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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 257 (Engine Mechanical - 4.0L (On-Vehicle)) >> Repair Instructions >> Cylinder Head Replacement - Right >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
  1. Make sure all the cylinder head locating pins are securely mounted in the cylinder block deck face.

    Important:  Failure to remove all the old thread sealant material from the cylinder block could cause false torque readings.

  2. Make sure any old thread sealant material is removed from the cylinder head bolt holes in the cylinder block.
    Fig 1: Locating Cylinder Head Locating Pins
    G01819533Courtesy of GENERAL MOTORS CORP.
  3. Install a new right cylinder head gasket using the deck face locating pins for retention.
    Fig 2: Installing Right Cylinder Head Gasket
    G01819534Courtesy of GENERAL MOTORS CORP.
  4. Align the cylinder head with the deck face locating pins.
  5. Place the cylinder head in position on the deck face.
    Fig 3: Installing Right Cylinder Head
    G01819535Courtesy of GENERAL MOTORS CORP.

    Important:  DO NOT reuse the old M11 cylinder head bolts.

  6. Install new M11 cylinder head bolts in the cylinder head.
  7. Install the M6 cylinder head bolts at the front of the cylinder head.
    Fig 4: Installing External Cylinder Head Drive Bolts
    G01819536Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer toFASTENER NOTICE .
  8. Tighten the right cylinder head bolts in the sequence shown.
    1. 8.1. First Pass

      Tighten 

      Tighten the right cylinder head M11 cylinder head bolts to 40 N.m (30 ft lbs) in the sequence shown.

    2. 8.2. Second Pass

      Tighten 

      Using the J 36660-A  , tighten the right cylinder head M11 cylinder head bolts an additional 70 degrees in the sequence shown.

    3. 8.3. Third Pass

      Tighten 

      Repeat the sequence turning each bolt another 60 degrees.

    4. 8.4. Final Pass

      Tighten 

      Repeat the sequence again turning each bolt a final 60 degrees (total 190 degrees)

    Fig 5: Identifying Cylinder Head Bolt Tightening Sequence
    G01819537Courtesy of GENERAL MOTORS CORP.
  9. Tighten the M6 bolts at the front of the cylinder head.

    Tighten 

    Tighten the M6 cylinder head bolts to 12 N.m (106 in lbs).

  10. Position the rear transaxle brace over the studs located at the rear of the right cylinder head.
  11. Loosely install the nuts (3) securing the rear transaxle brace (1) to the cylinder head.
  12. Raise and support the vehicle.
  13. Install the bolt (2) securing the rear transaxle brace (1) to the transaxle.

    Tighten 

    Tighten the rear transaxle brace bolt to 50 N.m (37 ft lbs).

    Fig 6: Installing Rear Transaxle Brace
    G01819538Courtesy of GENERAL MOTORS CORP.
  14. Install the bolt (1) securing the front transaxle brace (2) to the cylinder head.

    Tighten 

    Tighten the front transaxle brace bolts to 50 N.m (37 ft lbs).

  15. Lower the vehicle.
  16. Tighten the nuts installed in step 11.

    Tighten 

    Tighten the rear transaxle brace nuts to 50 N.m (37 ft lbs).

    Fig 7: Installing Front Transaxle Brace
    G01819539Courtesy of GENERAL MOTORS CORP.
  17. Connect the electrical connector (2) to the ECT sensor.
  18. Install the bolt securing the exhaust crossover pipe to the cylinder head.

    Tighten 

    Tighten the exhaust crossover pipe to cylinder head bolt to 25 N.m (18 ft lbs).

  19. Install the nut (3) securing the coil cassette ground wire to the cylinder head.

    Tighten 

    Tighten the coil cassette ground wire nut to 17 N.m (13 ft lbs).

    Fig 8: Installing Electrical Connectors & Nuts
    G01819540Courtesy of GENERAL MOTORS CORP.
  20. Install the following subassemblies: