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

Cylinder Head 2

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Removal & Installation



6.6L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Drain the coolant system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cables
     
    Left or right front splash shield from the fender well, as applicable
     
    Turbocharger
     
    Turbocharger charged air cooler inlet duct
     
    Thermostat housing crossover
     
    Left or right intake manifold, as necessary
     
    Upper left or right valve cover
     
    Fuel rail assembly
     
    Left or right exhaust manifold
     
    Bolt and ground straps from the rear of the cylinder head
     
    Lower left or right valve cover
     
    Rocker arm shaft assembly
     
    Glow plugs
     
    Fuel injector return pipe eye bolts and washers
     
    Fuel injector return pipe assembly
     
    Fuel injector bracket bolts
     
    Fuel injectors with the brackets, using a suitable removal tool
     
    Injector bracket pins
     
    Cylinder head bolts, in the proper sequence
     
    Cylinder head and gasket. Discard the gasket

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-6.6L Diesel engine

     

  6.  

To install:

  1. Clean the mating surfaces of the heads and block thoroughly.
  2.  
  3. Position a new left or right side head gasket on the block. Note that the left and right side gaskets are NOT interchangeable.
    NOTE
    The cylinder head bolts on these vehicles are pre-coated with an application of a molybdenum disulfide for thread lubrication. Do not remove the coating or add any additional lubrication.

  4.  
  5. Install the cylinder head and bolts.
  6.  
  7. Tighten the cylinder head bolts, in sequence, as follows:
    1. Step 1: M12 bolts to 37 ft. lbs. (50 Nm).
    2.  
    3. Step 2: M12 bolts to 59 ft. lbs. (80 Nm).
    4.  
    5. Step 3: Tighten the M12 bolts an additional 90 degrees using a torque angle meter.
    6.  
    7. Step 4: Tighten the M12 bolts an additional 75 degrees using a torque angle meter.
    8.  
    9. Step 5: M8 bolts to 18 ft. lbs. (25 Nm).

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-6.6L diesel engines

    10.  

  8.  
  9. Install or connect the following:
    NOTE
    If you are reusing the old injectors, clean the carbon from the tips, but do not use a wire brush.



    New O-ring onto the fuel injectors after coating with clean engine oil
     
    New copper washer into the fuel injector bore in the cylinder head
     
    Fuel injector bracket pin
     



    Fuel injector bracket bolt and tighten to 37 ft. lbs. (50 Nm)
     
    Fuel injector return pipe assembly
     
    Fuel injector return pipe-to-injector eye bolts and washers. Tighten to 11 ft. lbs. (15 Nm).
     
    Fuel return pipe-to-cylinder head eye bolts and washers. Tighten to 11 ft. lbs. (15 Nm).
     
    Bolt and ground straps to the rear of the cylinder head. Tighten to 18 ft. lbs. (25 Nm).
     
    Valve rocker shaft assembly
     
    Lower and upper valve covers
     
    Glow plugs
     
    Exhaust manifold
     
    Fuel rail assembly
     
    Intake manifold
     
    Thermostat housing crossover
     
    Turbocharger charged air cooler duct
     
    Clamp and hose to the charged air cooler. Tighten to 53 inch lbs. (6 Nm).
     
    Turbocharger
     
    Fender splash shield
     
    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 in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the coolant system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cables
     
    Left or right front splash shield from the fender well, as applicable
     
    Turbocharger
     
    Turbocharger charged air cooler inlet duct
     
    Thermostat housing crossover
     
    Left or right intake manifold, as necessary
     
    Upper left or right valve cover
     
    Fuel rail assembly
     
    Left or right exhaust manifold
     
    Bolt and ground straps from the rear of the cylinder head
     
    Lower left or right valve cover
     
    Rocker arm shaft assembly
     
    Glow plugs
     
    Fuel injector return pipe eye bolts and washers
     
    Fuel injector return pipe assembly
     
    Fuel injector bracket bolts
     
    Fuel injectors with the brackets, using a suitable removal tool
     
    Injector bracket pins
     
    Cylinder head bolts, in the proper sequence

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-6.6L diesel engine

     
    Cylinder head and gasket. Discard the gasket
     

  8.  

To install:

  1. Clean the mating surfaces of the heads and block thoroughly.
  2.  
  3. Position a new left or right side head gasket on the block. Note that the left and right side gaskets are NOT interchangeable.
    NOTE
    The cylinder head bolts on these vehicles are precoated with an application of a molybdenum disulfide for thread lubrication. Do not remove the coating or add any additional lubrication.

  4.  
  5. Install the cylinder head and bolts.
  6.  
  7. Tighten the cylinder head bolts, in sequence, as follows:
    1. Step 1: M12 bolts to 37 ft. lbs. (50 Nm).
    2.  
    3. Step 2: M12 bolts to 59 ft. lbs. (80 Nm).
    4.  
    5. Step 3: Tighten the M12 bolts an additional 150 degrees using a torque angle meter.
    6.  
    7. Step 4: M8 bolts to 18 ft. lbs. (25 Nm).

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-6.6L diesel engines

    8.  

  8.  
  9. Install or connect the following:
    NOTE
    If you are reusing the old injectors, clean the carbon from the tips, but do not use a wire brush.



    New O-ring onto the fuel injectors after coating with clean engine oil
     
    New copper washer into the fuel injector bore in the cylinder head
     
    Fuel injector bracket pin
     



    Fuel injector bracket bolt and tighten to 37 ft. lbs. (50 Nm)
     
    Fuel injector return pipe assembly
     
    Fuel injector return pipe-to-injector eye bolts and washers. Tighten to 11 ft. lbs. (15 Nm)
     
    Fuel return pipe-to-cylinder head eye bolts and washers. Tighten to 11 ft. lbs. (15 Nm)
     
    Bolt and ground straps to the rear of the cylinder head. Tighten to 18 ft. lbs. (25 Nm)
     
    Valve rocker shaft assembly
     
    Lower and upper valve covers
     
    Glow plugs
     
    Exhaust manifold
     
    Fuel rail assembly
     
    Intake manifold
     
    Thermostat housing crossover
     
    Turbocharger charged air cooler duct
     
    Clamp and hose to the charged air cooler. Tighten to 53 inch lbs. (6 Nm)
     
    Turbocharger
     
    Fender splash shield
     
    Negative battery cables
     

  10.  
  11. Refill the cooling system with the proper type and quantity of antifreeze.

    Negative battery cables
     

  12.  
  13. Refill the cooling system with the proper type and quantity of antifreeze.
  14.  
  15. Evacuate and recharge the air conditioning system.
  16.  

  1. Relieve the fuel system pressure.
  2.  
  3. Drain the coolant system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cables
     
    Left or right front splash shield from the fender well, as applicable
     
    Turbocharger
     
    Turbocharger charged air cooler inlet duct
     
    Thermostat housing crossover
     
    Left or right intake manifold, as necessary
     
    Upper left or right valve cover
     
    Fuel rail assembly
     
    Left or right exhaust manifold
     
    Bolt and ground straps from the rear of the cylinder head
     
    Lower left or right valve cover
     
    Rocker arm shaft assembly
     
    Glow plugs
     
    Fuel injector return pipe eye bolts and washers
     
    Fuel injector return pipe assembly
     
    Fuel injector bracket bolts
     
    Fuel injectors with the brackets, using a suitable removal tool
     
    Injector bracket pins
     
    Cylinder head bolts, in the proper sequence
     
    Cylinder head and gasket. Discard the gasket

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-6.6L engines

     

  6.  

To install:

  1. Clean the mating surfaces of the heads and block thoroughly.
  2.  
  3. Position a new left or right side head gasket on the block. Note that the left and right side gaskets are NOT interchangeable.
    NOTE
    The cylinder head bolts on these vehicles are pre-coated with an application of a molybdenum disulfide for thread lubrication. Do not remove the coating or add any additional lubrication.

  4.  
  5. Install the cylinder head and bolts.
  6.  
  7. Tighten the cylinder head bolts, in sequence, as follows:
    1. Step 1: M12 bolts to 37 ft. lbs. (50 Nm).
    2.  
    3. Step 2: M12 bolts to 59 ft. lbs. (80 Nm).
    4.  
    5. Step 3: Using a torque angle meter, tighten the M12 bolts an additional 60 degrees.
    6.  
    7. Step 4: Using a torque angle meter, tighten the M12 bolts an additional 60 degrees.
    8.  
    9. Step 5: M8 bolts to 18 ft. lbs. (25 Nm).

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-6.6L engines

    10.  

  8.  
  9. Install or connect the following:
    NOTE
    If you are reusing the old injectors, clean the carbon from the tips, but do not use a wire brush.



    New O-ring onto the fuel injectors after coating with clean engine oil
     
    New copper washer into the fuel injector bore in the cylinder head
     
    Fuel injector bracket pin
     



    Fuel injector bracket bolt and tighten to 37 ft. lbs. (50 Nm)
     
    Fuel injector return pipe assembly
     
    Fuel injector return pipe-to-injector eye bolts and washers. Tighten to 11 ft. lbs. (15 Nm).
     
    Fuel return pipe-to-cylinder head eye bolts and washers. Tighten to 11 ft. lbs. (15 Nm).
     
    Bolt and ground straps to the rear of the cylinder head. Tighten to 18 ft. lbs. (25 Nm).
     
    Valve rocker shaft assembly
     
    Lower and upper valve covers
     
    Glow plugs
     
    Exhaust manifold
     
    Fuel rail assembly
     
    Intake manifold
     
    Thermostat housing crossover
     
    Turbocharger charged air cooler duct
     
    Clamp and hose to the charged air cooler. Tighten to 53 inch lbs. (6 Nm).
     
    Turbocharger
     
    Fender splash shield
     
    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. Relieve the fuel system pressure.
  2.  
  3. Drain the coolant system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cables
     
    Left or right front splash shield from the fender well, as applicable
     
    Turbocharger
     
    Turbocharger charged air cooler inlet duct
     
    Thermostat housing crossover
     
    Left or right intake manifold, as necessary
     
    Upper left or right valve cover
     
    Fuel rail assembly
     
    Left or right exhaust manifold
     
    Bolt and ground straps from the rear of the cylinder head
     
    Lower left or right valve cover
     
    Rocker arm shaft assembly
     
    Glow plugs
     
    Fuel injector return pipe eye bolts and washers
     
    Fuel injector return pipe assembly
     
    Fuel injector bracket bolts
     
    Fuel injectors with the brackets, using a suitable removal tool
     
    Injector bracket pins
     
    Cylinder head bolts, in the proper sequence
     
    Cylinder head and gasket. Discard the gasket

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-6.6L engines

     

  6.  

To install:

  1. Clean the mating surfaces of the heads and block thoroughly.
  2.  
  3. Position a new left or right side head gasket on the block. Note that the left and right side gaskets are NOT interchangeable.
    NOTE
    The cylinder head bolts on these vehicles are pre-coated with an application of a molybdenum disulfide for thread lubrication. Do not remove the coating or add any additional lubrication.

  4.  
  5. Install the cylinder head and bolts.
  6.  
  7. Tighten the cylinder head bolts, in sequence, as follows:
    1. Step 1: M12 bolts to 37 ft. lbs. (50 Nm).
    2.  
    3. Step 2: M12 bolts to 59 ft. lbs. (80 Nm).
    4.  
    5. Step 3: Using a torque angle meter, tighten the M12 bolts an additional 90 degrees on 2005 models or 60 degrees on 2006-07 models.
    6.  
    7. Step 4: Using a torque angle meter, tighten the M12 bolts an additional 75 degrees on 2005 models or 60 degrees on 2006-07 models.
    8.  
    9. Step 5: M8 bolts to 18 ft. lbs. (25 Nm).

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-6.6L engines

    10.  

  8.  
  9. Install or connect the following:
    NOTE
    If you are reusing the old injectors, clean the carbon from the tips, but do not use a wire brush.



    New O-ring onto the fuel injectors after coating with clean engine oil
     
    New copper washer into the fuel injector bore in the cylinder head
     
    Fuel injector bracket pin
     



    Fuel injector bracket bolt and tighten to 37 ft. lbs. (50 Nm)
     
    Fuel injector return pipe assembly
     
    Fuel injector return pipe-to-injector eye bolts and washers. Tighten to 11 ft. lbs. (15 Nm).
     
