig 5: View Of Fuel Injector Return Pipe
    GM660477Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel injector return pipe to injector bolts and washers.

    Tighten:  Tighten the bolts to 16 N.m (12 lb ft).

  16. Install the fuel injector return pipe to cylinder head bolts and washers.

    Tighten:  Tighten the bolts to 17 N.m (13 lb ft).

  17. Position the ground straps to the rear of the cylinder head, and install the bolt.

    Tighten:  Tighten the bolt to 34 N.m (25 lb ft).

    18. Fig 6: View Cylinder Head Rear Ground Straps Bolt
    GM669307Courtesy of GENERAL MOTORS CORP.
  18. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
  19. Install the glow plugs. Refer to Glow Plug Replacement - Bank 2 in Engine Controls - 6.6L.
  20. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left (6.6L (LB7) Engine) in Engine Exhaust.
  21. Install the left fuel rail. Refer to Fuel Rail Assembly Replacement - Bank 2 in Engine Controls - 6.6L.
  22. Install the left intake manifold. Refer to Intake Manifold Replacement - Left .
  23. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (6.6L (LB7) Engine) in Engine Cooling.
  24. Install the charged air cooler inlet duct.
  25. Install the clamp (3) and duct to the charged air cooler inlet (3) duct.

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

    26. Fig 7: View Of Charged Air Cooler Aligning Marks & Clamps
    GM877283Courtesy of GENERAL MOTORS CORP.
  26. Install the turbocharger. Refer to Turbocharger Replacement .
  27. Install the wheelhouse inner panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  28. Road test the vehicle for normal operation.
  29. Inspect for coolant, oil, or exhaust leaks.
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