Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Cylinder Head 1

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Removal & Installation



4.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    NOTE
    Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

  2.  
  3. Drain the coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, if equipped
     
    Intake manifold
     
    Exhaust manifold
     
    Air pipe at the rear of the right cylinder head, if applicable
     
    Alternator mounting bolt at the right cylinder head
     
    Alternator, if necessary
     
    Power steering pump and brackets from the left cylinder head and lay aside
     
    Air conditioner compressor, and lay aside
     
    Spark plug wires at their brackets
     
    Ground strap from the right side and the coolant sensor wire from the left head
     
    Cylinder cover
     
    Spark plugs
     
    Pushrods. Identify the pushrods so that they can be installed in their original positions.
     
    Cylinder head bolts in the reverse order of the tightening sequence
     
    Cylinder head and gasket
     

  6.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following:
    NOTE
    Be sure the gasket has the word HEAD up.


    NOTE
    Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.



    New gasket
     



    Cylinder head
     




  4.  
  5. Clean the cylinder head bolts, apply sealer to the threads, and hand-tighten.
  6.  
  7. Install the cylinder head bolts in sequence to 22 ft. lbs. (30 Nm) The bolts must, then be tightened again in sequence in the following order:
    1. Step 1: Short length bolt: (11, 7, 3, 2, 6, 10) 55 degrees
    2.  
    3. Step 2: Medium length bolt: (12, 13) 65 degrees
    4.  
    5. Step 3: Long length bolts: (1, 4, 8, 5, 9) 75 degrees

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-4.3L engine



      Pushrods
       

    6.  

  8.  
  9. Adjust the rocker arms, if necessary

    Spark plugs
     
    Rocker arm cover
     
    Air conditioner compressor
     
    Power steering pump and brackets
     
    Alternator or the alternator mounting bolt at the cylinder head.
     
    Air pipe at the rear of the head if removed
     
    Exhaust manifold
     
    Intake manifold
     
    Engine cover, if removed
     

  10.  
  11. Refill the engine with coolant.
  12.  
  13. Connect the negative battery cable.
  14.  

Left Side
  1. Remove or disconnect the following:
    NOTE
    Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.



    Battery negative cable
     
    Coolant
     
    Accessory drive belt
     
    Cooling fan assembly
     
    Power steering pump mounting bracket
     
    Power steering pump mounting bracket stud from the cylinder head
     
    Lower intake manifold
     
    Exhaust manifold
     
    Spark plug wire harness and the spark plug wire support
     
    Valve pushrods
     
    Ground strap and ground wire bolt from the rear of the cylinder head
     
    Engine Coolant Temperature (ECT) sensor (if applicable)
     
    ECT gauge sensor (if applicable)
     
    Spark plugs
     
    Spark plug wire support
     
    Cylinder head bolts
     
    Cylinder head and the gasket
     

  2.  
  3. Clean the cylinder head bolts and the engine block bolt holes.
  4.  

To install:

  1. Inspect the dowel pins (cylinder head locator) for proper installation.
    NOTE
    Do not use any type sealer on the cylinder head gasket (unless specified).

  2.  
  3. Install or connect the following:

    NEW cylinder head gasket in position over the dowel pins (cylinder head locator)
     
    Cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
     
    Sealant GM P/N 12346004, or equivalent, to the threads of the cylinder head bolts
     
    Cylinder head bolts finger-tight

    Click image to see an enlarged view

    Fig. Dowel pin installation-4.3L

     

  4.  
  5. Tighten the cylinder head bolts in sequence:
    1. First pass: 22 ft. lbs. (30 Nm).
    2.  
    3. Second pass: Long bolts (1, 4, 5, 8, and 9)-+ 75 degrees.
    4.  
    5. Second pass: Medium bolts (12 and 13)-+ 65 degrees.
    6.  
    7. Second pass: Short bolts (2, 3, 6, 7, 10, and 11)-+ 55 degrees.
    8.  

  6.  
  7. Install or connect the following:

    Spark plug wire support and bolts. Tighten to 106 inch lbs. (12 Nm).
     
    Spark plugs. Tighten to 11 ft. lbs. (15 Nm), if USED; 22 ft. lbs. (30 Nm), if NEW.
     

  8.  
  9. If reusing the ECT gauge sensor (if applicable), apply sealant GM P/N 12346004 or equivalent to the threads of the ECT gauge sensor. Install the ECT gauge sensor (if applicable). Tighten the sensor to 15 ft. lbs. (20 Nm).
  10.  
  11. Install or connect the following:

    Ground strap and the ground wire bolt. Tighten the bolt to 12 ft. lbs. (16 Nm).
     
    Valve pushrods
     
    Lower intake manifold
     
    Exhaust manifold
     
    Stud for the power steering pump mounting bracket to the cylinder head. Tighten the power steering pump mounting bracket stud to 15 ft. lbs. (20 Nm).
     
    Power steering pump mounting bracket
     
    Engine cooling fan assembly
     
    Coolant
     
    Battery negative cable
     

  12.  

  1. Remove or disconnect the following:
    NOTE
    Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.



    Battery negative cable
     
    Coolant
     
    Accessory drive belt
     
    Cooling fan assembly
     
    Power steering pump mounting bracket
     
    Power steering pump mounting bracket stud from the cylinder head
     
    Lower intake manifold
     
    Exhaust manifold
     
    Spark plug wire harness and the spark plug wire support
     
    Valve pushrods
     
    Ground strap and ground wire bolt from the rear of the cylinder head
     
    Engine Coolant Temperature (ECT) sensor (if applicable)
     
    ECT gauge sensor (if applicable)
     
    Spark plugs
     
    Spark plug wire support
     
    Cylinder head bolts
     
    Cylinder head and the gasket
     

  2.  
  3. Clean the cylinder head bolts and the engine block bolt holes.
  4.  

To install:

  1. Inspect the dowel pins (cylinder head locator) for proper installation.
    NOTE
    Do not use any type sealer on the cylinder head gasket (unless specified).

  2.  
  3. Install or connect the following:

    NEW cylinder head gasket in position over the dowel pins (cylinder head locator)
     
    Cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
     
    Sealant GM P/N 12346004, or equivalent, to the threads of the cylinder head bolts
     
    Cylinder head bolts finger-tight

    Click image to see an enlarged view

    Fig. Dowel pin installation-4.3L engines

     

  4.  
  5. Tighten the cylinder head bolts in sequence:
    1. First pass: 22 ft. lbs. (30 Nm).
    2.  
    3. Second pass: Long bolts (1, 4, 5, 8, and 9)-+ 75 degrees.
    4.  
    5. Second pass: Medium bolts (12 and 13)-+ 65 degrees.
    6.  
    7. Second pass: Short bolts (2, 3, 6, 7, 10, and 11)-+ 55 degrees.
    8.  

  6.  
  7. Install or connect the following:

    Spark plug wire support and bolts. Tighten to 106 inch lbs. (12 Nm).
     
    Spark plugs. Tighten to 11 ft. lbs. (15 Nm), if USED; 22 ft. lbs. (30 Nm), if NEW.
     

  8.  
  9. If reusing the ECT gauge sensor (if applicable), apply sealant GM P/N 12346004 or equivalent to the threads of the ECT gauge sensor. Install the ECT gauge sensor (if applicable). Tighten the sensor to 15 ft. lbs. (20 Nm).
  10.  
  11. Install or connect the following:

    Ground strap and the ground wire bolt. Tighten the bolt to 12 ft. lbs. (16 Nm).
     
    Valve pushrods
     
    Lower intake manifold
     
    Exhaust manifold
     
    Stud for the power steering pump mounting bracket to the cylinder head. Tighten the power steering pump mounting bracket stud to 15 ft. lbs. (20 Nm).
     
    Power steering pump mounting bracket
     
    Engine cooling fan assembly
     
    Coolant
     
    Battery negative cable
     

  12.  

  1. Remove or disconnect the following:
    NOTE
    Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.



    Battery negative cable
     
    Coolant
     
    Accessory drive belt
     
    Cooling fan assembly
     
    Power steering pump mounting bracket
     
    Power steering pump mounting bracket stud from the cylinder head
     
    Lower intake manifold
     
    Exhaust manifold
     
    Spark plug wire harness and the spark plug wire support
     
    Valve pushrods
     
    Ground strap and ground wire bolt from the rear of the cylinder head
     
    Engine Coolant Temperature (ECT) sensor (if applicable)
     
    ECT gauge sensor (if applicable)
     
    Spark plugs
     
    Spark plug wire support
     
    Cylinder head bolts
     
    Cylinder head and the gasket
     

  2.  
  3. Clean the cylinder head bolts and the engine block bolt holes.
  4.  

To install:

  1. Inspect the dowel pins (cylinder head locator) for proper installation.
    NOTE
    Do not use any type sealer on the cylinder head gasket (unless specified).

  2.  
  3. Install or connect the following:

    NEW cylinder head gasket in position over the dowel pins (cylinder head locator)
     
    Cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
     
    Sealant GM P/N 12346004, or equivalent, to the threads of the cylinder head bolts
     
    Cylinder head bolts finger-tight

    Click image to see an enlarged view

    Fig. Dowel pin installation-4.3L engines

     

  4.  
  5. Tighten the cylinder head bolts in sequence:
    1. First pass: 22 ft. lbs. (30 Nm).
    2.  
    3. Second pass: Long bolts (1, 4, 5, 8, and 9)-+ 75 degrees.
    4.  
    5. Second pass: Medium bolts (12 and 13)-+ 65 degrees.
    6.  
    7. Second pass: Short bolts (2, 3, 6, 7, 10, and 11)-+ 55 degrees.
    8.  

  6.  
  7. Install or connect the following:

    Spark plug wire support and bolts. Tighten to 106 inch lbs. (12 Nm).
     
    Spark plugs. Tighten to 11 ft. lbs. (15 Nm), if USED; 22 ft. lbs. (30 Nm), if NEW.
     

  8.  
  9. If reusing the ECT gauge sensor (if applicable), apply sealant GM P/N 12346004 or equivalent to the threads of the ECT gauge sensor. Install the ECT gauge sensor (if applicable). Tighten the sensor to 15 ft. lbs. (20 Nm).
  10.  
  11. Install or connect the following:

    Ground strap and the ground wire bolt. Tighten the bolt to 12 ft. lbs. (16 Nm).
     
    Valve pushrods
     
    Lower intake manifold
     
    Exhaust manifold
     
    Stud for the power steering pump mounting bracket to the cylinder head. Tighten the power steering pump mounting bracket stud to 15 ft. lbs. (20 Nm).
     
    Power steering pump mounting bracket
     
    Engine cooling fan assembly
     
    Coolant
     
    Battery negative cable
     

  12.  

Right Side
  1. Remove or disconnect the following:

    Battery negative cable
     
    Coolant
     
    Engine cooling fan assembly
     
    Alternator mounting bracket
     
    Alternator mounting bracket stud from the cylinder head
     
    Lower intake manifold
     
    Exhaust manifold
     
    Spark plug wire harness and spark plug wire support
     
    Valve pushrods
     
    Cylinder head and the gasket
     

  2.  
  3. Clean the engine block and the cylinder head sealing surfaces.
  4.  

To install:

  1. Inspect the dowel pins (cylinder head locator) for proper installation.
    NOTE
    Do not use any type sealer on the cylinder head gasket (unless specified).

  2.  
  3. Install or connect the following:

    NEW cylinder head gasket in position over the dowel pins (cylinder head locator)
     
    Cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
     
    Sealant GM P/N 12346004 or equivalent to the threads of the cylinder head bolts
     
    Cylinder head bolts finger-tight
     

  4.  
  5. Tighten the cylinder head bolts in sequence:
    1. First pass: 22 ft. lbs. (30 Nm).
    2.  
    3. Second pass: Long bolts (1, 4, 5, 8, and 9)-+ 75 degrees.
    4.  
    5. Second pass: Medium bolts (12 and 13)-+ 65 degrees.
    6.  
    7. Second pass: Short bolts (2, 3, 6, 7, 10, and 11)-+ 55 degrees.
    8.  

  6.  
  7. Install or connect the following:
    NOTE
    The front spark plug wire support bolt is used to fasten the oil level indicator tube, and will be installed within the oil level indicator tube installation procedure.



    Spark plug wire support and bolts. Tighten only the rear support bolt to 106 inch lbs. (12 Nm).
     



    Front spark plug wire support bolt
     
    Spark plugs. Tighten to 11 ft. lbs. (15 Nm), if USED; 22 ft. lbs. (30 Nm), if NEW.
     
    Valve pushrods
     
    Lower intake manifold
     
    Spark plug wire harness and wire support. Tighten to 106 inch lbs. (12 Nm).
     
    Exhaust manifold
     
    Stud for the alternator mounting bracket. Tighten the alternator mounting bracket stud to 15 ft. lbs. (20 Nm).
     
    Alternator mounting bracket
     
    Engine cooling fan assembly
     
    Coolant
     
    Battery negative cable
     

  8.  

  1. Remove or disconnect the following:

    Battery negative cable
     
    Coolant
     
    Engine cooling fan assembly
     
    Alternator mounting bracket
     
    Alternator mounting bracket stud from the cylinder head
     
    Lower intake manifold
     
    Exhaust manifold
     
    Spark plug wire harness and spark plug wire support
     
    Valve pushrods
     
    Cylinder head and the gasket
     

  2.  
  3. Clean the engine block and the cylinder head sealing surfaces.
  4.  

To install:

  1. Inspect the dowel pins (cylinder head locator) for proper installation.
    NOTE
    Do not use any type sealer on the cylinder head gasket (unless specified).

  2.  
  3. Install or connect the following:

    NEW cylinder head gasket in position over the dowel pins (cylinder head locator)
     
    Cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
     
    Sealant GM P/N 12346004 or equivalent to the threads of the cylinder head bolts
     
    Cylinder head bolts finger-tight
     

  4.  
  5. Tighten the cylinder head bolts in sequence:
    1. First pass: 22 ft. lbs. (30 Nm).
    2.  
    3. Second pass: Long bolts (1, 4, 5, 8, and 9)-+ 75 degrees.
    4.  
    5. Second pass: Medium bolts (12 and 13)-+ 65 degrees.
    6.  
    7. Second pass: Short bolts (2, 3, 6, 7, 10, and 11)-+ 55 degrees.
    8.  

  6.  
  7. Install or connect the following:
    NOTE
    The front spark plug wire support bolt is used to fasten the oil level indicator tube, and will be installed within the oil level indicator tube installation procedure.



    Spark plug wire support and bolts. Tighten only the rear support bolt to 106 inch lbs. (12 Nm).
     



    Front spark plug wire support bolt
     
    Spark plugs. Tighten to 11 ft. lbs. (15 Nm), if USED; 22 ft. lbs. (30 Nm), if NEW.
     
    Valve pushrods
     
    Lower intake manifold
     
    Spark plug wire harness and wire support. Tighten to 106 inch lbs. (12 Nm).
     
    Exhaust manifold
     
    Stud for the alternator mounting bracket. Tighten the alternator mounting bracket stud to 15 ft. lbs. (20 Nm).
     
    Alternator mounting bracket
     
    Engine cooling fan assembly
     
    Coolant
     
    Battery negative cable
     

  8.  

  1. Remove or disconnect the following:

    Battery negative cable
     
    Coolant
     
    Engine cooling fan assembly
     
    Alternator mounting bracket
     
    Alternator mounting bracket stud from the cylinder head
     
    Lower intake manifold
     
    Exhaust manifold
     
    Spark plug wire harness and spark plug wire support
     
    Valve pushrods
     
    Cylinder head and the gasket
     

  2.  
  3. Clean the engine block and the cylinder head sealing surfaces.
  4.  

To install:

  1. Inspect the dowel pins (cylinder head locator) for proper installation.
    NOTE
    Do not use any type sealer on the cylinder head gasket (unless specified).

  2.  
  3. Install or connect the following:

    NEW cylinder head gasket in position over the dowel pins (cylinder head locator)
     
    Cylinder head onto the engine block. Guide the cylinder head carefully into place over the dowel pins and the cylinder head gasket.
     
    Sealant GM P/N 12346004 or equivalent to the threads of the cylinder head bolts
     
    Cylinder head bolts finger-tight
     

  4.  
  5. Tighten the cylinder head bolts in sequence:
    1. First pass: 22 ft. lbs. (30 Nm).
    2.  
    3. Second pass: Long bolts (1, 4, 5, 8, and 9)-+ 75 degrees.
    4.  
    5. Second pass: Medium bolts (12 and 13)-+ 65 degrees.
    6.  
    7. Second pass: Short bolts (2, 3, 6, 7, 10, and 11)-+ 55 degrees.
    8.  

  6.  
  7. Install or connect the following:
    NOTE
    The front spark plug wire support bolt is used to fasten the oil level indicator tube, and will be installed within the oil level indicator tube installation procedure.



    Spark plug wire support and bolts. Tighten only the rear support bolt to 106 inch lbs. (12 Nm).
     



    Front spark plug wire support bolt
     
    Spark plugs. Tighten to 11 ft. lbs. (15 Nm), if USED; 22 ft. lbs. (30 Nm), if NEW.
     
    Valve pushrods
     
    Lower intake manifold
     
    Spark plug wire harness and wire support. Tighten to 106 inch lbs. (12 Nm).
     
    Exhaust manifold
     
    Stud for the alternator mounting bracket. Tighten the alternator mounting bracket stud to 15 ft. lbs. (20 Nm).
     
    Alternator mounting bracket
     
    Engine cooling fan assembly
     
    Coolant
     
    Battery negative cable
     

  8.  

4.8L, 5.3L & 6.0L Engines
Left Side

CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during assembly.



    Negative battery cable
     
    Intake manifold
     
    Push rods
     
    Exhaust manifold(s)
     
    Alternator
     
    Alternator mounting bracket-to-cylinder head bolts
     
    Bolt behind the power steering pump
     
    Alternator mounting bracket and set it aside
     
    Oil level indicator tube-to-cylinder head bolt
     
    Oil level indicator tube
     
    Cylinder head from the engine
     
    Spark plugs
     

  2.  
  3. Remove the cylinder head bolts.
    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.

  4.  
  5. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts.
  6.  

To install:


NOTE
Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old thread locking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the left cylinder head gasket will be located left of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW left cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket
     
    NEW M11 cylinder head bolts.
     

  10.  
  11. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.
    NOTE
    First design engine blocks have different drill and tap depths using both medium length 3.94 inch (100mm) and long 6.1 inch (155mm) M11 cylinder head bolts. Second design engine blocks use only the medium length 3.94 inch (100mm) bolt with a common drill and tap depth.



    M8 cylinder head bolts
     



    M8 cylinder head bolts.
     

  12.  
  13. Tighten the first design cylinder head bolts as follows:
    1. M11 bolts 1st pass: in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. M11 bolts 2nd pass: in sequence + 90 degrees.
    4.  
    5. M11 bolts (1,2,3,4,5,6,7,8): + 90 degrees.
    6.  
    7. M11 bolts (9 and 10): + 50 degrees.
    8.  
    9. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
    10.  

  14.  
  15. Tighten the second design cylinder head bolts as follows:
    1. M11 bolts (1-10) 1st pass: in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. M11 bolts (1-10) 2nd pass: in sequence + 90 degrees.
    4.  
    5. M11 bolts (1-10): + 70 degrees.
    6.  
    7. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
      NOTE
      The cylinder head gasket displacement can be verified by markings visible on the top side of the left gasket locating tab. Some 4.8/5.3L head gaskets may have 53 stamped onto the locating tab. Some 6.0L head gaskets may have 60 stamped onto the locating tab.

    8.  

  16.  
  17. Install or connect the following:

    Alternator mounting bracket. Tighten the four bolts to 37 ft. lbs. (50 Nm).
     
    Bolt at the rear of the power steering pump and tighten to 37 ft. lbs. (50 Nm).
     
    Exhaust manifold(s)
     
    Pushrods
     
    Intake manifold
     
    Negative battery cable
     

  18.  


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during assembly.


    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.



    Negative battery cable
     
    Alternator bracket
     
    Coolant air bleed pipe
     
    Intake manifold
     
    Pushrods
     
    Exhaust manifold
     
    Spark plugs from the cylinder head
     



    Cylinder head bolts
     
    Cylinder head(s) from the engine
     

  2.  
  3. Remove and discard the gasket. Discard the M11 cylinder head bolts.
  4.  

To install:


NOTE
Do not use any type of sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the left cylinder head gasket will be located left of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW left cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket
     
    NEW M11 cylinder head bolts. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.
     
    M8 cylinder head bolts
     

  10.  
  11. On 2001-04 models, tighten the cylinder head bolts, as follows:
    1. M11 bolts, first pass: in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. M11 bolts, second pass: in sequence + 90 degrees.
    4.  
    5. M11 bolts (1,2,3,4,5,6,7,8): + 90 degrees.
    6.  
    7. M11 bolts (9 and 10): + 50 degrees.
    8.  
    9. M8 bolts (11,12,13,14,15): to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
    10.  

  12.  
  13. On 2005-06 models, tighten the cylinder head bolts, as follows:
    1. Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees.
    4.  
    5. Tighten the M11 cylinder head bolts (1-10 ) a final pass to 70 degrees in sequence.
    6.  
    7. Tighten the M8 cylinder head bolts (11-15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
      NOTE
      The cylinder head gasket displacement can be verified by markings visible on the top side of the left gasket locating tab. Some 4.8 and 5.3L head gaskets may have 53 stamped onto the locating tab. Some 6.0L head gaskets may have 60 stamped onto the locating tab.

    8.  

  14.  
  15. Install or connect the following:

    Alternator mounting bracket. Tighten the four bolts to 37 ft. lbs. (50 Nm).
     
    Exhaust manifold
     
    Pushrods
     
    Intake manifold
     
    Coolant air bleed pipe
     
    Negative battery cable
     

  16.  


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during assembly.



    Negative battery cable
     
    Intake manifold
     
    Push rods
     
    Exhaust manifold(s)
     
    Alternator
     
    Three bolts holding the alternator mounting bracket to the cylinder head
     
    The bolt behind the power steering pump
     
    Alternator mounting bracket and set it aside
     
    Bolt holding the oil level indicator tube to the right side cylinder head
     
    Oil level indicator tube
     
    Cylinder head (s) from the engine
     
    Spark plugs from the cylinder head
     

  2.  
  3. Remove the cylinder head bolts.
    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.