    Fuel return pipe-to-cylinder head eye bolts and washers. Tighten to 11 ft. lbs. (15 Nm).
     
    Bolt and ground straps to the rear of the cylinder head. Tighten to 18 ft. lbs. (25 Nm).
     
    Valve rocker shaft assembly
     
    Lower and upper valve covers
     
    Glow plugs
     
    Exhaust manifold
     
    Fuel rail assembly
     
    Intake manifold
     
    Thermostat housing crossover
     
    Turbocharger charged air cooler duct
     
    Clamp and hose to the charged air cooler. Tighten to 53 inch lbs. (6 Nm).
     
    Turbocharger
     
    Fender splash shield
     
    Negative battery cables
     

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

7.4L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Intake manifold
     
    Exhaust manifolds
     
    Alternator and bracket
     
    Air pump, if equipped
     
    Air conditioning compressor and the forward mounting bracket. Do not disconnect any of the refrigerant lines.
     
    Rocker arm cover
     
    Spark plugs
     
    Air pipes at the rear of the head, if equipped
     
    Ground strap at the rear of the head
     
    Temperature sensor wire
     
    Pushrods. Identify the pushrods so that they can be installed in their original positions.
     
    Cylinder head bolts and the heads
     

  6.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.

  2.  
  3. Install or connect the following:

    New gaskets, with the word HEAD up
     
    Cylinder heads
     

  4.  
  5. Apply sealer to the threads of the head bolts, then install and tighten in sequence, in 3 stages, as follows:
    1. Step 1: 30 ft. lbs. (40 Nm).
    2.  
    3. Step 2: 60 ft. lbs. (80 Nm).
    4.  
    5. Step 3: 85 ft. lbs. (115 Nm).

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-7.4L engines



      Intake and exhaust manifolds
       
      Pushrods
       
      Rocker arms
       
      Temperature sensor wire
       
      Ground strap at the rear of the head
       
      AIR pipes at the rear of the head
       
      Spark plugs
       
      Rocker arm cover
       
      Air conditioning compressor and forward mounting bracket
       
      AIR pump
       
      Alternator
       
      Engine cover
       

    6.  

  6.  
  7. Connect the battery cable and refill the cooling system.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Intake manifold
     
    Exhaust manifolds
     
    Alternator and bracket
     
    Air pump, if equipped
     
    Air conditioning compressor and the forward mounting bracket. Do not disconnect any of the refrigerant lines.
     
    Rocker arm cover
     
    Spark plugs
     
    Air pipes at the rear of the head, if equipped
     
    Ground strap at the rear of the head
     
    Temperature sensor wire
     
    Pushrods. Identify the pushrods so that they can be installed in their original positions.
     
    Cylinder head bolts and the heads
     

  6.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.

  2.  
  3. Install or connect the following:

    New gaskets, with the word HEAD up
     
    Cylinder heads
     
    Cylinder head bolts, apply sealer to the threads, and hand-tighten.
     

  4.  
  5. Tighten the head bolts a little at a time, in the proper sequence, in 3 stages:
    1. Step 1: Torque to 30 ft. lbs. (40 Nm).
    2.  
    3. Step 2: Torque to 60 ft. lbs. (80 Nm).
    4.  
    5. Step 3: Torque to 85 ft. lbs. (115 Nm).

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-7.4L engines



      Intake and exhaust manifolds
       
      Pushrods
       
      Rocker arms
       
      Temperature sensor wire
       
      Ground strap at the rear of the head
       
      AIR pipes at the rear of the head
       
      Spark plugs
       
      Rocker arm cover
       
      Air conditioning compressor and the forward mounting bracket
       
      AIR pump
       
      Alternator
       
      Engine cover
       

    6.  

  6.  
  7. Connect the battery cable and refill the cooling system.
  8.  

