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Cylinder Head: Installation

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The left and right cylinder head gaskets are not interchangeable. Improper placement of cylinder head gasket will block coolant and oil passages. Blocked coolant and oil passages will cause severe engine damage.
  1. If injector sleeve is pulled from cylinder head when removing injector, injector sleeve installation procedure is as follows: An injector sleeve with scoring or other damage must be replaced. Set new injector sleeve gaskets to injector sleeve. Apply Sealant (Loctite 272) to lower sealing area of injector sleeve.
    2. NOTE: This component uses bolts with a pre-applied molybdenum disulfide coating for thread lubrication. Do not remove coating or use any additional lubricant. Improperly lubricated threads will adversely affect bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
  2. Install NEW cylinder head bolts. Tighten cylinder head bolts to specification and in sequence. See Fig 1. See TORQUE SPECIFICATIONS .
  3. Install NEW O-ring onto fuel injector. Lubricate O-ring with clean engine oil. Ensure injector bore is clean and free from carbon. Install a new copper washer into fuel injector bore in cylinder head.
  4. Install fuel injector bracket pin. If you are reusing injectors, clean injector tip of carbon. Do not clean with a wire brush. Install fuel injector with fuel injector bracket. Install fuel injector bracket bolt.
  5. Install fuel injector return pipe assembly. Install fuel injector return pipe to injector eye bolts and washers.
  6. Install fuel return pipe to cylinder head eye bolts and washers. Install bolt and ground straps to rear of cylinder head. Install valve rocker arm shaft assembly, push rods, and valve bridges. See VALVE ROCKER ARM, SHAFT & PUSH ROD .
  7. Install lower left valve rocker arm cover. See VALVE ROCKER ARM COVERS . Install upper left valve rocker arm cover. Install glow plugs. See GLOW PLUGS . Install left exhaust manifold. See EXHAUST MANIFOLD . Install left fuel rail assembly. FUEL RAIL ASSEMBLY .
  8. Install left intake manifold. See INTAKE MANIFOLD . Install thermostat housing crossover. See THERMOSTAT HOUSING COVER . Install turbocharger charged air cooler duct. Install clamp and hose to charged air cooler. Install turbocharger.
  9. Install left fender wheelhouse inner panel. Connect battery negative cable. Fill cooling system. See DRAINING & REFILLING COOLING SYSTEM . Road test vehicle for normal operation. Inspect for coolant, oil, or exhaust leaks.
Fig 1: Cylinder Head Bolt Installation Sequence
G00241017Courtesy of GENERAL MOTORS CORP.


  1. If injector sleeve is pulled from cylinder head when removing injector, injector sleeve installation procedure is as follows: An injector sleeve with scoring or other damage must be replaced. Set new injector sleeve gaskets to injector sleeve. Apply Sealant (Loctite 272) to lower sealing area of injector sleeve.
    2. NOTE: The left and right cylinder head gaskets are not interchangeable. Improper placement of cylinder head gasket will block coolant and oil passages. Blocked coolant and oil passages will cause severe engine damage.
  2. Install right cylinder head gasket of correct grade selected. Confirm discerning mark "R" for RH and "L" for LH of cylinder head gasket. Install right cylinder head assembly.
    3. NOTE: This component uses bolts with a pre-applied molybdenum disulfide coating for thread lubrication. Do not remove coating or use any additional lubricant. Improperly lubricated threads will adversely affect bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
  3. Install NEW cylinder head bolts. Tighten cylinder head bolts to specification and in sequence. See Figure. See TORQUE SPECIFICATIONS .
  4. Install a new O-ring onto fuel injector. Lubricate O-ring with clean engine oil. Ensure injector bore is clean and free from carbon. Install a new copper washer into fuel injector bore in cylinder head. Install fuel injector bracket pin.
  5. If reusing injectors, clean injector tip of carbon. Do not clean with a wire brush. Install fuel injector with fuel injector bracket. Install fuel injector bracket bolt.
  6. Install fuel injector return pipe assembly. Install fuel injector return pipe to injector eye bolts and washers. Install fuel return pipe to cylinder head eye bolts and washers.
  7. Install valve rocker arm shaft assembly, push rods, and valve bridges. See VALVE ROCKER ARM, SHAFT & PUSH ROD . Install glow plugs. See GLOW PLUGS . Install right exhaust manifold. See EXHAUST MANIFOLD . Install lower right valve rocker arm cover. See VALVE ROCKER ARM COVERS .
  8. Install upper right valve rocker arm cover. See VALVE ROCKER ARM COVERS . Install right fuel rail assembly. See FUEL RAIL ASSEMBLY . Install right intake manifold. See INTAKE MANIFOLD . Install thermostat housing crossover. See THERMOSTAT HOUSING COVER .
  9. Install turbocharger charged air cooler duct. Install clamp and hose to charged air cooler. Install turbocharger.
  10. Install right fender wheelhouse inner panel. Connect battery negative cables. Fill cooling system. See DRAINING & REFILLING COOLING SYSTEM . Road test vehicle for normal operation. Inspect for coolant, oil, or exhaust leaks.
CYLINDER HEAD GASKET SELECTION

Gasket Grade Projection Value Gasket Thickness
"A" (No Hole) Over .0088" (.223 mm) To Less Than .0108" (.274 mm ) .0354-.0394" (.90-1.00 mm)
"B" (One Hole) Over .0108" (.274 mm) To Less Than .0128" (.325 mm) .0374-.0413" (.95-1.05 mm)
"C" (2 Holes) Over .0128" (.325 mm) To Less Than .0148" (.376 mm) .0394-.0433" (1.00-1.10 mm)
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