Cylinder Head Assembly: Service and Repair

This article has been updated with bulletin No: 99-06-01-016.


REMOVAL PROCEDURE

^ Tools Required
- J 28410 Gasket Remover
- J 36660 Torque Angle Meter





1. Remove the powertrain assembly. Refer to Engine Replacement.
2. Remove the intake manifold. Refer to Intake Manifold Replacement.
3. Remove the camshaft covers. Refer to Camshaft Cover Replacement (Left) and Camshaft Cover Replacement (Right).

NOTICE: Align all timing marks before removing the timing chains, especially if you are removing only one head.

4. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
5. Remove the engine front cover. Refer to Engine Front Cover Replacement.
6. Remove the oil pump. Refer to Oil Pump Replacement.
7. Remove the chain tensioner from the secondary drive chain for the cylinder head being removed.
8. Remove the camshaft sprockets from the head being removed. The secondary drive chain should remain in the crankcase.





9. Remove the timing chain guides. Access to the retaining screws is through the plugs at the front of the cylinder head.
10. Remove the water crossover. Refer to Water Crossover.





11. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement (Left) and Exhaust Manifold Replacement (Right).
12. Remove the cylinder head bolts.
13. Remove the cylinder head.

NOTICE: With the camshafts remaining in the cylinder head, some valves will be open, therefore, do not place the cylinder head on a flat surface with the valves face down. Valve damage may occur.





14. Remove the cylinder head gasket.
15. Clean the gasket surfaces.

CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.

NOTICE: Exercise caution when cleaning aluminum gasket surfaces in order to prevent damage to the sealing surfaces. Use only plastic, wood, or dull gasket scrapers such as J 28410. You can also use chemical agents to dissolve gasket materials. Follow the manufacturer's recommendations.

16. Clean the combustion chambers.
17. Clean the head bolt holes in the crankcase with compressed air.
18. Clean the head bolt bosses in the cylinder head.


INSTALLATION PROCEDURE





1. Install the new cylinder head gasket.
2. Install the cylinder head.





3. Apply sealer GM P/N 12345382, or equivalent to the cylinder head bolts.
4. Install the cylinder head bolts.









The torque specification and sequence for the cylinder head bolts (1--10) using J 36660-A is:
a. First Pass 40 Nm (30 lb. ft.).
b. Second Pass 70 Degrees.
c. Third Pass 60 Degrees.
d. Fourth Pass 60 Degrees (190 Degrees total).
e. The 3 front M6 cylinder head bolts 12 Nm (106 lb. in.).

NOTICE: Refer to Fastener Notice in Service Precautions.

5. Set the camshaft timing. Refer to Setting Camshaft Timing.
6. Install the camshaft covers. Refer to Camshaft Cover Replacement (Left) and Camshaft Cover Replacement (Right).
7. Install the oil pump. Refer to Oil Pump Replacement.
8. Install the engine front cover. Refer to Engine Front Cover Replacement.
9. Install the, crankshaft balancer. Refer to Crankshaft Balancer Replacement.
10. Install the intake manifold. Refer to Intake Manifold Replacement.
11. Install the water crossover. Refer to Water Crossover.
12. Install the exhaust manifold. Refer to Exhaust Manifold Replacement (Left) and Exhaust Manifold Replacement (Right).
13. Install the powertrain assembly. Refer to Engine Replacement.