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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 994 (Engine Mechanical - 6.6L (LLY)) >> 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, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 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 the cylinder head gasket will block coolant and oil passages. Blocked coolant and oil passages will cause severe engine damage.
  1. Install the cylinder head gasket of the correct grade. Refer to Cylinder Head Gasket Selection Specifications .
  2. Install the cylinder head.
    3. Fig 1: View Of Left Cylinder Head Gasket
    GM1336110Courtesy of GENERAL MOTORS CORP.
    NOTE: This component uses bolts with a pre-applied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage.
  3. Install NEW M12 cylinder head bolts.
  4. Reuse the M8 cylinder head bolts.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Tighten the cylinder head bolts in the following steps using the sequence shown.

    Tighten: 

    1. Tighten the M12 bolts a first pass to 50 N.m (37 lb ft).
    2. Tighten the M12 bolts a second pass to 80 N.m (59 lb ft)
    3. Tighten the M12 bolts a third pass to 60 degrees, using J 45059  .
    4. Tighten the M12 bolts a final pass to 60 degrees, using J 45059  .
    5. Tighten the M8 bolts to 25 N.m (18 lb ft).
      6. Fig 2: Cylinder Head Bolt Installation Sequence
      GM663831Courtesy of GENERAL MOTORS CORP.

  6. Position the ground straps to the rear of the cylinder head, and install the bolt.

    Tighten:  Tighten the bolt to 34 N.m (25 lb ft).

  7. Install the glow plugs. Refer to Glow Plug Replacement - Bank 2 in Engine Controls - 6.6L (LLY).
  8. Install the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
  9. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Left (6.6L (LLY) Engine) in Engine Exhaust.
  10. Install the intake manifold. Refer to Intake Manifold Replacement - Left .
  11. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (6.6L (LLY) Engine) in Engine Cooling.
  12. Road test the vehicle for normal operation.
  13. Inspect for coolant, oil, or exhaust leaks.
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