  4.  
  5. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts.
  6.  

To install:


NOTE
Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the left cylinder head gasket will be located left of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW left cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket.
     
    NEW M11 cylinder head bolts. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.
     
    M8 cylinder head bolts.
     

  10.  
  11. Tighten the cylinder head bolts.
    1. M11 cylinder head bolts first pass in sequence to 30 Nm (22 ft. lbs.).
    2.  
    3. M11 cylinder head bolts second pass + 90 degrees
    4.  
    5. M11 cylinder head bolts (1,2,3,4,5,6,7,8) + 90 degrees
    6.  
    7. M11 cylinder head bolts (9 and 10) + 50 degrees
    8.  
    9. M8 cylinder head bolts (11,12,13,14,15) to 30 Nm (22 ft. lbs.). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
      NOTE
      The cylinder head gasket displacement can be verified by markings visible on the top side of the left gasket locating tab. Some 4.8/5.3L head gaskets may have 53 stamped onto the locating tab. Some 6.0L head gaskets may have 60 stamped onto the locating tab.

    10.  

  12.  
  13. Install the alternator mounting bracket using the four bolts. Tighten the mounting bracket to the cylinder head bolts to 50 Nm (37 ft. lbs.).
  14.  
  15. Tighten the bolt at the rear of the power steering pump. Tighten the bolt to 50 Nm (37 ft. lbs.).
  16.  
  17. Install the exhaust manifold (s) to the engine.
  18.  
  19. Install the pushrods to the engine.
  20.  
  21. Install the intake manifold to the engine.
  22.  
  23. Connect the negative battery cable.
  24.  


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during assembly.



    Negative battery cable
     
    Intake manifold
     
    Push rods
     
    Exhaust manifold(s)
     
    Alternator
     
    Three bolts holding the alternator mounting bracket to the cylinder head
     
    The bolt behind the power steering pump
     
    Alternator mounting bracket and set it aside
     
    Bolt holding the oil level indicator tube to the right side cylinder head
     
    Oil level indicator tube
     
    Cylinder head (s) from the engine
     
    Spark plugs from the cylinder head
     

  2.  
  3. Remove the cylinder head bolts.
    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.

  4.  
  5. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts.
  6.  

To install:


NOTE
Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the left cylinder head gasket will be located left of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW left cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket.
     
    NEW M11 cylinder head bolts. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.
     
    M8 cylinder head bolts.
     

  10.  
  11. Tighten the cylinder head bolts.
    1. M11 cylinder head bolts first pass in sequence to 30 Nm (22 ft. lbs.).
    2.  
    3. M11 cylinder head bolts second pass + 90 degrees
    4.  
    5. M11 cylinder head bolts (1,2,3,4,5,6,7,8) + 90 degrees
    6.  
    7. M11 cylinder head bolts (9 and 10) + 50 degrees
    8.  
    9. M8 cylinder head bolts (11,12,13,14,15) to 30 Nm (22 ft. lbs.). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
      NOTE
      The cylinder head gasket displacement can be verified by markings visible on the top side of the left gasket locating tab. Some 4.8/5.3L head gaskets may have 53 stamped onto the locating tab. Some 6.0L head gaskets may have 60 stamped onto the locating tab.

    10.  

  12.  
  13. Install the alternator mounting bracket using the four bolts. Tighten the mounting bracket to the cylinder head bolts to 50 Nm (37 ft. lbs.).
  14.  
  15. Tighten the bolt at the rear of the power steering pump. Tighten the bolt to 50 Nm (37 ft. lbs.).
  16.  
  17. Install the exhaust manifold (s) to the engine.
  18.  
  19. Install the pushrods to the engine.
  20.  
  21. Install the intake manifold to the engine.
  22.  
  23. Connect the negative battery cable.
  24.  


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during assembly.



    Negative battery cable
     
    Intake manifold
     
    Push rods
     
    Exhaust manifold(s)
     
    Alternator
     
    Alternator mounting bracket-to-cylinder head bolts
     
    Bolt behind the power steering pump
     
    Alternator mounting bracket and set it aside
     
    Oil level indicator tube-to-cylinder head bolt
     
    Oil level indicator tube
     
    Cylinder head from the engine
     
    Spark plugs
     

  2.  
  3. Remove the cylinder head bolts.
    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.

  4.  
  5. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts.
  6.  

To install:


NOTE
Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old thread locking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the left cylinder head gasket will be located left of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW left cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket
     
    NEW M11 cylinder head bolts.
     

  10.  
  11. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.

    M8 cylinder head bolts
     
    M8 cylinder head bolts.
     

  12.  
  13. Tighten the cylinder head bolts as follows:
    1. M11 bolts (1-10) 1st pass: in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. M11 bolts (1-10) 2nd pass: in sequence + 90 degrees.
    4.  
    5. M11 bolts (1-10): + 70 degrees.
    6.  
    7. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
    8.  

  14.  
  15. Install or connect the following:

    Alternator mounting bracket. Tighten the four bolts to 37 ft. lbs. (50 Nm).
     
    Bolt at the rear of the power steering pump and tighten to 37 ft. lbs. (50 Nm).
     
    Exhaust manifold(s)
     
    Pushrods
     
    Intake manifold
     
    Negative battery cable
     

  16.  

Right Side

CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during reassembly.


    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.



    Negative battery cable
     
    Coolant air bleed pipe
     
    Intake manifold
     
    Push rods
     
    Exhaust manifold(s)
     
    Alternator
     
    Alternator mounting bracket-to-cylinder head bolts
     
    Bolt behind the power steering pump
     
    Alternator mounting bracket and set it aside
     
    Bolt holding the oil level indicator tube to the right side cylinder head
     
    Oil level indicator tube
     
    Cylinder head(s) from the engine
     
    Spark plugs
     



    Cylinder head bolts
     

  2.  
  3. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts.
  4.  

To install:


NOTE
Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old thread locking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:
    NOTE
    First design engine blocks have different drill and tap depths using both medium length 3.94 inch (100mm) and long 6.1 inch (155mm) M11 cylinder head bolts. Second design engine blocks use only the medium length 3.94 inch (100mm) bolt with a common drill and tap depth.



    NEW right cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket
     
    NEW M11 cylinder head bolts. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.
     



    M8 cylinder head bolts.
     

  10.  
  11. Tighten the first design cylinder head bolts as follows:
    1. M11 bolts 1st pass: in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. M11 bolts 2nd pass: in sequence + 90 degrees.
    4.  
    5. M11 bolts (1,2,3,4,5,6,7,8): + 90 degrees.
    6.  
    7. M11 bolts (9 and 10): + 50 degrees.
    8.  
    9. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
    10.  

  12.  
  13. Tighten the second design cylinder head bolts as follows:
    1. M11 bolts (1-10) 1st pass: in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. M11 bolts (1-10) 2nd pass: in sequence + 90 degrees.
    4.  
    5. M11 bolts (1-10): + 70 degrees.
    6.  
    7. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
      NOTE
      The cylinder head gasket displacement can be verified by markings visible on the underside of the right gasket locating tab. Some 4.8/5.3L head gaskets may have 53 stamped onto the locating tab. Some 6.0L head gaskets may have 60 stamped onto the locating tab.



