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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 992 (Engine Mechanical - 4.3L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Cylinder Head Replacement - Left >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Assemble the cylinder head, if necessary. Refer to Cylinder Head Assemble .
  2. Install the cylinder head locator pins, if necessary.
    3. Fig 1: Installing Cylinder Head Locator Pins
    GM334303Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not use any type of sealer on the cylinder head gasket.
  3. Install a NEW cylinder head gasket.
    4. Fig 2: View Of Cylinder Head Gasket And Alignment Pins - Left
    GM334299Courtesy of GENERAL MOTORS CORP.
  4. Install the cylinder head.
    5. Fig 3: Removing/Installing Cylinder Head (Left)
    GM480536Courtesy of GENERAL MOTORS CORP.
  5. Apply sealant GM P/N 12346004, (Canadian P/N 109534480), or equivalent to the threads of the cylinder head bolts.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the cylinder head bolts until snug.
    7. Fig 4: Locating Cylinder Head Bolts (Left)
    GM480533Courtesy of GENERAL MOTORS CORP.
  7. Tighten the cylinder head bolts using the sequence shown.

    Tighten: 

    1. Tighten the bolts a first pass to 30 N.m (22 lb ft).
    2. Tighten the long bolts (1, 4, 5, 8, 9) a final pass to 75 degrees using J 45059  .
    3. Tighten the medium bolts (12, 13) a final pass to 65 degrees using J 45059  .
    4. Tighten the short bolts (2, 3, 6, 7, 10, 11) a final pass to 55 degrees using J 45059  .

    8. Fig 5: Identifying Cylinder Head Bolt Tightening Sequence
    GM5132Courtesy of GENERAL MOTORS CORP.
  8. Install the spark plug wire support and bolts.

    Tighten:  Tighten the bolts to 12 N.m (106 lb in).

    9. Fig 6: Installing Spark Plug Wire Support
    GM328588Courtesy of GENERAL MOTORS CORP.
  9. Install the spark plugs.
    10. Fig 7: Installing Spark Plugs
    GM328582Courtesy of GENERAL MOTORS CORP.
  10. If installing NEW spark plugs measure for the correct gap. Adjust the spark plug gap if necessary.

    Specification:  Spark plug gap to 1.52 mm (0.060 in).

    Tighten: 

    • Tighten the plugs in a USED cylinder head to 15 N.m (11 lb ft).
    • Tighten the plugs on the initial installation of a NEW cylinder head to 30 N.m (22 lb ft).

  11. Install the ECT sensor. If reusing the old sensor, apply sealant GM P/N 12346004 (Canadian P/N 109534480), or equivalent to the threads.

    Tighten:  Tighten the sensor to 20 N.m (15 lb ft).

    12. Fig 8: View Of Engine Coolant Temperature Sensor
    GM387769Courtesy of GENERAL MOTORS CORP.
  12. Position the ground strap (5) and harness ground (4).
    13. Fig 9: View Of Ground Strap And CMP & Fuel Pump/Oil Pressure Sensor Connectors
    GM782680Courtesy of GENERAL MOTORS CORP.
  13. Install the harness ground bolt.

    Tighten:  Tighten the bolt to 16 N.m (12 lb ft).

  14. Install the P/S pump bracket stud.

    Tighten:  Tighten the stud to 20 N.m (15 lb ft).

    15. Fig 10: Installing Power Steering Pump Bracket Stud
    GM475833Courtesy of GENERAL MOTORS CORP.
  15. Slide the P/S pump bracket rearward.
  16. Install the bolts and nuts for the P/S pump bracket.
  17. Install the P/S pump rear bracket front nut.
  18. Tighten the P/S pump rear bracket nut.

    Tighten:  Tighten the bolts and nuts to 41 N.m (30 lb ft).

    19. Fig 11: View Of Power Steering Pump Bracket
    GM340090Courtesy of GENERAL MOTORS CORP.
  19. Position the bracket and wiring harness.
  20. Install the junction block bracket bolt.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    21. Fig 12: Installing Junction Block Bracket Bolt
    GM782670Courtesy of GENERAL MOTORS CORP.
  21. Install the left side pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
  22. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left (4.3L Engine) in Engine Exhaust.
  23. Install the lower intake manifold. Refer to Intake Manifold Replacement - Lower .
  24. Install the drive belt. Refer to Drive Belt Replacement .
  25. Fill the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
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