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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1352 (Engine Mechanical - 1.8L (LV6)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Cylinder Head Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 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.
  1. Clean the threads in the cylinder block.
  2. Install the new cylinder head gasket on the cylinder block.
  3. Install the cylinder head on the cylinder block.
    4. 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.
  4. Install the cylinder head bolts and washers into the cylinder head.
    5. Fig 1: Cylinder Head Bolts
    GM235572Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Progressively torque the cylinder head bolts using 3 steps in the sequence shown.
    1. 1st Pass:  Tighten the cylinder head bolts to 25 N.m (18 lb ft).
    2. 2nd Pass:  Tighten the cylinder head bolts to 49 N.m (36 lb ft).
    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.
  6. Install the intake manifold. Refer to Intake Manifold Replacement .
  7. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (2WD) or Exhaust Manifold Replacement (AWD) in Engine Exhaust.
  8. Install the intake camshaft. Refer to Intake Camshaft and Lifter Replacement .
  9. Install the exhaust camshaft. Refer to Exhaust Camshaft and Lifter Replacement .
  10. Install the timing chain. Refer to Timing Chain and Sprockets Replacement .
  11. Install the timing chain housing. Refer to Timing Chain Housing Replacement .
  12. Install the crankshaft pulley. Refer to Crankshaft Pulley Replacement .
  13. Install the cylinder head cover. Refer to Cylinder Head Cover Replacement .
  14. Install the engine mount bracket as follows:
    • Position the engine mount bracket
    • Install the 3 bolts

      Tighten:  Tighten the bolts to 47 N.m (35 lb ft).

  15. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  16. Install the right side engine mount. Refer to Engine Mount Replacement .
  17. Install the crankshaft position sensor. Refer to Crankshaft Position (CKP) Sensor Replacement in Engine Controls-1.8L (LV6).
  18. Install the power steering pump.

    Tighten:  Tighten the power steering pump bolts to 37 N.m (27 lb ft).

  19. Connect the power steering oil pressure switch electrical connector.
  20. Install the engine coolant temperature (ECT) sensor.
  21. Install the camshaft sensor.
  22. Use the 1 bolt in order to secure the camshaft sensor.

    Tighten:  Tighten the camshaft sensor bolt to 15 N.m (11 lb ft).

  23. Install the camshaft position actuator O-ring, filter and oil filter.
  24. Install a new O-ring and the camshaft position actuator solenoid.

    Tighten:  Tighten the camshaft position actuator solenoid valve bolt to 15 N.m (11 lb ft).

  25. Connect the camshaft position actuator solenoid valve electrical connector.
  26. Connect the engine coolant temperature sensor electrical connector.
    27. Fig 2: Cylinder Head Components
    GM235545Courtesy of GENERAL MOTORS CORP.
  27. Install the water bypass pipe (1) to the cylinder head.
  28. 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).

  29. Install the heater hose to the cylinder head.
  30. Install the engine ground wires to the cylinder head.
  31. 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).

  32. Install the fuel rail to the cylinder head.
  33. Use the 3 bolts in order to secure the fuel rail.

    Tighten:  Tighten the fuel rail bolts to 14 N.m (10 lb ft).

  34. Connect the fuel line to the fuel rail.
  35. Install the heater hose to the cylinder head.
    36. Fig 3: Identifying Ignition Coils
    GM621682Courtesy of GENERAL MOTORS CORP.
  36. Install the 4 ignition coils (1, 2, 3, 4).
  37. Connect the ignition coil connectors.
  38. Remove the engine support fixture.
  39. Raise and support the vehicle.
    40. Fig 4: Exhaust Support Bracket Bolt
    GM234425Courtesy of GENERAL MOTORS CORP.
  40. 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).

    41. Fig 5: Exhaust Manifold Support Bracket
    GM824940Courtesy of GENERAL MOTORS CORP.
  41. On 2WD, install the exhaust manifold support bracket bolt.

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

    42. Fig 6: Exhaust Pipe Bolts And Springs
    GM236842Courtesy of GENERAL MOTORS CORP.
  42. Use a new seal in order to install the exhaust pipe to the exhaust manifold.
  43. 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).

  44. Install the left side engine splash shield. Refer to Splash Shield Replacement - Engine - Left in Body Front End.
  45. Install the right side engine splash shield. Refer to Splash Shield Replacement - Engine - Right in Body Front End.
  46. Lower the vehicle.
  47. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Position 1 (FWD) or Heated Oxygen Sensor Replacement - Position 1 (AWD) in Engine Controls-1.8L (LV6).
  48. Install the injector harness brackets.
  49. Connect all of the necessary vacuum hoses.
  50. Install the intake manifold support bracket.
  51. 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).

  52. Install the fuel injector harness to the intake manifold.
  53. 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).

  54. Install the radiator inlet hose. Refer to Radiator Hose Replacement - Inlet in Engine Cooling.
  55. Connect the 4 fuel injector connectors.
  56. Connect the temperature sensor connector.
  57. Install the 2 coolant bypass hoses to the throttle body.
  58. Use the 2 hose clamps in order to secure the two coolant bypass hoses.
  59. Connect the MAP sensor connector.
  60. Connect the IAC valve connector.
  61. Connect the TP sensor connector.
  62. Install the air cleaner hose and cap assembly.
  63. Connect the IAT sensor connector.
  64. Install the accelerator cable to the throttle body.
  65. Install the generator (1). Refer to Generator Replacement in Engine Electrical.
    66. Fig 7: Identifying Serpentine Drive Belt Routing
    GM244267Courtesy of GENERAL MOTORS CORP.
  66. Install the serpentine drive belt. Refer to Drive Belt Replacement .
  67. Refill the engine oil.
  68. Refill the engine coolant.
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