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Home >> Chevrolet >> 2005 >> Chevy Express H1500, Van Passenger >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Cylinder Head Replacement - Left >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Installing Cylinder Head Locator Pins
    GM334303Courtesy of GENERAL MOTORS CORP.
  1. Clean the cylinder head gasket surfaces on the engine block.
  2. Inspect the dowel pins (cylinder head locator) for proper installation.
  3. Clean the cylinder head gasket surfaces on the cylinder head.
    4. Fig 2: View Of Cylinder Head Gasket And Alignment Pins - Left
    GM334299Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not use any type sealer on the cylinder head gasket, unless specified.
  4. Install the NEW cylinder head gasket in position over the dowel pins, cylinder head locator.
    5. Fig 3: Removing/Installing Cylinder Head (Left)
    GM480536Courtesy of GENERAL MOTORS CORP.
  5. Install the cylinder head onto the engine block.

    Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.

    6. Fig 4: Locating Cylinder Head Bolts (Left)
    GM480533Courtesy of GENERAL MOTORS CORP.
  6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the cylinder head bolts.
  7. Install the cylinder head bolts finger tight.
    8. Fig 5: Identifying Cylinder Head Bolt Tightening Sequence
    GM5132Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Tighten the cylinder head bolts in sequence on the first pass.

    Tighten:  Tighten the bolts in sequence on the first pass to 30 N.m (22 lb ft).

  9. Using theJ 45059  tighten the cylinder head bolts in sequence on the final pass. See Special Tools .

    Tighten: 

    • Tighten the long bolts (1, 4, 5, 8, and 9) on the final pass in sequence to 75 degrees.
    • Tighten the medium bolts (12, and 13) on the final pass in sequence to 65 degrees.
    • Tighten the short bolts (2, 3, 6, 7, 10, and 11) on the final pass in sequence to 55 degrees.

    10. Fig 6: Spark Plug Wire Support
    GM328588Courtesy of GENERAL MOTORS CORP.
  10. Install the spark plug wire support and bolts.

    Tighten:  Tighten the spark plug wire support bolts to 12 N.m (106 lb in).

    11. Fig 7: Spark Plugs
    GM328582Courtesy of GENERAL MOTORS CORP.
  11. Measure the NEW spark plugs for the proper gap.

    Adjust the spark plug gap if necessary.

    Specification:  Spark plug gap: 1.52 mm (0.060 in).

  12. Install the spark plugs.

    Tighten: 

    • Tighten the spark plugs for a USED cylinder head to 15 N.m (11 lb ft).
    • Tighten the spark plugs for the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).

    13. Fig 8: Engine Coolant Temperature Gage Sensor
    GM387767Courtesy of GENERAL MOTORS CORP.
  13. If reusing the engine coolant temperature gage sensor, if applicable, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the engine coolant temperature gage sensor.
  14. Install the engine coolant temperature gage sensor, if applicable.

    Tighten:  Tighten the engine coolant temperature gage sensor to 20 N.m (15 lb ft).

    15. Fig 9: View Of Engine Coolant Temperature Sensor
    GM387769Courtesy of GENERAL MOTORS CORP.
  15. If reusing the engine coolant temperature sensor, if applicable, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the engine coolant temperature gage sensor.
  16. Install the engine coolant temperature sensor, if applicable.

    Tighten:  Tighten the engine coolant temperature sensor to 20 N.m (15 lb ft).

  17. Install the valve pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
    18. Fig 10: Rear Of Cylinder Head Ground Wires
    GM375408Courtesy of GENERAL MOTORS CORP.
  18. Install the ground wires and nut at the rear of the cylinder head.

    Tighten:  Tighten the ground wire nut to 10 N.m (88 lb in).

  19. Install the transmission control cable bracket and bolts at the rear of the cylinder head.

    Tighten:  Tighten the transmission control cable bracket bolts to 40 N.m (30 lb ft).

  20. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Left (4.3L) or Exhaust Manifold Replacement - Left (4.8L, 5.3L, 6.0L) in Engine Exhaust.
  21. Install the lower intake manifold. Refer to Intake Manifold Replacement - Lower .
    22. Fig 11: Power Steering Pump Bracket Stud
    GM475833Courtesy of GENERAL MOTORS CORP.
  22. Install the stud for the power steering pump mounting bracket to the cylinder head.

    Tighten:  Tighten the power steering pump mounting bracket stud to 20 N.m (15 lb ft).

    23. Fig 12: Accessory Mounting Bracket
    GM188295Courtesy of GENERAL MOTORS CORP.
  23. Slide the power steering pump mounting bracket on the stud and the power steering pump.
  24. Install the 3 bolts and the nut.

    Tighten:  Tighten the power steering pump mounting bolts and the nut to 41 N.m (30 lb ft).

    25. Fig 13: Power Steering Pump & Mounting Bolts
    GM288829Courtesy of GENERAL MOTORS CORP.
  25. Install the 3 bolts for the power steering pump.

    Tighten:  Tighten the power steering pump mounting bracket to the power steering pump bolts to 50 N.m (37 lb ft).

  26. Install the power steering pump pulley. Refer to Power Steering Pulley Replacement in Power Steering Systems.
  27. Install the air conditioning compressor, if equipped. Refer to Compressor Replacement (4.3L) or Compressor Replacement (4.8L, 5.3L, 6.0L) in Heating, Ventilation and Air Conditioning.
  28. Install the air conditioning compressor discharge hose, if equipped. Refer to Discharge Hose Replacement (4.8L, 5.3L, 6.0L ) in Heating, Ventilation and Air Conditioning.
  29. Install the air conditioning compressor suction hose, if equipped. Refer to Suction Hose Replacement in Heating, Ventilation and Air Conditioning.
  30. Install the drive belt idler pulley if not equipped with A/C. Refer to Drive Belt Idler Pulley Replacement - without Air Conditioning .
  31. Install the fan shroud. Refer to Fan Shroud Replacement - Upper and to Fan Shroud Replacement - Lower in Engine Cooling.
  32. Fill the engine coolant system. Refer to Draining and Filling Cooling System in Engine Cooling.
  33. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  34. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
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