Aztek, Rendezvous 2001-2005

Cylinder Head

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Removal & Installation



3.4L & 3.5L Engines
Left (Front) Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the oil.
  8.  
  9. Remove or disconnect the following:

    Remove the engine mount struts
     
    Negative battery cable
     
    Upper intake manifold
     
    Lower intake manifold
     
    Valve cover
     
    Valve rocker arms and pushrods
     
    Exhaust crossover pipe
     
    Thermostat bypass pipe
     
    Engine mount strut and bracket
     
    Oil level indicator tube
     
    Left side spark plug wires and spark plugs
     
    Left side exhaust manifold
     
    Left side cylinder head bolts
     
    Left side cylinder head and gasket
     

  10.  

To install:

  1. Clean all parts well. Clean all gasket surfaces. Carefully remove all varnish soot and carbon to the bare metal. DO NOT use a motorized wire brush on any gasket surface since the soft aluminum will be damaged. If necessary, the head can be disassembled for thorough inspection and reconditioning.
  2.  
  3. Inspect the cylinder head for cracks. Do not attempt to weld the cylinder head. If cracked, replace it. Check the cylinder head deck, intake and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by milling. If the surfaces are warped more than 0.005 in. (0.127mm), the surface should be milled. If more than 0.010 in. (0.251mm) of metal must be removed from the head, the head should be replaced.
  4.  
  5. Clean the cylinder bolt holes. New replacement head bolts are recommended.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-3.4L and 3.5L Engines

  6.  
  7. Install or connect the following:
    NOTE
    Coat the bearing surface of the rocker arms, pushrods and rocker arm bolts with a prelube (such as GM 1052365). Make certain to install the components in their original position.



    New cylinder head gasket which is marked which side is UP
     
    Cylinder head by aligning it with the dowel pins
     
    New cylinder head bolts coated with a sealant (such as GM 1052080). Torque the bolts in the proper sequence (1-8) to 44 ft. lbs. (60 Nm) for -05. Using a torque angle meter turn the bolts 95 degrees for -05, in the proper sequence.
     
    Left side exhaust manifold. Torque the bolts to 12 ft. lbs. (16 Nm).
     
    Spark plugs. Torque the plugs 11 ft. lbs. (15 Nm).
     
    Spark plug wires
     
    Oil level indicator tube. Torque the fastener to 18 ft. lbs. (25 Nm).
     
    Thermostat bypass pipe. Torque it to 18 ft. lbs. (25 Nm).
     
    Exhaust crossover pipe. Torque the fastener to 18 ft. lbs. (25 Nm).
     



    3.4L intake valve pushrods are 5.75 inches (146.00mm) long
     
    3.5L intake valve pushrods are 5.67 inches (144.2mm) long
     
    Exhaust valve pushrods are 6.0 inches (152.51mm) long
     
    Rocker arms. Torque bolts to 24 ft. lbs. (32 Nm).
     
    Valve cover. Torque the fastener to 89 inch lbs. (10 Nm)
     
    Lower intake manifold. Torque the bolts to 115 inch lbs. (13 Nm).
     
    Upper intake manifold. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Engine mount strut and bracket. Torque the fastener to 37 ft. lbs. (50 Nm).
     
    Negative battery cable
     

  8.  
  9. Refill the coolant system.
  10.  
  11. Change the oil filter and fill the engine with clean oil.
  12.  
  13. Turn the ignition to the ON position several times to pressurize the fuel system. Start the engine and inspect for any leaks, repair if necessary. Check and top off the fluid levels if required.
  14.  

Right (Rear) Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Drain the coolant system.
  6.  
  7. Drain the oil from the engine.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Upper intake manifold
     
    Lower intake manifold
     
    Valve rocker arms and pushrods
     
    Exhaust crossover pipe
     
    Engine mount strut and bracket
     
    Right side spark plug wires
     
    Right side exhaust manifold
     
    Right side cylinder head and gasket
     
    Right side spark plugs from the cylinder head
     

  10.  

To install:

  1. Clean all parts well. Clean all gasket surfaces. Carefully remove all varnish soot and carbon to the bare metal. DO NOT use a motorized wire brush on any gasket surface since the soft aluminum will be damaged. If necessary, the head can be disassembled for thorough inspection and reconditioning.
  2.  
  3. Inspect the cylinder head for cracks. Do not attempt to weld the cylinder head. If cracked, replace it. Check the cylinder head deck, intake and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by milling. If the surfaces are "out of flat" by more than 0.005 inch, the surface should be milled. If more than 0.010 inch of metal must be removed from the head, the head should be replaced.
  4.  
  5. Clean the cylinder head bolts and the bolt holes. Check the head bolts for damaged threads or stretching. New replacement head bolts are recommended.
  6.  
  7. Install or connect the following:
    NOTE
    Coat the bearing surface of the rocker arms, pushrods and rocker arm bolts with a prelube (such as GM 1052365). Make certain to install the components in their original position.