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

    Negative battery cable
     
    Engine cover
     
    Intake manifold
     
    Exhaust manifolds
     
    Alternator and bracket
     
    Air pump, if equipped
     
    Air conditioning compressor and the forward mounting bracket. Do not disconnect any of the refrigerant lines.
     
    Rocker arm cover
     
    Spark plugs
     
    Air pipes at the rear of the head, if equipped
     
    Ground strap at the rear of the head
     
    Temperature sensor wire
     
    Pushrods. Identify the pushrods so that they can be installed in their original positions.
     
    Cylinder head bolts and the heads
     

  6.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.

  2.  
  3. Install or connect the following:

    Bolts, apply sealer to the threads, and hand-tighten.
     

  4.  
  5. Tighten the head bolts a little at a time in the sequence in 3 stages,
    1. Step 1: Torque the bolts to 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: Then torque the bolts to 60 ft. lbs. (80 Nm)
    4.  
    5. Step 3: Torque the bolts to 85 ft. lbs. (115 Nm)

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-7.4L engines

    6.  

  6.  
  7. Install or connect the following:

    New gaskets, with the word HEAD up
     
    Cylinder heads
     
    Intake and exhaust manifolds
     
    Pushrods
     
    Rocker arms
     
    Temperature sensor wire
     
    Ground strap at the rear of the head
     
    AIR pipes at the rear of the head
     
    Spark plugs
     
    Rocker arm cover
     
    Air conditioning compressor and the forward mounting bracket
     
    AIR pump
     
    Alternator
     
    Engine cover
     

  8.  
  9. Connect the battery cable and refill the cooling system.
  10.  

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

    Negative battery cable
     
    Engine cover
     
    Intake manifold
     
    Exhaust manifolds
     
    Alternator and bracket
     
    Air pump, if equipped
     
    Air conditioning compressor and the forward mounting bracket. Do not disconnect any of the refrigerant lines.
     
    Rocker arm cover
     
    Spark plugs
     
    Air pipes at the rear of the head, if equipped
     
    Ground strap at the rear of the head
     
    Temperature sensor wire
     
    Pushrods. Identify the pushrods so that they can be installed in their original positions.
     
    Cylinder head bolts and the heads
     

  6.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    Coat a steel gasket on both sides with sealer. If a composition gasket is used, do not use sealer.

  2.  
  3. Install or connect the following:

    Bolts, apply sealer to the threads, and hand-tighten.
     

  4.  
  5. Tighten the head bolts a little at a time in the sequence in 3 stages,
    1. Step 1: Torque the bolts to 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: Then torque the bolts to 60 ft. lbs. (80 Nm)
    4.  
    5. Step 3: Torque the bolts to 85 ft. lbs. (115 Nm)

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-7.4L engines

    6.  

  6.  
  7. Install or connect the following:

    New gaskets, with the word HEAD up
     
    Cylinder heads
     
    Intake and exhaust manifolds
     
    Pushrods
     
    Rocker arms
     
    Temperature sensor wire
     
    Ground strap at the rear of the head
     
    AIR pipes at the rear of the head
     
    Spark plugs
     
    Rocker arm cover
     
    Air conditioning compressor and the forward mounting bracket
     
    AIR pump
     
    Alternator
     
    Engine cover
     

  8.  
  9. Connect the battery cable and refill the cooling system.
  10.  

8.1L Engine
Left Side
  1. Drain the cooling system.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Water crossover
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine harness ground bolts
     

  4.  
  5. Reposition the engine harness grounds and ground straps from the cylinder head.
    NOTE
    The cylinder head bolts must be replaced for installation.



    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  6.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the No. 1 and 2 cylinder for proper installation.
  4.  
  5. Install or connect the following:
    NOTE
    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.



    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     

  6.  
  7. Tighten the head bolts, in sequence, in 4 stages, as follows:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  

  8.  
  9. Step 2: 22 ft. lbs. (30 Nm)
    1. Step 3: Additional 120 degrees using a torque angle meter.
    2.  
    3. Step 4: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees.
    4.  
    5. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-8.1L engine

    6.  

  10.  
  11. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Engine harness grounds and ground strap
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  12.  
  13. Connect the battery cable and refill the cooling system.
  14.  

