Cylinder Head & Gasket: Installation
- Install cylinder head gasket. Install cylinder head with intake manifold and exhaust manifold attached. Install cylinder head bolts. Tighten cylinder head bolts gradually and in sequence shown. See Figure. Tighten cylinder head bolts to 25 N.m (18 ft. lbs.) and turn bolts another three turns of 90 degrees using angular torque gauge.
- Connect throttle cable at throttle body and intake manifold. Install generator-to-intake manifold support bracket. Install generator-to-intake manifold support bracket bolts. Tighten generator-to-intake manifold support bracket bolts to 35 N.m (26 ft. lbs.). Install intake manifold strap bracket bolts to alternator. Tighten generator-to-intake manifold strap bracket bolts to 20 N.m (15 ft. lbs.).
- Connect surge tank coolant hose at throttle body. Connect coolant hose to rear cylinder head and ignition coil EGR bracket. Connect fuel feed line at fuel rail. Connect fuel return line at fuel rail. Connect all previous disconnected vacuum hoses. Install fuel rail assembly.
- Install auxiliary catalytic converter nuts. Tighten auxiliary catalytic converter-to-exhaust manifold nuts to 40 N.m (30 ft. lbs.). Install exhaust manifold heat shield bolts. Tighten exhaust manifold heat shield bolts to 8 N.m (71 INCH Lbs.). Install rear timing belt cover. Install rear timing belt cover bolts. Tighten rear timing belt cover bolts to 6 N.m (53 INCH Lbs.).
Courtesy of DAEWOO MOTOR AMERICA, INC.
- Install engine mount bolts. Tighten engine mount bolts to 60 N.m (44 ft. lbs.). Install timing belt automatic tensioner. Install timing belt automatic tensioner bolt. Tighten timing belt automatic tensioner bolt to 25 N.m (18 ft. lbs.). Install timing belt idler pulleys. Install timing belt idler pulley nuts. Tighten timing belt idler pulley nuts to 25 N.m (18 ft. lbs.).
- Install camshaft gears with timing marks at front. Insert guide pin of intake camshaft into "IN" bore. Insert guide pin of exhaust camshaft into "EX" bore. Install camshaft gears by counterholding on hex of camshaft with an open end wrench. Install camshaft gear to camshaft with a new bolt. Tighten intake camshaft gear bolt to 50 N.m (37 ft. lbs.). Using angular torque gauge, tighten bolt an additional turn of 60 degrees, plus another turn of 15 degrees. See Fig 1.
- While holding exhaust camshaft firmly in place, install exhaust camshaft gear bolt. Tighten exhaust camshaft gear bolt to 50 N.m (37 ft. lbs.). Using angular torque gauge, tighten bolt an additional turn of 60 degrees, plus another turn of 15 degrees. Apply a small amount of gasket sealant to corners of front camshaft caps and to top of rear valve cover-to-cylinder head seal.
- Install valve cover and valve cover gasket. Install valve cover washers. Install valve cover bolts. Tighten valve cover bolts to 8 N.m (71 INCH Lbs.). Connect ignition wires to spark plugs. Install spark plug cover. Install spark plug cover bolts. Tighten spark plug cover bolts to 3 N.m (27 INCH Lbs.).
- Connect breather tube to valve cover. Align timing marks on camshaft gears to notches on valve cover using intake gear mark for intake gear and exhaust gear mark for exhaust gear. See Fig 2. Align mark on crankshaft gear with notch at bottom of rear timing belt cover. See Fig 3. Install timing belt. Check and adjust timing belt tension.
Courtesy of DAEWOO MOTOR AMERICA, INC.
Courtesy of DAEWOO MOTOR AMERICA, INC.
- Install front timing belt cover. Install front timing belt cover bolts. Tighten front timing belt cover bolts to 8 N.m (71 INCH Lbs.). Install crankshaft pulley. Install crankshaft pulley bolts. Tighten crankshaft pulley bolts to 20 N.m (15 ft. lbs.). Install right engine mount bracket, retaining bolts, and nut. Tighten engine mount bolts to 60 N.m (44 ft. lbs.).
- Remove engine support fixture. Install serpentine accessory drive belt. Connect upper radiator hose to thermostat housing. Install right front wheel well splash shield. Install right front wheel. Install air filter housing. Install air filter housing bolts. Tighten air filter housing bolts to 8 N.m (71 INCH Lbs.). Connect air intake tube to throttle body.
- Connect breather tube to valve cover. Connect IAT sensor connector. Install resonator and retaining bolts. Tighten resonator retaining bolts to 8 N.m (71 INCH Lbs.). Connect CMP sensor connector. Connect CTS connector. Connect ECT sensor connector. Connect IAC connector. Connect TPS connector.
- Install EVAP canister purge solenoid bracket bolt. Tighten canister purge solenoid bracket bolt to 5 N.m (44 INCH Lbs.). Connect EI system ignition coil connector. Connect oxygen sensor connector. Connect ECM ground terminal. Install fuel pump fuse. Connect negative battery ground cable. Refill engine cooling system.