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Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 20 (Engine Mechanical - 4.3L) >> Repair Instructions - On Vehicle >> Cylinder Head Replacement - Right Side >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Cylinder Head Dowel Pins Measurement
    GM334314Courtesy 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 - Right
    GM334312Courtesy 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 (Right)
    GM480538Courtesy 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 (Right)
    GM480537Courtesy of GENERAL MOTORS CORP.
  6. Apply sealant to the threads of the cylinder head bolts. Refer to Sealers, Adhesives, and Lubricants  for the correct part number.
  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 .
  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 the J 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
    GM328590Courtesy of GENERAL MOTORS CORP.
  10. Install the spark plug wire support and bolts.

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

  11. Remove the front spark plug wire support bolt.

    The front spark plug wire support bolt is used to fasten the oil level indicator tube, and will be installed within the oil level indicator tube installation procedure.

    12. Fig 7: Locating Spark Plugs
    GM328586Courtesy of GENERAL MOTORS CORP.
  12. Measure the NEW spark plugs for the proper gap.

    Adjust the spark plug gap if necessary.

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

  13. 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).

  14. Install the valve pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
    15. Fig 8: Rear Of Cylinder Head Ground Wires
    GM375426Courtesy of GENERAL MOTORS CORP.
  15. 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).

  16. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (4.3L) .
  17. Install the intake manifold. Refer to Lower Intake Manifold Replacement .
    18. Fig 9: View Of Generator Bracket Stud
    GM475837Courtesy of GENERAL MOTORS CORP.
  18. Install the stud for the generator mounting bracket to the cylinder head.

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

  19. Install the generator mounting bracket. Refer to Generator Bracket Replacement (4.3L) .
  20. Install the fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L) and Engine Coolant Fan Lower Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L) .
  21. Fill the engine coolant system. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (Vac N Fill) .
  22. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
  23. Install the engine cover. Refer to Engine Cover Replacement .
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