  1. Drain the cooling system.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine harness ground bolts
     

  4.  
  5. Reposition the engine harness grounds and ground straps from the cylinder head.
    NOTE
    The cylinder head bolts must be replaced for installation.



    Water crossover
     
    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  6.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinders for proper installation.
  4.  
  5. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     
    Cylinder head bolts and hand-tighten
     

  6.  
  7. On 2001-04 models, tighten the head bolts a little at a time, in the proper sequence, in 3 stages:
    1. Step 1: Torque to 30 ft. lbs. (40 Nm).
    2.  
    3. Step 2: Tighten an additional 120 degrees using a torque angle meter.
    4.  
    5. Step 3: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.
    6.  

  8.  
  9. On 2005-06 models, tighten the head bolts a little at a time, in the proper sequence, in 3 stages:
    1. Tighten the bolts a first pass in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten the bolts a second pass in sequence to 22 ft. lbs. (30  Nm) then an additional 120 degrees,
    4.  
    5. Tighten the bolts (1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, 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 in sequence. Cylinder head bolt tightening sequence-8.1L engine

      Click image to see an enlarged view

      Fig.

    6.  

  10.  
  11. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Engine harness grounds and ground strap
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  12.  
  13. Connect the battery cable and refill the cooling system.
  14.  

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

    Negative battery cable
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine harness ground bolts
     

  6.  
  7. Reposition the engine harness grounds and ground straps from the cylinder head.
    NOTE
    The cylinder head bolts must be replaced for installation.



    Water crossover
     
    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  8.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinder for proper installation.
  4.  
  5. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     

  6.  
  7. Tighten the head bolts a little at a time in the sequence in 3 stages,
    1. Step 1: Torque the bolts to 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: Then tighten the bolts, in sequence, an additional 120 degrees using a torque angle meter.
    4.  
    5. Step 3: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-8.1L engine

    6.  

  8.  
  9. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Engine harness grounds and ground strap
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  10.  
  11. Connect the battery cable and refill the cooling system.
  12.  

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

    Negative battery cable
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine harness ground bolts
     

  6.  
  7. Reposition the engine harness grounds and ground straps from the cylinder head.
    NOTE
    The cylinder head bolts must be replaced for installation.



    Water crossover
     
    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  8.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinder for proper installation.
  4.  
  5. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     

  6.  
  7. Tighten the head bolts a little at a time in the sequence in 3 stages,
    1. Step 1: Torque the bolts to 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: Then tighten the bolts, in sequence, an additional 120 degrees using a torque angle meter.
    4.  
    5. Step 3: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-8.1L engine

    6.  

  8.  
  9. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Engine harness grounds and ground strap
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  10.  
  11. Connect the battery cable and refill the cooling system.
  12.  

  1. Drain the cooling system.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Water crossover
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine harness ground bolts
     

  4.  
  5. Reposition the engine harness grounds and ground straps from the cylinder head.
    NOTE
    The cylinder head bolts must be replaced for installation.



    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  6.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the No. 1 and 2 cylinder for proper installation.
  4.  
  5. Install or connect the following:
    NOTE
    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.



    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     

  6.  
  7. Tighten the head bolts, in sequence, in 4 stages, as follows:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  

  8.  
  9. Step 2: 22 ft. lbs. (30 Nm)
    1. Step 3: Additional 120 degrees using a torque angle meter.
    2.  
    3. Step 4: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees.
    4.  
    5. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-8.1L engines

    6.  

  10.  
  11. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Engine harness grounds and ground strap
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  12.  
  13. Connect the battery cable and refill the cooling system.
  14.  

  1. Drain the cooling system.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Water crossover
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine harness ground bolts
     

  4.  
  5. Reposition the engine harness grounds and ground straps from the cylinder head.
    NOTE
    The cylinder head bolts must be replaced for installation.



    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  6.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the No. 1 and 2 cylinder for proper installation.
  4.  
  5. Install or connect the following:
    NOTE
    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.



    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     

  6.  
  7. Tighten the head bolts, in sequence, in 4 stages, as follows:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  

  8.  
  9. Step 2: 22 ft. lbs. (30 Nm)
    1. Step 3: Additional 120 degrees using a torque angle meter.
    2.  
    3. Step 4: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees.
    4.  
    5. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-8.1L engines

    6.  

