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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1629 (Engine Mechanical - 2.4L) >> Repair Instructions - On Vehicle >> Cylinder Head Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Cylinder Head And Gasket
    GM412427Courtesy of GENERAL MOTORS CORP.
    NOTE: DO NOT use any sealing material.
  1. Install the cylinder head gasket.
  2. Install the cylinder head.
  3. Install NEW cylinder head bolts.
    4. Fig 2: Identifying Cylinder Head Bolt Tightening Sequence
    GM412510Courtesy of GENERAL MOTORS CORP.
  4. Install and tighten the cylinder head bolts in the sequence shown to 30 N.m (22 lb ft) plus an additional 155 degrees using the J 45059  . See Special Tools .
    5. Fig 3: Locating Front Cylinder Head Bolts
    GM412425Courtesy of GENERAL MOTORS CORP.
  5. Install the NEW front cylinder head bolts and tighten the bolts to 35 N.m (26 lb ft).
    6. Fig 4: Aligning Marks On Cylinder Head In Relationship To Camshaft Actuator Notches
    GM2066509Courtesy of GENERAL MOTORS CORP.
  6. Ensure the cylinder head (1) and the camshaft (2) are correctly aligned.
    7. Fig 5: View Of Rubber Band To Pull Guides Together
    GM2066512Courtesy of GENERAL MOTORS CORP.
  7. Remove the rubber band (1) from around the top of the upper timing chain guides (2).
  8. Install the fixed guide bolt into the cylinder head and tighten to 12 N.m (106 lb in)..
    9. Fig 6: View Of Fixed Timing Chain Guide Access Plug
    GM412164Courtesy of GENERAL MOTORS CORP.
  9. Apply sealant compound to thread and install the timing chain guide bolt access hole plug. Refer to Adhesives, Fluids, Lubricants, and Sealers  for the correct part number.
  10. Install the fixed timing chain guide access plug and tighten the plug to 90 N.m (59 lb ft).
    11. Fig 7: Timing Chain & Camshaft Position Actuator
    GM1578297Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure that the alignment mark made previously on the intaket camshaft actuator is still aligned properly with the mark on the timing chain. If the mark made previously on the intaket camshaft actuator is not aligned properly, refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement .
  11. Install the timing chain onto the intake camshaft actuator.
  12. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
  13. Install a NEW intake camshaft actuator bolt (2) until snug.
    14. Fig 8: View Of Timing Chain & Chain Retention Tool
    GM2066475Courtesy of GENERAL MOTORS CORP.
  14. Remove the timing chain retention tool EN-48749  (1) from the intake side of the timing chain.
    15. Fig 9: Exhaust Camshaft Sprocket
    GM1578298Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure that the alignment mark made previously on the exhaust camshaft actuator is still aligned properly with the mark on the timing chain. The exhaust cam may have to be rotated clockwise to install the eshaust actucator.
  15. Install the timing chain onto the exhaust camshaft actuator.
  16. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
  17. Install a NEW exhaust camshaft actuator bolt (2) until snug.
  18. Remove the timing chain retention tool EN-48749  (1) from the exhaust side of the timing chain.
    19. NOTE: Failure to reset the chain tensioner wil put excess tension on the chain, limiting the chains life.
  19. Reset and install the timing chain tensioner. Refer to Timing Chain Tensioner Replacement .
    20. Fig 10: Loosening/Tightening Camshaft Actuator Retainer Bolts
    GM2066456Courtesy of GENERAL MOTORS CORP.
  20. Install the EN-48953  (1) to the actuators.
  21. Install the camshaft actuator locking tool bolts and tighten to 10 N.m (89 lb in).
  22. Tighten the NEW camshaft actuator bolt to 30 N.m (22 lb ft), plus an additional 100 degrees using the J 45059  . See Special Tools .
  23. Release the tensioner by applying a counterclockwise rotational torque of 45 N.m (33 lb ft) to the harmonic balancer bolt.
  24. Remove the camshaft actuator locking tool, EN-48953  .
    25. Fig 11: View Of Upper Timing Chain Guide Bolts And Guide
    GM1578296Courtesy of GENERAL MOTORS CORP.
  25. Install the upper timing chain guide bolts and guide. Tighten the bolts to 10 N.m (89 lb in).
  26. Install the camshaft cover. Refer to Camshaft Cover Replacement (LE5)  or Camshaft Cover Replacement (LAT) .
  27. Install the spark plugs. Refer to Spark Plug Replacement .
    28. Fig 12: View Of Radiator Inlet Hose To Engine
    GM1656126Courtesy of GENERAL MOTORS CORP.
  28. Connect all electrical connectors as necessary.
  29. Install the radiator inlet hose to the cylinder head.
  30. Position the radiator inlet hose clamp using the J 38185  . See Special Tools .
  31. Install the radiator surge tank air bleed hose to the cylinder head.
  32. Position the radiator surge tank air bleed hose clamp.
  33. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (LAT or LE5) .
  34. Install the intake manifold. Refer to Intake Manifold Replacement (LAT)  or Intake Manifold Replacement (LE5) .
  35. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill With HP5) or Cooling System Draining and Filling (Static Fill Without HP5) or Cooling System Draining and Filling (GE 47716 Fill With HP5) or Cooling System Draining and Filling (GE 47716 Fill Without HP5) .
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