Cylinder Head Installation

Special Tools

• EN-45059  Angle Meter
• EN-51140  Crankshaft Fixing Tool
• GE-7872  Magnetic Base Dial Indicator

Equivalent regional tools: Special Tools 

Fig 1: Deflectors
Courtesy of GENERAL MOTORS COMPANY
1. Check that the 2 deflectors (1) are installed in the engine block and install 2 NEW deflectors if the deflectors are missing.
NOTE:

Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil, grease and old gasket material.

2. Clean all sealing surfaces.
3. Inspect the flatness of the cylinder head and cylinder block sealing surfaces.
4. Set the TDC of cylinder 1.
Fig 2: Crankshaft Fixing Tool And Bolts
Courtesy of GENERAL MOTORS COMPANY
5. Install the EN-51140  fixing tool (2).
6. Install the fixing pin into the engine block bore (1) and tighten the 2 bolts (3).
Fig 3: Indicator
Courtesy of GENERAL MOTORS COMPANY
NOTE:

For the measurement, the piston has to stay on TDC. Measure the piston projection dimensions at all pistons.

7. Install the GE-7872  indicator (1).
8. Measure the piston projection of the cylinder 1 and the cylinder 4.
Fig 4: Crankshaft Fixing Tool And Bolts
Courtesy of GENERAL MOTORS COMPANY
9. Remove Bolts (3) (Qty: 2)
10. Remove the EN-51140  fixing tool (2).
Fig 5: Crankshaft Pulley Bolts
Courtesy of GENERAL MOTORS COMPANY
11. Install Crankshaft Pulley Bolts (1) (Qty: 4)
12. Rotate the crankshaft 360 degrees, use a pry bar at the 4 crankshaft pulley bolts (1).
13. Remove Crankshaft Pulley Bolts (1) (Qty: 4)
Fig 6: Crankshaft Fixing Tool And Bolts
Courtesy of GENERAL MOTORS COMPANY
14. Install the EN-51140  fixing tool (2).
15. Install the fixing pin into the engine block bore (1) and tighten the 2 bolts (3).
16. Measure the piston projection of the cylinder 2 and the cylinder 3.
Fig 7: Cylinder Head Gasket Identification Marks
Courtesy of GENERAL MOTORS COMPANY
NOTE:

The largest piston projection is decisive for the selection of the cylinder head gasket with the corresponding marking. The different between the three max. projection measurements must be no greater than 0.1 mm (0.0039 in).

17. Select the cylinder head gasket with the correct identification marks (1):
    1. Piston projection 0.440 - 0.535 mm (0.0173 - 0.0211 in), choose cylinder head gasket with identification mark on Position I, thickness 1.25 mm (0.049 in).
    2. Piston projection 0.535 - 0.630 mm (0.0211 - 0.0248 in), choose cylinder head gasket with identification mark on Position II, thickness 1.35 mm (0.053 in).
    3. Piston projection 0.630 - 0.725 mm (0.0248 - 0.0285 in), choose cylinder head gasket with identification mark on Position III, thickness 1.45 mm (0.057 in).
Fig 8: Crankshaft Fixing Tool And Bolts
Courtesy of GENERAL MOTORS COMPANY
18. Remove Bolts (3) (Qty: 2)
19. Remove the EN-51140  fixing tool (2).
Fig 9: Crankshaft Pulley Bolts
Courtesy of GENERAL MOTORS COMPANY
20. Install Crankshaft Pulley Bolts (1) (Qty: 4)
21. Rotate the crankshaft 360 degrees, use a pry bar at the 4 crankshaft pulley bolts (1).
22. Remove Crankshaft Pulley Bolts (1) (Qty: 4)
Fig 10: Crankshaft Fixing Tool And Bolts
Courtesy of GENERAL MOTORS COMPANY
23. Install the EN-51140  fixing tool (2) to fix the TDC of cylinder 1.
24. Install the fixing pin into the engine block bore (1) and tighten the 2 bolts (3).
Fig 11: Cylinder Head, Guide Sleeves, Gasket And Bolts
Courtesy of GENERAL MOTORS COMPANY
25. Install NEW Cylinder Head Gasket (3)
NOTE:

Ensure the guide sleeves (4) are properly seated in the engine block.

26. Install Cylinder Head (2)
27. Install NEW Cylinder Head Bolts (1) (Qty: 10) - Do NOT tighten.
Fig 12: Cylinder Head Bolt Tightening Sequence
Courtesy of GENERAL MOTORS COMPANY
28. Tighten Cylinder Head Bolts in sequence
    CAUTION:

    Refer to Fastener Caution

    CAUTION:

    Refer to Torque-to-Yield Fastener Caution

    1. First Pass: 50 N.m (37 lb ft)
    2. Second Pass: 90 degrees - Use the special tool: EN-45059  angle meter
    3. Third Pass: 90 degrees - Use the special tool: EN-45059  angle meter
    4. Final Pass: 90 degrees - Use the special tool: EN-45059  angle meter
Fig 13: Cylinder Head Outer Bolts
Courtesy of GENERAL MOTORS COMPANY
29. Install the NEW 2 cylinder head outer bolts (1) and tighten in 2 passes:
    CAUTION:

    Refer to Torque-to-Yield Fastener Caution

    1. First Pass: 20 N.m (15 lb ft)
    2. Final Pass: 45 degrees - Use the special tool: EN-45059  angle meter
Fig 14: Bearing Bracket
Courtesy of GENERAL MOTORS COMPANY
30. Install the bearing bracket (1).