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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1353 (Engine Mechanical - 1.8L (LNK)) >> 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.
    Fig 1: Exhaust Manifold Components
    GM827276Courtesy of GENERAL MOTORS CORP.
  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)
    2. 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.
  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.
    6. 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.
  6. Install the cylinder head bolts and washers into the cylinder head.
    7. Fig 2: Cylinder Head Bolts
    GM235572Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Progressively torque the cylinder head bolts using two steps in the sequence shown.
    1. -

      1st Pass:  Tighten the cylinder head bolts to 35 N.m (26 lb ft).

    2. Mark the front of the cylinder head bolts with paint.
    3. -

      2nd Pass:  After reaching the torque of 35 N.m (26 lb ft). Use a J 36660-A  and tighten the cylinder head bolts an additional 180 degrees. See Special Tools and Equipment .

  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.

    Tighten:  Tighten the oil control valve bolt to 29 N.m (22 lb ft).

    12. Fig 3: Bolt And The Water By-Pass Pipe
    GM1258110Courtesy of GENERAL MOTORS CORP.
  12. Install the bolt and the water by-pass pipe.

    Tighten:  Tighten the oil water by-pass bolt to 21 N.m (15 lb ft).

  13. Install the exhaust camshaft. Refer to Camshaft Replacement - Exhaust .
  14. Install the intake camshaft. Refer to Camshaft Replacement - Intake .
  15. Install the PCV valve and grommet. Refer to Positive Crankcase Ventilation (PCV) Valve Replacement .
  16. Install the ECT sensor. Refer to Engine Coolant Temperature (ECT) Sensor Replacement .
  17. Install the camshaft position sensor. Refer to Camshaft Position (CMP) Sensor Replacement .
  18. Install the intake manifold. Refer to Intake Manifold Replacement .
  19. Install the intake manifold insulator.
  20. Install 2 bolts to the engine wire harness bracket.
    21. Fig 4: Oil Pressure Switch And Ground Electrical Connectors
    GM824991Courtesy of GENERAL MOTORS CORP.
  21. Connect the oil pressure switch and two ground electrical connectors.
  22. Connect the VVT and the VVTL electrical connectors.
  23. Connect the ECT sensor and camshaft position sensor electrical connectors.
  24. Install 2 bolts from the accelerator cable bracket.

    Tighten:  Tighten the accelerator cable bolts to 13 N.m (10 lb ft).

  25. Install the fuel injectors. Refer to Fuel Injector Replacement .
  26. Install the throttle body. Refer to Throttle Body Assembly Replacement .
    27. Fig 5: PCV Hoses At Cylinder Head Cover
    GM824977Courtesy of GENERAL MOTORS CORP.
  27. Connect the positive crankcase ventilation (PCV) hoses to the cylinder head cover.
  28. Install the spark plugs. Refer to Spark Plug Replacement .
  29. Install the ignition coils. Refer to Ignition Coil(s) Replacement .
    30. Fig 6: Exhaust Manifold Bracket Nut And Bolts
    GM824940Courtesy of GENERAL MOTORS CORP.
  30. Install the exhaust manifold bracket.

    Tighten:  Tighten the exhaust manifold bracket nut and bolts to 50 N.m (37 lb ft).

    31. Fig 7: Exhaust Pipe
    GM824870Courtesy of GENERAL MOTORS CORP.
  31. Install the exhaust pipe.

    Tighten:  Tighten the exhaust pipe to 43 N.m (32 lb ft).

  32. Install the timing chain and sprockets. Refer to Timing Chain and Sprockets Installation .
  33. Install the right engine splash shield. Refer to Splash Shield Replacement - Engine - Right in Body Front End.
  34. Install the left engine splash shield. Refer to Splash Shield Replacement - Engine - Left in Body Front End.
  35. Install the generator. Refer to Generator Replacement in Engine Electrical.
  36. Install the AIR shut-off valve. Refer to Secondary Air Injection (AIR) Solenoid Valve Replacement in Engine Controls.
  37. Install the serpentine drive belt. Refer to Drive Belt Replacement .
  38. Connect the accelerator cable.
  39. Install the air cleaner assembly.
  40. Install the engine cover.
  41. Refill the engine oil.
  42. Refill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
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