      Click image to see an enlarged view

      Fig. Locating tab-4.8L, 5.3L and 6.0L engines



      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-4.8L, 5.3L and 6.0L engines

    8.  

  14.  
  15. Install or connect the following:

    Alternator
     
    Exhaust manifold(s)
     
    Pushrods
     
    Intake manifold
     
    Negative battery cable
     

  16.  

  1. Remove or disconnect the following:
    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.



    Negative battery cable
     
    Oil level indicator tube
     
    Intake manifold
     
    Coolant air bleed pipe
     
    Exhaust manifold
     
    Push rods
     
    Cylinder head bolts and discard
     
    Cylinder head from the engine
     

  2.  
  3. Remove and discard the gasket.
  4.  

To install:


NOTE
Do not use any type of sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, with FRONT on the right side, the tab on the cylinder head gasket should be located right of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW right cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket
     
    NEW M11 cylinder head bolts. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.
     
    M8 cylinder head bolts.
     

  10.  
  11. On 2002-04 models, tighten the cylinder head bolts, as follows:
    1. M11 bolts, first pass: in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. M11 bolts, second pass: in sequence + 90 degrees.
    4.  
    5. M11 bolts (1,2,3,4,5,6,7,8): + 90 degrees.
    6.  
    7. M11 bolts (9 and 10): + 50 degrees.
    8.  
    9. M8 bolts (11,12,13,14,15): to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
    10.  

  12.  
  13. On 2005-06 models, tighten the cylinder head bolts, as follows:
    1. Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees.
    4.  
    5. Tighten the M11 cylinder head bolts (1-10 ) a final pass to 70 degrees in sequence.
    6.  
    7. Tighten the M8 cylinder head bolts (11-15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
      NOTE
      The cylinder head gasket displacement can be verified by markings visible on the underside of the right gasket locating tab. Some 4.8 and 5.3L head gaskets may have -53- stamped onto the locating tab. Some 6.0L head gaskets may have -60- stamped onto the locating tab.



      Click image to see an enlarged view

      Fig. Locating tab-4.8L, 5.3L and 6.0L engines



      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-4.8L, 5.3L and 6.0L engines



      Install or connect the following:
       



      Alternator
       
      Exhaust manifold(s)
       
      Pushrods
       
      Intake manifold
       
      Coolant air bleed pipe
       
      Oil level indicator tube
       
      Negative battery cable
       

    8.  

  14.  


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during assembly.



    Negative battery cable
     
    Intake manifold
     
    Push rods
     
    Exhaust manifold(s)
     
    Alternator
     
    Three bolts holding the alternator mounting bracket to the cylinder head
     
    The bolt behind the power steering pump
     
    Alternator mounting bracket and set it aside
     
    Bolt holding the oil level indicator tube to the right side cylinder head
     
    Oil level indicator tube
     
    Cylinder head (s) from the engine
     
    Spark plugs from the cylinder head
     

  2.  
  3. Remove the cylinder head bolts.
    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.

  4.  
  5. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts.
  6.  

To install:


NOTE
Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW right cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket.
     
    NEW M11 cylinder head bolts. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.
     
    M8 cylinder head bolts.
     

  10.  
  11. Tighten the cylinder head bolts:
    1. M11 cylinder head bolts first pass in sequence to 30 Nm (22 ft. lbs.).
    2.  
    3. M11 cylinder head bolts second pass in sequence + 90 degrees.
    4.  
    5. M11 cylinder head bolts (1,2,3,4,5,6,7,8) + 90 degrees
    6.  
    7. M11 cylinder head bolts (9 and 10) + 50 degrees
    8.  
    9. M8 cylinder head bolts (11,12,13,14,15) to 30 Nm (22 ft. lbs.). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
      NOTE
      The cylinder head gasket displacement can be verified by markings visible on the underside of the right gasket locating tab. Some 4.8/5.3L head gaskets may have 53 stamped onto the locating tab. Some 6.0L head gaskets may have 60 stamped onto the locating tab.



      Click image to see an enlarged view

      Fig. Locating tab-4.8L, 5.3L, 6.0L



      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-4.8L, 5.3L and 6.0L engines

    10.  

  12.  
  13. Install the alternator to the engine.
  14.  
  15. Install the exhaust manifold (s) to the engine.
  16.  
  17. Install the pushrods to the engine.
  18.  
  19. Install the intake manifold to the engine.
  20.  
  21. Connect the negative battery cable.
  22.  


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during assembly.



    Negative battery cable
     
    Intake manifold
     
    Push rods
     
    Exhaust manifold(s)
     
    Alternator
     
    Three bolts holding the alternator mounting bracket to the cylinder head
     
    The bolt behind the power steering pump
     
    Alternator mounting bracket and set it aside
     
    Bolt holding the oil level indicator tube to the right side cylinder head
     
    Oil level indicator tube
     
    Cylinder head (s) from the engine
     
    Spark plugs from the cylinder head
     

  2.  
  3. Remove the cylinder head bolts.
    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.

  4.  
  5. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts.
  6.  

To install:


NOTE
Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old threadlocking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW right cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket.
     
    NEW M11 cylinder head bolts. Apply a 5 mm (0.20 in) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.
     
    M8 cylinder head bolts.
     

  10.  
  11. Tighten the cylinder head bolts:
    1. M11 cylinder head bolts first pass in sequence to 30 Nm (22 ft. lbs.).
    2.  
    3. M11 cylinder head bolts second pass in sequence + 90 degrees.
    4.  
    5. M11 cylinder head bolts (1,2,3,4,5,6,7,8) + 90 degrees
    6.  
    7. M11 cylinder head bolts (9 and 10) + 50 degrees
    8.  
    9. M8 cylinder head bolts (11,12,13,14,15) to 30 Nm (22 ft. lbs.). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
      NOTE
      The cylinder head gasket displacement can be verified by markings visible on the underside of the right gasket locating tab. Some 4.8/5.3L head gaskets may have 53 stamped onto the locating tab. Some 6.0L head gaskets may have 60 stamped onto the locating tab.



      Click image to see an enlarged view

      Fig. Locating tab-4.8L, 5.3L, 6.0L



      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-4.8L, 5.3L and 6.0L engines

    10.  

  12.  
  13. Install the alternator to the engine.
  14.  
  15. Install the exhaust manifold (s) to the engine.
  16.  
  17. Install the pushrods to the engine.
  18.  
  19. Install the intake manifold to the engine.
  20.  
  21. Connect the negative battery cable.
  22.  


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during reassembly.


    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.



    Negative battery cable
     
    Coolant air bleed pipe
     
    Intake manifold
     
    Push rods
     
    Exhaust manifold(s)
     
    Alternator
     
    Alternator mounting bracket-to-cylinder head bolts
     
    Bolt behind the power steering pump
     
    Alternator mounting bracket and set it aside
     
    Bolt holding the oil level indicator tube to the right side cylinder head
     
    Oil level indicator tube
     
    Cylinder head(s) from the engine
     
    Spark plugs
     



    Cylinder head bolts
     

  2.  
  3. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts.
  4.  

To install:


NOTE
Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old thread locking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW right cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket
     
    NEW M11 cylinder head bolts. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.
     
    M8 cylinder head bolts.
     

  10.  
  11. Tighten the cylinder head bolts as follows:
    1. M11 bolts (1-10) 1st pass: in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. M11 bolts (1-10) 2nd pass: in sequence + 90 degrees.
    4.  
    5. M11 bolts (1-10): + 70 degrees.
    6.  
    7. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.

