Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Vibe. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: 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.

Clean the threads in the cylinder block.
Install the new cylinder head gasket on the cylinder block.
Install the cylinder head on the cylinder block.
NOTE: 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.
Install the cylinder head bolts and washers into the cylinder head.
NOTE: Refer to FASTENER NOTICE .
Progressively torque the cylinder head bolts using 3 steps in the sequence shown.
1. 5.1 1st Pass
  Tighten the cylinder head bolts to 25 N.m (18 lb ft).
2. 5.2 2nd Pass
  Tighten the cylinder head bolts to 49 N.m (36 lb ft).
3. 5.3 3rd Pass
  After reaching the torque of 49 N.m (36 lb ft). Use a J 36660-A and tighten the cylinder head bolts an additional 90 degrees.
  
  Fig 1: Identifying Cylinder Head Bolt Tightening Sequence
  Courtesy of GENERAL MOTORS CORP.
Important: Use a wooden block in order to protect the oil pan when lifting the engine.
Use a floor jack in order to raise the engine.
Reposition the holding fixture.
Support the engine by the support hook.
Lower the floor jack.
Install the intake camshaft. Refer to INTAKE CAMSHAFT AND LIFTER REPLACEMENT .
Install the exhaust camshaft. Refer to EXHAUST CAMSHAFT AND LIFTER REPLACEMENT .
Install the timing chain. Refer to TIMING CHAIN AND SPROCKETS REPLACEMENT .
Install the timing chain housing. Refer to TIMING CHAIN HOUSING REPLACEMENT .
Install the crankshaft pulley. Refer to CRANKSHAFT PULLEY REPLACEMENT .
Install the cylinder head cover. Refer to CYLINDER HEAD COVER REPLACEMENT .
Install the engine coolant temperature (ECT) sensor.
Install the camshaft sensor.
Use the 1 bolt in order to secure the camshaft sensor.
Tighten

Tighten the camshaft sensor bolt to 15 N.m (11 lb ft).
Install the water bypass pipe (1) to the cylinder head.

Fig 2: Installing Water Bypass Pipe To Cylinder Head
Courtesy of GENERAL MOTORS CORP.
Use the 1 bolt in order to secure the coolant bypass pipe to the cylinder head.
Tighten

Tighten the coolant bypass pipe to 15 N.m (11 lb ft).
Install the heater hose to the cylinder head.
Install the engine ground wires to the cylinder head.
Use the 2 bolts in order to secure the engine ground wires.
Tighten

Tighten the ground wire bolts to 15 N.m (11 lb ft).
Install the fuel rail to the cylinder head.
Use the 3 bolts in order to secure the fuel rail.
Tighten

Tighten the fuel rail bolts to 14 N.m (10 lb ft).
Connect the fuel line to the fuel rail.
Install the 4 ignition coils (1, 2, 3, 4).

Fig 3: Installing Ignition Coils
Courtesy of GENERAL MOTORS CORP.
Connect the ignition coil connectors.
Install the right side engine mount. Refer to ENGINE MOUNT REPLACEMENT .
Remove the engine support fixture.
Raise and support the vehicle.
On AWD, install the one bolt (1) from the manifold to the support bracket.
Tighten

Tighten the exhaust support bracket bolt to 35 N.m (26 lb ft).

Fig 4: Installing Bolt From Manifold To Support Bracket
Courtesy of GENERAL MOTORS CORP.
On 2WD, install the exhaust manifold support bracket bolt.
Tighten

Tighten the exhaust support bracket bolt to 50 N.m (37 lb ft).

Fig 5: Installing Exhaust Manifold Support Bracket Bolt
Courtesy of GENERAL MOTORS CORP.
Use a new seal in order to install the exhaust pipe to the exhaust manifold.

Fig 6: Installing Exhaust Pipe To Exhaust Manifold
Courtesy of GENERAL MOTORS CORP.
Use the 2 bolts and two springs (1, 2) in order to secure the exhaust pipe.
Tighten

Tighten the exhaust pipe flange bolts to 62 N.m (46 lb ft).
Install the left side engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE - LEFT in Body Front End.
Install the right side engine splash shield. Refer to SPLASH SHIELD REPLACEMENT - ENGINE - RIGHT in Body Front End.
Lower the vehicle.
Install the oxygen sensor and the oxygen sensor gasket.
Install the 2 oxygen sensor nuts.
Tighten

Tighten the heated oxygen sensor nuts to 41 N.m (30 lb ft).
Connect the oxygen sensor connector.
Install the injector harness brackets.
Connect all of the necessary vacuum hoses.
Install the intake manifold support bracket.
Use the support bracket bolts in order to secure the intake manifold support bracket.
Tighten

Tighten the intake support bracket bolts to 50 N.m (37 lb ft).
Install the fuel injector harness to the intake manifold.
Use the three bolts in order to secure the fuel injector harness.
Tighten

Tighten the fuel injector harness bolts to 12 N.m (106 lb in).
Install the radiator inlet hose. Refer to RADIATOR HOSE REPLACEMENT - INLET in Engine Cooling.
Connect the 4 fuel injector connectors.
Connect the temperature sensor connector.
Install the 2 coolant bypass hoses to the throttle body.
Use the 2 hose clamps in order to secure the two coolant bypass hoses.
Connect the MAP sensor connector.
Connect the IAC valve connector.
Connect the TP sensor connector.
Install the air cleaner hose and cap assembly.
Connect the IAT sensor connector.
Install the accelerator cable to the throttle body.
Install the generator (1). Refer to GENERATOR .
Install the serpentine drive belt. Refer to DRIVE BELT REPLACEMENT .

Fig 7: Installing Serpentine Drive Belt
Courtesy of GENERAL MOTORS CORP.
Refill the engine oil.
Refill the engine coolant.