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Home >> Pontiac >> 2009 >> Vibe Base, 2.4 0, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 6 (Engine Mechanical - 1.8L (Lay)) >> Repair Instructions - On Vehicle >> Cylinder Head Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Identifying Cylinder Block Contact Surface
    GM2016809Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Remove any oil from the contact surface.
    • Make sure that the gasket is installed in the correct direction.
  1. Install cylinder head gasket.
  2. Place a new gasket on the cylinder block surface with the Lot No. stamp facing upward.
    3. IMPORTANT: The cylinder head bolts are tightened in 2 progressive steps.
  3. Install the cylinder head sub-assembly.
  4. Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.
  5. Install the bolts and plate washers to the cylinder head.
    6. Fig 2: Identifying Cylinder Head Bolt Tightening Sequence
    GM2016811Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER CAUTION .
  6. Using several passes, uniformly install and tighten the 10 cylinder head set bolts and plate washers with a 10 mm bi-hexagon wrench in the order shown.

    Tighten:  Tighten to 49 N.m (36 lb ft)

    7. Fig 3: Marking Front Side Of Cylinder Head Bolts For Final Tightening Pass
    GM2016813Courtesy of GENERAL MOTORS CORP.
  7. Mark the front side of the cylinder head bolts with paint.
  8. Retighten the cylinder head bolts an additional 90 degrees, then once more 45 degrees as shown in the illustration.
  9. Check that the paint mark is now at a 135 degrees angle to the front.
  10. Install the valve lash adjuster assembly.
  11. Install the No. 1 valve rocker arm sub-assembly.
  12. Install the No. 1 camshaft bearing.
  13. Install the No. 2 camshaft bearing.
  14. Install the No. 2 camshaft.
  15. Install the camshaft.
  16. Install the camshaft bearing cap.
  17. Install the camshaft housing sub-assembly.
  18. Install the camshaft timing gear assembly.
  19. Install the camshaft timing exhaust gear assembly.
    20. Fig 4: Identifying No. 1 Chain Vibration Damper
    GM2016814Courtesy of GENERAL MOTORS CORP.
  20. Install the No. 1 chain vibration damper with the 2 bolts.

    Tighten:  Tighten the bolts to 21 N.m (16 lb ft).

  21. Install the No. 2 chain vibration damper.
  22. Install the chain sub-assembly.
  23. Check the No. 1 cylinder TDC/compression.
  24. Hand tighten the crankshaft pulley bolt.
    25. Fig 5: Identifying Timing Gear Key
    GM2016815Courtesy of GENERAL MOTORS CORP.
  25. Turn the crankshaft counterclockwise to position the timing gear key to the top.
  26. Remove the crankshaft pulley bolt.
    27. Fig 6: Checking Timing Marks On Each Camshaft Timing Gear
    GM2016816Courtesy of GENERAL MOTORS CORP.
  27. Check the timing marks on each camshaft timing gear.
    28. Fig 7: View Of Properly Positioning Timing Marks
    GM2016817Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Be sure to position the mark plate at the front of the engine.
    • The mark plate on the camshaft side is colored orange.
    • Do not pass the chain around the sprocket of the camshaft timing gear assembly. Only place it on the sprocket.
    • Pass the chain through the No. 1 vibration damper
  28. Align the mark plate, orange, with the timing mark as shown in the illustration and install the chain.
    29. Fig 8: View Of Correctly Placing Chain On Crankshaft
    GM2016831Courtesy of GENERAL MOTORS CORP.
  29. Place the chain on the crankshaft without passing it around the shaft.
    30. Fig 9: Checking Marks On Plate
    GM2016832Courtesy of GENERAL MOTORS CORP.
    IMPORTANT:
    • Be sure to position the mark plate at the front of the engine.
    • The mark plate on the camshaft side is colored orange.
  30. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to align the mark plate, orange, and timing mark.
    31. IMPORTANT: To tension the chain, slowly turn the camshaft timing gear assembly clockwise to prevent the chain from being misaligned.
  31. Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly clockwise.
    32. Fig 10: Aligning Marks On Crankshaft Plate
    GM2016839Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The mark plate on the crankshaft side is colored yellow.
  32. Align the mark plate, yellow, and timing mark and install the chain to the crankshaft timing gear.
  33. Recheck each timing mark at TDC/compression.
    34. Fig 11: View Of Chain Tensioner Slipper Installation
    GM2016841Courtesy of GENERAL MOTORS CORP.
  34. Install the chain tensioner slipper.
    35. Fig 12: Identifying Timing Chain Tensioner Slipper
    GM2016802Courtesy of GENERAL MOTORS CORP.
  35. Install the timing chain cover oil seal.
  36. Install the timing chain cover sub-assembly.
  37. Install the crankshaft pulley.
  38. Install the No. 1 chain tensioner assembly.
  39. Install the cylinder head cover sub-assembly.
  40. Install the radio setting condenser.
  41. Install the thermostat.
  42. Install the inlet water.
  43. Install the inlet water hose.
  44. Install the water by-pass hose.
  45. Install the No. 1 water by-pass pipe.
  46. Install the No. 3 water by-pass hose.
  47. Install the ventilation hose.
  48. Inspect the exhaust manifold.
  49. Install the exhaust manifold.
  50. Install the manifold stay.
  51. Install the No. 1 exhaust manifold heat insulator.
  52. Install the oil level dipstick sub-assembly.
  53. Install the ignition coil assembly.
  54. Install the fuel injector assembly.
  55. Install the No. 1 delivery pipe spacer.
  56. Install the fuel delivery pipe sub-assembly.
  57. Install the fuel tube sub-assembly.
  58. Install the intake manifold.
  59. Remove the engine stand.
  60. Install the engine assembly with transaxle. Refer to Engine Replacement .
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