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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.
IMPORTANT: Make sure the threaded holes in the engine block are clean and not damaged. Do not use sealer on any engines that use a composition type gasket. Align the cylinder head gasket locating mark to face up. Ensure that the head gasket tabs are located over the numbers 1 and 2 cylinders for correct installation.
  1. Place a NEW cylinder head gasket into position.
    2. Fig 1: View Of Right Cylinder Head Gasket And Alignment Pins
    GM470992Courtesy of GENERAL MOTORS CORP.
  2. Install the cylinder head.
    3. Fig 2: View Of Right Cylinder Head And Alignment Pin
    GM470991Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not reuse the cylinder head bolts. NEW cylinder head bolts must be used. The cylinder head bolts are torque-to-yield bolts and cannot be reused once the initial torque is applied. During the initial torque of the cylinder head bolt the cylinder head bolt is stretched to achieve proper clamp load. Proper clamp load will not be achieved if a used cylinder head bolt is torqued again. A stretched cylinder head bolt can also break when torqued. Failure to replace the used cylinder head bolts with NEW cylinder head bolts can lead to improper clamp loads and extensive engine damage.
    IMPORTANT: The sealer must be applied to a minimum of eight threads starting at the point of the cylinder head bolt.
  3. If not pre-applied to the new cylinder heads bolts, apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the cylinder head bolts.
  4. Install the cylinder head bolts (1, 2, and 3).
    5. Fig 3: View Of Right Cylinder Head Bolts
    GM470989Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: The long bolts are used in locations 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, and 17. The medium length bolts are used in locations 15 and 18. The short bolts are used in locations 4, 5, 12, and 13.
  5. Tighten the cylinder head bolts.

    Tighten: 

    1. Tighten the cylinder head bolts a first pass in sequence to 30 N.m (22 lb ft).
    2. Tighten the cylinder head bolts a second pass in sequence to 30 N.m (22 lb ft) then an additional 120 degrees using J 45059  .
    3. Tighten the bolts (1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, and 17) an additional 60 degrees, bolts (15, and 18) an additional 45 degrees, and bolts (4, 5, 12, and 13) an additional 30 degrees a final pass using J 45059  .

    6. Fig 4: Cylinder Head Bolt Tightening Sequence
    GM470987Courtesy of GENERAL MOTORS CORP.
  6. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Right (8.1L Engine) in Engine Exhaust.
  7. Install the water crossover. Refer to Coolant Crossover Pipe Replacement (8.1L) in Engine Cooling.
  8. Install the heater hose bracket and bolts to the cylinder head.

    Tighten:  Tighten the heater hose bracket bolts to 50 N.m (37 lb ft).

  9. Install the heater inlet and outlet hoses to the hose bracket.
    10. Fig 5: View Of Heater Hose Bracket & Bolts
    GM750695Courtesy of GENERAL MOTORS CORP.
  10. Install a NEW O-ring seal onto the indicator tube.
  11. Install the indicator tube into the oil pan.
  12. Align the indicator tube bracket with the bolt hole in the block.
  13. Install the indicator tube bolt.

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

    14. Fig 6: View Of Indicator Tube Bracket
    GM843863Courtesy of GENERAL MOTORS CORP.
  14. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the ECT sensor.
  15. Install the ECT sensor to the cylinder head.

    Tighten:  Tighten the ECT sensor to 50 N.m (37 lb ft).

    16. Fig 7: View Of ECT Sensor Electrical Connector
    GM843867Courtesy of GENERAL MOTORS CORP.
  16. Install the ECT sensor clip to the bracket.
  17. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
  18. Install the intake manifold. Refer to Intake Manifold Replacement .
  19. Drain the cooling system. Refer to Draining and Filling Cooling System (without HP2) in Engine Cooling.
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