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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 721 (Engine Mechanical - 8.1L (On-Vehicle)) >> Repair Instructions >> Cylinder Head Replacement - Left >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Yukon XL, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Do not reuse a cylinder head gasket once the initial clamping loads are applied. The initial tightening sequence procedure of the cylinder head bolts compresses the cylinder head gasket. If any bolt must be loosened once the initial sequence is started the cylinder head gasket must be replaced. Failure to replace the cylinder head gasket can lead to cylinder head bolt breakage or cylinder head gasket failure. A broken cylinder head bolt or failed cylinder head gasket can lead to extensive engine damage.
IMPORTANT: Make sure the threaded holes in the engine block are clean and not damaged. Do not use sealer on any engines that use a composition type gasket. Align the cylinder head gasket locating marks to face up. Ensure that the head gasket tabs are located over the numbers 1 and 2 cylinders for correct installation.
    Fig 1: View Of Left Cylinder Head Gasket And Alignment Pins
    GM470974Courtesy of GENERAL MOTORS CORP.
  1. Place a NEW cylinder head gasket into position.
    2. Fig 2: View Of Left Cylinder Head And Alignment Pin
    GM470916Courtesy of GENERAL MOTORS CORP.
  2. Install the cylinder head.
    3. Fig 3: View Of Cylinder Left Head Bolts
    GM470914Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not reuse the cylinder head bolts. NEW cylinder head bolts must be used. The cylinder head bolts are torque-to-yield bolts and cannot be reused once the initial torque is applied. During the initial torque of the cylinder head bolt the cylinder head bolt is stretched to achieve proper clamp load. Proper clamp load will not be achieved if a used cylinder head bolt is torqued again. A stretched cylinder head bolt can also break when torqued. Failure to replace the used cylinder head bolts with NEW cylinder head bolts can lead to improper clamp loads and extensive engine damage.
    IMPORTANT: The sealer must be applied to a minimum of eight threads starting at the point of the cylinder head bolt.
  3. If not pre-applied to the NEW cylinder head bolts, apply sealant GM U.S. P/N 12346004, Canada P/N 10953480, or equivalent to the cylinder head bolts.
  4. Install the cylinder head bolts (1, 2, and 3).
    5. Fig 4: Cylinder Head Bolt Tightening Sequence
    GM470987Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
    NOTE: The cylinder head bolt tightening sequence must be followed. The final angle tightening sequence of the cylinder head bolts varies depending on the length of the cylinder head bolt. Failure to angle tighten the specific length bolt the proper number of degrees can lead to cylinder head bolt failure or improper clamping load of the cylinder head gasket. Cylinder head bolt or cylinder head gasket failure can lead to extensive engine damage.
    IMPORTANT: The long bolts are used in locations 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, and 17. The medium length bolts are used in locations 15 and 18. The short bolts are used in locations 4, 5, 12, and 13.
  5. Tighten the cylinder head bolts.

    Tighten: 

    1. Tighten the cylinder head bolts a first pass in sequence to 30 N.m (22 lb ft)
    2. Tighten the cylinder head bolts a second pass in sequence to 30 N.m (22 lb ft) then an additional 120 degrees using J 36660-A  .
    3. Tighten the bolts (1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, 17) an additional 60 degrees, bolts (15, and 18) an additional 45 degrees, and bolts (4, 5, 12, and 13) an additional 30 degrees a final pass in sequence using J 36660-A  .

  6. Install the exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - LEFT (8.1L ENGINE) in Engine Exhaust.
  7. Install the water crossover. Refer to WATER CROSSOVER REPLACEMENT (8.1L ENGINE) in Engine Cooling.
    8. Fig 5: EGR Valve, Oil Pressure Sensor Electrical Connector & Engine Harness Ground Bolts & Straps
    GM750530Courtesy of GENERAL MOTORS CORP.
  8. Position the engine harness grounds (3 and 4) and ground strap (5) to the cylinder head.
  9. Install the engine harness ground bolts.

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

  10. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
  11. Install the intake manifold. Refer to Intake Manifold Replacement .
  12. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
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