  10.  
  11. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Engine harness grounds and ground strap
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  12.  
  13. Connect the battery cable and refill the cooling system.
  14.  

Right Side
  1. Drain the cooling system.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The cylinder head bolts must be replaced for installation.



    Negative battery cable
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine Coolant Temperature (ECT) sensor clip from the bracket
     
    ECT sensor
     
    ECT sensor bracket bolt and bracket
     
    Heater inlet and outlet hoses from the hose bracket
     
    Water crossover
     
    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  4.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinder for proper installation.
  4.  
  5. Install or connect the following:
    NOTE
    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.



    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     

  6.  
  7. Tighten the head bolts, in sequence, in 4 stages, as follows:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  

  8.  
  9. Step 2: 22 ft. lbs. (30 Nm)
    1. Step 3: Additional 120 degrees using a torque angle meter.
    2.  
    3. Step 4: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees.
    4.  
    5. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.
    6.  

  10.  
  11. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Heater hose bracket and bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    ECT sensor bracket and bolt. Tighten to 37 ft. lbs. (50 Nm).
     
    ECT sensor
     
    ECT sensor clip
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  12.  
  13. Connect the battery cable and refill the cooling system.
  14.  

  1. Drain the cooling system.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The cylinder head bolts must be replaced for installation.



    Negative battery cable
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine Coolant Temperature (ECT) sensor clip from the bracket
     
    ECT sensor
     
    ECT sensor bracket bolt and bracket
     
    Heater inlet and outlet hoses from the hose bracket
     
    Oil level indicator tube
     
    Water crossover
     
    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  4.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinders for proper installation.
  4.  
  5. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     
    Cylinder head bolts and hand-tighten
     

  6.  
  7. On 2002-04 models, tighten the head bolts a little at a time, in the proper sequence, in 3 stages:
    1. Step 1: Torque to 30 ft. lbs. (40 Nm).
    2.  
    3. Step 2: Tighten an additional 120 degrees using a torque angle meter.
    4.  
    5. Step 3: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.
    6.  

  8.  
  9. On 2005-06 models, tighten the head bolts a little at a time, in the proper sequence, in 3 stages:
    1. Tighten the bolts a first pass in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten the bolts a second pass in sequence to 22 ft. lbs. (30  Nm) then an additional 120 degrees,
    4.  
    5. Tighten the bolts (1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16, 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 in sequence.
    6.  

  10.  
  11. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Oil level indicator tube
     
    Heater hose bracket and bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    ECT sensor bracket and bolt. Tighten to 37 ft. lbs. (50 Nm).
     
    ECT sensor
     
    ECT sensor clip
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  12.  
  13. Connect the battery cable and refill the cooling system.
  14.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The cylinder head bolts must be replaced for installation.



    Negative battery cable
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine Coolant Temperature (ECT) sensor clip from the bracket
     
    ECT sensor
     
    ECT sensor bracket bolt and bracket
     
    Heater inlet and outlet hoses from the hose bracket
     
    Water crossover
     
    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  6.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinder for proper installation.
  4.  
  5. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     

  6.  
  7. Tighten the head bolts a little at a time in the sequence in 3 stages,
    1. Step 1: Torque the bolts to 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: Then tighten the bolts, in sequence, an additional 120 degrees using a torque angle meter.
    4.  
    5. Step 3: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.
    6.  

  8.  
  9. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Heater hose bracket and bolts. Tighten the bolts to 37 ft. lbs. (50 Nm)
     
    ECT sensor bracket and bolt. Tighten to 37 ft. lbs. (50 Nm)
     
    ECT sensor
     
    ECT sensor clip
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  10.  
  11. Connect the battery cable and refill the cooling system.
  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The cylinder head bolts must be replaced for installation.