      Click image to see an enlarged view

      Fig. Locating tab-4.8L, 5.3L and 6.0L engines



      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-4.8L, 5.3L and 6.0L engines

    8.  

  12.  
  13. Install or connect the following:

    Alternator
     
    Exhaust manifold(s)
     
    Pushrods
     
    Intake manifold
     
    Negative battery cable
     

  14.  

4.8L, 5.3L, 6.0L & 6.2L Engines
Left Side

CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during assembly.



    Negative battery cable
     
    Intake manifold
     
    Push rods
     
    Exhaust manifold(s)
     
    Alternator
     
    Alternator mounting bracket-to-cylinder head bolts
     
    Bolt behind the power steering pump
     
    Alternator mounting bracket and set it aside
     
    Oil level indicator tube-to-cylinder head bolt
     
    Oil level indicator tube
     
    Cylinder head from the engine
     
    Spark plugs
     

  2.  
  3. Remove the cylinder head bolts.
    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.

  4.  
  5. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts.
  6.  

To install:


NOTE
Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old thread locking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the left cylinder head gasket will be located left of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW left cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket
     
    NEW M11 cylinder head bolts.
     

  10.  
  11. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.

    M8 cylinder head bolts
     
    M8 cylinder head bolts.
     

  12.  
  13. Tighten the cylinder head bolts as follows:
    1. M11 bolts (1-10) 1st pass: in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. M11 bolts (1-10) 2nd pass: in sequence + 90 degrees.
    4.  
    5. M11 bolts (1-10): + 70 degrees.
    6.  
    7. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
    8.  

  14.  
  15. Install or connect the following:

    Alternator mounting bracket. Tighten the four bolts to 37 ft. lbs. (50 Nm).
     
    Bolt at the rear of the power steering pump and tighten to 37 ft. lbs. (50 Nm).
     
    Exhaust manifold(s)
     
    Pushrods
     
    Intake manifold
     
    Negative battery cable
     

  16.  

Right Side

CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Remove or disconnect the following:
    NOTE
    The M11 cylinder head bolts are NOT reusable. Install NEW M11 cylinder head bolts during reassembly.


    NOTE
    After removal, place the cylinder head on two wood blocks to prevent damage.



    Negative battery cable
     
    Coolant air bleed pipe
     
    Intake manifold
     
    Push rods
     
    Exhaust manifold(s)
     
    Alternator
     
    Alternator mounting bracket-to-cylinder head bolts
     
    Bolt behind the power steering pump
     
    Alternator mounting bracket and set it aside
     
    Bolt holding the oil level indicator tube to the right side cylinder head
     
    Oil level indicator tube
     
    Cylinder head(s) from the engine
     
    Spark plugs
     



    Cylinder head bolts
     

  2.  
  3. Remove the gasket. Discard the gasket. Discard the M11 cylinder head bolts.
  4.  

To install:


NOTE
Do not use any type sealant on the cylinder head gasket (unless specified). The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the engine block cylinder head bolt holes (if required). Thread repair tool J 42385-107 may be used to clean the threads of old thread locking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981, or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation.
    NOTE
    When properly installed, the tab on the right cylinder head gasket will be located right of center or closer to the front of the engine.

  8.  
  9. Install or connect the following:

    NEW right cylinder head gasket onto the locating pins
     
    Cylinder head onto the locating pins and the gasket
     
    NEW M11 cylinder head bolts. Apply a 0.20 in. (5mm) band of threadlock GM P/N 12345382 or equivalent to the threads of the M8 cylinder head bolts.
     
    M8 cylinder head bolts.
     

  10.  
  11. Tighten the cylinder head bolts as follows:
    1. M11 bolts (1-10) 1st pass: in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. M11 bolts (1-10) 2nd pass: in sequence + 90 degrees.
    4.  
    5. M11 bolts (1-10): + 70 degrees.
    6.  
    7. M8 cylinder head bolts (11,12,13,14,15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.

      Click image to see an enlarged view

      Fig. Locating tab-4.8L, 5.3L, 6.0L and 6.2L engines



      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-4.8L, 5.3L, 6.0L and 6.2L engines

    8.  

  12.  
  13. Install or connect the following:

    Alternator
     
    Exhaust manifold(s)
     
    Pushrods
     
    Intake manifold
     
    Negative battery cable
     

  14.  

5.0L And 5.7L Engines
  1. Drain the coolant.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Coolant recovery reservoir, if applicable
     
    Intake manifold
     
    Exhaust manifolds and position them out of the way
     
    Ground strap at the rear of the right AIR pipe, if equipped
     
    Exhaust Gas Recirculation (EGR) inlet tube
     

  4.  
  5. On the right side cylinder head, disconnect the fuel pipe, spark plug wires and wiring harness bracket.
    NOTE
    You may have to loosen the remaining bolts and studs in order to remove the head.



    Nut and stud attaching the main accessory bracket to the cylinder head
     



    Coolant sensor wire
     
    Spark plug wire bracket
     
    Cylinder head covers
     
    Spark plugs
     
    Pushrods. Identify the pushrods so that they can be installed in their original positions.
     
    Cylinder head bolts in the reverse order of the tightening sequence
     
    Heads
     

  6.  

To install:

  1. Inspect the cylinder head and block mating surfaces. Clean all old gasket material.
  2.  
  3. Install or connect the following:
    NOTE
    Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.



    Cylinder heads using new gaskets. Install the gaskets with the word HEAD up.
     

  4.  
  5. Clean the bolts, apply sealer to the threads, and hand-tighten.
  6.  
  7. Install the cylinder head bolts in sequence to 22 ft. lbs. (30 Nm). The bolts must be tightened once, then be tightened again in sequence in the following order:
    1. Step 1: Short length bolt: (3, 4, 7, 8, 11, 12, 15, 16), plus 55 degrees.
    2.  
    3. Step 2: Medium length bolt: (14, 17), plus 65 degrees.
    4.  
    5. Step 3: Long length bolts: (1, 2, 5, 6, 9, 10, 13), plus 75 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-5.0L and 5.7L engines

    6.  

  8.  
  9. Install or connect the following:

    Pushrods in their original positions
     
    Cylinder head covers
     
    Spark plugs
     
    Coolant sensor wire
     
    Spark plug wire bracket
     
    Main accessory bracket to the cylinder head
     
    EGR vent tube
     
    Fuel pipe
     
    Spark plug wires
     
    Wiring harness bracket
     
    Ground strap to the rear of the right AIR pipe
     
    Exhaust manifolds
     
    Intake manifold
     
    Coolant recovery reservoir, if removed
     
    Engine cover
     
    Negative battery cable
     

  10.  
  11. Refill the engine with coolant.
  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Coolant recovery reservoir, if applicable
     
    Intake manifold
     
    Exhaust manifolds and position them out of the way
     
    Ground strap at the rear of the right AIR pipe, if equipped
     

  6.  
  7. If the van is equipped with air conditioning, remove the air conditioning compressor and the forward mounting bracket and lay the compressor aside. Do not disconnect any of the refrigerant lines.

    Exhaust Gas Recirculation (EGR) inlet tube
     

  8.  
  9. On the right side cylinder head, disconnect the fuel pipe, spark plug wires and wiring harness bracket.
    NOTE
    You may have to loosen the remaining bolts and studs in order to remove the head.



    Nut and stud attaching the main accessory bracket to the cylinder head.
     



    Coolant sensor wire
     
    Spark plug wire bracket
     
    Cylinder head covers
     
    Spark plugs
     
    Pushrods, Identify the pushrods so that they can be installed in their original positions.
     
    Cylinder head bolts in the reverse order of the tightening sequence
     
    Heads
     

  10.  

To install:

  1. Inspect the cylinder head and block mating surfaces. Clean all old gasket material.
  2.  
  3. Install or connect the following:
    NOTE
    Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.



    Cylinder heads using new gaskets. Install the gaskets with the word HEAD up.
     

  4.  
  5. Clean the bolts, apply sealer to the threads, and hand-tighten.
  6.  
  7. Install the cylinder head bolts in sequence to 22 ft. lbs. (30 Nm) The bolts must be tightened once, then be tightened again in sequence in the following order:
    1. Step 1: Short length bolt: (3, 4, 7, 8, 11, 12, 15, 16) 55 degrees
    2.  
    3. Step 2: Medium length bolt: (14, 17) 65 degrees
    4.  
    5. Step 3: Long length bolts: (1, 2, 5, 6, 9, 10, 13) 75 degrees

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-5.0L and 5.7L engines



      Pushrods so that they are in their original positions
       
      Cylinder head covers
       
      Spark plugs
       
      Coolant sensor wire
       
      Spark plug wire bracket
       
      Main accessory bracket to the cylinder head
       
      EGR vent tube
       
      Fuel pipe
       
      Spark plug wires
       
      Wiring harness bracket
       
      Air conditioning compressor and forward mounting bracket
       
      Ground strap to the rear of the right AIR pipe
       
      Exhaust manifolds
       
      Intake manifold
       
      Coolant recovery reservoir, if removed
       
      Engine cover.
       

    6.  

  8.  
  9. Connect the negative battery cable.
  10.  
  11. Refill the engine with coolant.
  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the coolant.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Coolant recovery reservoir, if applicable
     
    Intake manifold
     
    Exhaust manifolds and position them out of the way
     
    Ground strap at the rear of the right AIR pipe, if equipped
     

  6.  
  7. If the van is equipped with air conditioning, remove the air conditioning compressor and the forward mounting bracket and lay the compressor aside. Do not disconnect any of the refrigerant lines.

    Exhaust Gas Recirculation (EGR) inlet tube
     

  8.  
  9. On the right side cylinder head, disconnect the fuel pipe, spark plug wires and wiring harness bracket.
    NOTE
    You may have to loosen the remaining bolts and studs in order to remove the head.



    Nut and stud attaching the main accessory bracket to the cylinder head.
     



    Coolant sensor wire
     
    Spark plug wire bracket
     
    Cylinder head covers
     
    Spark plugs
     
    Pushrods, Identify the pushrods so that they can be installed in their original positions.
     
    Cylinder head bolts in the reverse order of the tightening sequence
     
    Heads
     

  10.  

To install:

  1. Inspect the cylinder head and block mating surfaces. Clean all old gasket material.
  2.  
  3. Install or connect the following:
    NOTE
    Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.



    Cylinder heads using new gaskets. Install the gaskets with the word HEAD up.
     

  4.  
  5. Clean the bolts, apply sealer to the threads, and hand-tighten.
  6.  
  7. Install the cylinder head bolts in sequence to 22 ft. lbs. (30 Nm) The bolts must be tightened once, then be tightened again in sequence in the following order:
    1. Step 1: Short length bolt: (3, 4, 7, 8, 11, 12, 15, 16) 55 degrees
    2.  
    3. Step 2: Medium length bolt: (14, 17) 65 degrees
    4.  
    5. Step 3: Long length bolts: (1, 2, 5, 6, 9, 10, 13) 75 degrees

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-5.0L and 5.7L engines



      Pushrods so that they are in their original positions
       
      Cylinder head covers
       
      Spark plugs
       
      Coolant sensor wire
       
      Spark plug wire bracket
       
      Main accessory bracket to the cylinder head
       
      EGR vent tube
       
      Fuel pipe
       
      Spark plug wires
       
      Wiring harness bracket
       
      Air conditioning compressor and forward mounting bracket
       
      Ground strap to the rear of the right AIR pipe
       
      Exhaust manifolds
       
      Intake manifold
       
      Coolant recovery reservoir, if removed
       
      Engine cover.
       

    6.  

  8.  
  9. Connect the negative battery cable.
  10.  
  11. Refill the engine with coolant.
  12.  

6.5L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Drain the coolant system.
  4.  
  5. Discharge the air conditioning system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Mark all components so they may be returned to their original location.



    Negative battery cables
     
    Intake manifold
     
    Fan upper shroud
     
    Compressor assembly, if equipped
     
    Turbocharger, if equipped
     
    Exhaust manifold
     
    Valve cover
     
    Rocker arm assemblies and pushrods
     



    Air cleaner resonator and bracket
     
    Transmission and oil dipstick tube; remove the oil fill tube from the coolant crossover pipe
     
    Heater, radiator and bypass hoses
     
    Alternator upper bracket
     
    Alternator
     
    Power steering pump
     
    Vacuum pump
     
    Fuel bleeder valve at the coolant crossover pipe
     
    Fuel return crossover line clamp bolts from both cylinder heads
     
    Wire connector from the sensor in the coolant crossover pipe
     
    Electrical connection and brackets from cylinder head
     
    Coolant crossover pipe/thermostat assembly
     
    Head bolts and the cylinder heads
     

  8.  

To install:

  1. Clean the mating surfaces of the heads and block thoroughly.
  2.  
  3. Clean the head bolts thoroughly. Coat the threads of the head bolts with sealing compound GM part 1052080 or equivalent, before installation.

    Click image to see an enlarged view

    Fig. Tighten the cylinder head bolts according to the sequence shown for proper cylinder sealing-6.5L diesel engines

  4.  
  5. Install a new gaskets, and the cylinder head and bolts. Torque the bolts, in sequence, as follows:
    1. Step 1: 20 ft. lbs. (25 Nm)
    2.  
    3. Step 2: 50 ft. lbs. (65 Nm).
    4.  
    5. Step 3: An additional 90 degrees ( 1 / 4 turn).
    6.  

  6.  
  7. Install or connect the following:

    Coolant crossover pipe and thermostat
     
    Fuel valve
     
    Bypass hose
     
    Upper radiator hose
     
    Heater hoses at the head
     
    Transmission and oil dipstick tube
     
    Air cleaner resonator and bracket
     
    Pushrods, hardened ends facing up
     
    Rocker arm assemblies
     

  8.  
  9. Adjust the valves.

    Valve cover
     
    Alternator and upper bracket
     
    Exhaust manifolds. Torque bolts to 22 ft. lbs. (30 Nm).
     
    Upper fan shroud
     
    Intake manifold
     
    Turbocharger, if equipped
     
    Vacuum pump, if equipped
     
    Air conditioning compressor, if equipped
     
    Engine electrical connection
     
    Negative battery cables
     

  10.  
  11. Refill the cooling system with the proper type and quantity of antifreeze.
  12.  
  13. Evacuate and recharge the air conditioning system.
  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the coolant system.
  6.  
  7. Discharge the air conditioning system.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Mark all components so they may be returned to their original location.



    Negative battery cables
     
    Intake manifold
     
    Fan upper shroud
     
    Compressor assembly, if equipped
     
    Turbocharger, if equipped
     
    Exhaust manifold
     
    Valve cover
     
    Rocker arm assemblies and pushrods
     



    Air cleaner resonator and bracket
     
    Transmission and oil dipstick tube; remove the oil fill tube from the coolant crossover pipe
     
    Heater, radiator and bypass hoses
     
    Alternator upper bracket
     
    Alternator
     
    Power steering pump
     
    Vacuum pump
     
    Fuel bleeder valve at the coolant crossover pipe
     
    Fuel return crossover line clamp bolts from both cylinder heads
     
    Wire connector from the sensor in the coolant crossover pipe
     
    Electrical connection and brackets from cylinder head
     
    Coolant crossover pipe/thermostat assembly
     
    Head bolts and the cylinder heads
     

  10.  