    Negative battery cable
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine Coolant Temperature (ECT) sensor clip from the bracket
     
    ECT sensor
     
    ECT sensor bracket bolt and bracket
     
    Heater inlet and outlet hoses from the hose bracket
     
    Water crossover
     
    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  6.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinder for proper installation.
  4.  
  5. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     

  6.  
  7. Tighten the head bolts a little at a time in the sequence in 3 stages,
    1. Step 1: Torque the bolts to 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: Then tighten the bolts, in sequence, an additional 120 degrees using a torque angle meter.
    4.  
    5. Step 3: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.
    6.  

  8.  
  9. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Heater hose bracket and bolts. Tighten the bolts to 37 ft. lbs. (50 Nm)
     
    ECT sensor bracket and bolt. Tighten to 37 ft. lbs. (50 Nm)
     
    ECT sensor
     
    ECT sensor clip
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  10.  
  11. Connect the battery cable and refill the cooling system.
  12.  

  1. Drain the cooling system.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The cylinder head bolts must be replaced for installation.



    Negative battery cable
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine Coolant Temperature (ECT) sensor clip from the bracket
     
    ECT sensor
     
    ECT sensor bracket bolt and bracket
     
    Heater inlet and outlet hoses from the hose bracket
     
    Water crossover
     
    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  4.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinder for proper installation.
  4.  
  5. Install or connect the following:
    NOTE
    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.



    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     

  6.  
  7. Tighten the head bolts, in sequence, in 4 stages, as follows:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  

  8.  
  9. Step 2: 22 ft. lbs. (30 Nm)
    1. Step 3: Additional 120 degrees using a torque angle meter.
    2.  
    3. Step 4: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees.
    4.  
    5. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-8.1L engines

    6.  

  10.  
  11. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Heater hose bracket and bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    ECT sensor bracket and bolt. Tighten to 37 ft. lbs. (50 Nm).
     
    ECT sensor
     
    ECT sensor clip
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  12.  
  13. Connect the battery cable and refill the cooling system.
  14.  

  1. Drain the cooling system.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The cylinder head bolts must be replaced for installation.



    Negative battery cable
     
    Intake manifold
     
    Valve cover
     
    Rocker arms and pushrods, keeping them in order for installation
     
    Engine Coolant Temperature (ECT) sensor clip from the bracket
     
    ECT sensor
     
    ECT sensor bracket bolt and bracket
     
    Heater inlet and outlet hoses from the hose bracket
     
    Water crossover
     
    Exhaust manifold
     
    Cylinder head bolts, then discard
     



    Cylinder head. Place the head on 2 wood blocks to protect the sealing surfaces while it is removed.
     

  4.  

To install:


NOTE
The cylinder head should be cleaned and inspected for warpage or damage before installation.

  1. Thoroughly clean the mating surfaces of the head and block. Clean the bolt holes thoroughly.
    NOTE
    If a composition gasket is used, do not use sealer.

  2.  
  3. Align the cylinder head gasket locating marks to face up. Make sure that the gasket tabs are located of the no. 1 and 2 cylinder for proper installation.
  4.  
  5. Install or connect the following:
    NOTE
    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.



    New cylinder head gasket
     
    Cylinder head
     
    Sealer to the threads of new cylinder head bolts, if not pre-applied
     

  6.  
  7. Tighten the head bolts, in sequence, in 4 stages, as follows:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  

  8.  
  9. Step 2: 22 ft. lbs. (30 Nm)
    1. Step 3: Additional 120 degrees using a torque angle meter.
    2.  
    3. Step 4: Torque bolt numbers. 1, 2, 3, 6, 7, 8, 9, 10, 11, 14, 16 and 17 an additional 60 degrees.
    4.  
    5. Tighten bolts 15 and 18 an additional 45 degrees, and bolt numbers 4, 5, 12 and 13 an additional 30 degrees.
    6.  

  10.  
  11. Install or connect the following:

    Exhaust manifold
     
    Water crossover
     
    Heater hose bracket and bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    ECT sensor bracket and bolt. Tighten to 37 ft. lbs. (50 Nm).
     
    ECT sensor
     
    ECT sensor clip
     
    Rocker arms and pushrods
     
    Valve cover
     
    Intake manifold
     

  12.  
  13. Connect the battery cable and refill the cooling system.
  14.  

 
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