To install:

  1. Clean the mating surfaces of the heads and block thoroughly.
  2.  
  3. Clean the head bolts thoroughly. Coat the threads of the head bolts with sealing compound GM part 1052080 or equivalent, before installation.

    Click image to see an enlarged view

    Fig. Tighten the cylinder head bolts according to the sequence shown for proper cylinder sealing-6.5L diesel engines

  4.  
  5. Install or connect the following:

    New gasket
     
    Cylinder head and bolts. Torque the bolts in the follows:
     

    1. Step 1: Torque the bolts to 20 ft. lbs. (25 Nm).
    2.  
    3. Step 2: Torque the bolts to 50 ft. lbs. (65 Nm).
    4.  
    5. Step 3: Then an additional 90 degrees ( 1 / 4 turn).

      Coolant crossover pipe and thermostat
       
      Fuel valve
       
      Bypass hose
       
      Upper radiator hose
       
      Heater hoses at the head
       
      Transmission and oil dipstick tube
       
      Air cleaner resonator and bracket
       
      Pushrods, hardened ends facing up
       
      Rocker arm assemblies
       

    6.  

  6.  
  7. Adjust the valves.

    Valve cover
     
    Alternator and upper bracket
     
    Exhaust manifolds. Torque bolts to 22 ft. lbs. (30 Nm).
     
    Upper fan shroud
     
    Intake manifold
     
    Turbocharger, if equipped
     
    Vacuum pump, if equipped
     
    Air conditioning compressor, if equipped
     
    Engine electrical connection
     
    Negative battery cables
     

  8.  
  9. Refill the cooling system with the proper type and quantity of antifreeze.
  10.  
  11. Evacuate and recharge the air conditioning system.
  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the coolant system.
  6.  
  7. Discharge the air conditioning system.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Mark all components so they may be returned to their original location.



    Negative battery cables
     
    Intake manifold
     
    Fan upper shroud
     
    Compressor assembly, if equipped
     
    Turbocharger, if equipped
     
    Exhaust manifold
     
    Valve cover
     
    Rocker arm assemblies and pushrods
     



    Air cleaner resonator and bracket
     
    Transmission and oil dipstick tube; remove the oil fill tube from the coolant crossover pipe
     
    Heater, radiator and bypass hoses
     
    Alternator upper bracket
     
    Alternator
     
    Power steering pump
     
    Vacuum pump
     
    Fuel bleeder valve at the coolant crossover pipe
     
    Fuel return crossover line clamp bolts from both cylinder heads
     
    Wire connector from the sensor in the coolant crossover pipe
     
    Electrical connection and brackets from cylinder head
     
    Coolant crossover pipe/thermostat assembly
     
    Head bolts and the cylinder heads
     

  10.  

To install:

  1. Clean the mating surfaces of the heads and block thoroughly.
  2.  
  3. Clean the head bolts thoroughly. Coat the threads of the head bolts with sealing compound GM part 1052080 or equivalent, before installation.

    Click image to see an enlarged view

    Fig. Tighten the cylinder head bolts according to the sequence shown for proper cylinder sealing-6.5L diesel engines

  4.  
  5. Install or connect the following:

    New gasket
     
    Cylinder head and bolts. Torque the bolts in the follows:
     

    1. Step 1: Torque the bolts to 20 ft. lbs. (25 Nm).
    2.  
    3. Step 2: Torque the bolts to 50 ft. lbs. (65 Nm).
    4.  
    5. Step 3: Then an additional 90 degrees ( 1 / 4 turn).

      Coolant crossover pipe and thermostat
       
      Fuel valve
       
      Bypass hose
       
      Upper radiator hose
       
      Heater hoses at the head
       
      Transmission and oil dipstick tube
       
      Air cleaner resonator and bracket
       
      Pushrods, hardened ends facing up
       
      Rocker arm assemblies
       

    6.  

  6.  
  7. Adjust the valves.

    Valve cover
     
    Alternator and upper bracket
     
    Exhaust manifolds. Torque bolts to 22 ft. lbs. (30 Nm)
     
    Upper fan shroud
     
    Intake manifold
     
    Turbocharger, if equipped
     
    Vacuum pump, if equipped
     
    Air conditioning compressor, if equipped
     
    Engine electrical connection
     
    Negative battery cables
     

  8.  
  9. Refill the cooling system with the proper type and quantity of antifreeze.
  10.  
  11. Evacuate and recharge the air conditioning system.
  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the coolant system.
  6.  
  7. Discharge the air conditioning system.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Mark all components so they may be returned to their original location.



    Negative battery cables
     
    Intake manifold
     
    Fan upper shroud
     
    Compressor assembly, if equipped
     
    Turbocharger, if equipped
     
    Exhaust manifold
     
    Valve cover
     
    Rocker arm assemblies and pushrods
     



    Air cleaner resonator and bracket
     
    Transmission and oil dipstick tube; remove the oil fill tube from the coolant crossover pipe
     
    Heater, radiator and bypass hoses
     
    Alternator upper bracket
     
    Alternator
     
    Power steering pump
     
    Vacuum pump
     
    Fuel bleeder valve at the coolant crossover pipe
     
    Fuel return crossover line clamp bolts from both cylinder heads
     
    Wire connector from the sensor in the coolant crossover pipe
     
    Electrical connection and brackets from cylinder head
     
    Coolant crossover pipe/thermostat assembly
     
    Head bolts and the cylinder heads
     

  10.  

To install:

  1. Clean the mating surfaces of the heads and block thoroughly.
  2.  
  3. Clean the head bolts thoroughly. Coat the threads of the head bolts with sealing compound GM part 1052080 or equivalent, before installation.

    Click image to see an enlarged view

    Fig. Tighten the cylinder head bolts according to the sequence shown for proper cylinder sealing-6.5L diesel engines

  4.  
  5. Install or connect the following:

    New gasket
     
    Cylinder head and bolts. Torque the bolts in the follows:
     

    1. Step 1: Torque the bolts to 20 ft. lbs. (25 Nm).
    2.  
    3. Step 2: Torque the bolts to 50 ft. lbs. (65 Nm).
    4.  
    5. Step 3: Then an additional 90 degrees ( 1 / 4 turn).

      Coolant crossover pipe and thermostat
       
      Fuel valve
       
      Bypass hose
       
      Upper radiator hose
       
      Heater hoses at the head
       
      Transmission and oil dipstick tube
       
      Air cleaner resonator and bracket
       
      Pushrods, hardened ends facing up
       
      Rocker arm assemblies
       

    6.  

  6.  
  7. Adjust the valves.

    Valve cover
     
    Alternator and upper bracket
     
    Exhaust manifolds. Torque bolts to 22 ft. lbs. (30 Nm)
     
    Upper fan shroud
     
    Intake manifold
     
    Turbocharger, if equipped
     
    Vacuum pump, if equipped
     
    Air conditioning compressor, if equipped
     
    Engine electrical connection
     
    Negative battery cables
     

  8.  
  9. Refill the cooling system with the proper type and quantity of antifreeze.
  10.  
  11. Evacuate and recharge the air conditioning system.
  12.  

 
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