    New cylinder head gasket
     
    Cylinder head on top of the gasket and make certain it is lined up properly with the dowel pins
     
    New cylinder head bolts coated with a sealant (such as GM 1052080). Torque the bolts in the proper sequence (1-8) to 37 ft. lbs. (50 Nm). Using a torque angle meter turn the bolts 90 degrees in the proper sequence.
     
    Right side exhaust manifold. Torque the bolts to 12 ft. lbs. (16 Nm).
     
    Spark plugs. Torque the plugs 11 ft. lbs. (15 Nm).
     
    Spark plug wires
     
    Exhaust crossover pipe. Torque the fastener to 18 ft. lbs. (25 Nm).
     



    3.4L intake valve pushrods are 5.75 inches (146.00mm) long
     
    3.5L intake valve pushrods are 5.67 inches (144.2mm) long
     
    Exhaust valve pushrods are 6.0 inches (152.51mm) long
     
    Rocker arms. Torque bolts to 24 ft. lbs. (32 Nm).
     
    Valve cover. Torque the fastener to 89 inch lbs. (10 Nm)
     
    Lower intake manifold. Torque the bolts to 115 inch lbs. (13 Nm).
     
    Upper intake manifold. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Mount strut bracket. Torque the fastener to 37 ft. lbs. (50 Nm).
     
    Engine mount strut and bracket. Torque the fastener to 37 ft. lbs. (50 Nm).
     
    Negative battery cable
     

  8.  
  9. Refill the coolant system.
  10.  
  11. Change the oil filter and fill the engine with clean oil.
  12.  
  13. Start the vehicle and verify no leaks, abnormal noises and correct engine operation.
  14.  
  15. Check the fluid levels and top off if necessary.
  16.  

3.4L Engine

This engine uses aluminum cylinder heads. Use care when working with light alloy parts. Valve guides are pressed in. Roller rocker arms are located on a pedestal in a slot in the cylinder head and are retained on individual threaded bolts.

The cylinder heads are retained by torque-to-yield bolts. A torque angle meter is required for proper torque during assembly. New replacement head bolts are recommended.

Before removing the cylinder head(s) from the engine and before disassembling the valve mechanism, perform a compression test and note the results. During disassembly, be sure that the valvetrain components are kept together and identified so that they can be installed in their original locations.

Left (Front) Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Upper intake manifold
     
    Lower intake manifold
     
    Valve rocker arms and pushrods
     
    Exhaust crossover pipe
     
    Thermostat bypass pipe
     
    Right side engine mount strut bracket
     
    Oil level indicator tube
     
    Left side spark plug wires and spark plugs
     
    Left side exhaust manifold
     
    Left side cylinder head and gasket
     

  10.  

To install:

  1. Clean all parts well. Clean all gasket surfaces. Carefully remove all varnish soot and carbon to the bare metal. DO NOT use a motorized wire brush on any gasket surface since the soft aluminum will be damaged. If necessary, the head can be disassembled for thorough inspection and reconditioning.
  2.  
  3. Inspect the cylinder head for cracks. Do not attempt to weld the cylinder head. If cracked, replace it. Check the cylinder head deck, intake and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by milling. If the surfaces are warped more than 0.005 in. (0.127mm), the surface should be milled. If more than 0.010 in. (0.251mm) of metal must be removed from the head, the head should be replaced.
  4.  
  5. Clean the cylinder head bolts and the bolt holes. Check the head bolts for damaged threads or stretching. New replacement head bolts are recommended.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-3.4L engine

  6.  
  7. Install or connect the following:

    New cylinder head gasket which is marked which side is UP
     
    Cylinder head by aligning it with the dowel pins
     
    New cylinder head bolts coated with a sealant (such as GM 1052080). Torque the bolts in the proper sequence (1-8) to 37 ft. lbs. (50 Nm) for 2001-03; 44 ft. lbs. (60 Nm) for 2004-05. Using a torque angle meter turn the bolts 90 degrees for 2001-03; 95 degrees for 2004-05, in the proper sequence.
     
    Left side exhaust manifold. Torque the bolts to 12 ft. lbs. (16 Nm).
     
    Spark plugs. Torque the plugs 11 ft. lbs. (15 Nm).
     
    Spark plug wires
     
    Oil level indicator tube. Torque the fastener to 18 ft. lbs. (25 Nm).
     
    Right side mount strut bracket. Torque the fastener to 37 ft. lbs. (50 Nm).
     
    Thermostat bypass pipe. Torque it to 18 ft. lbs. (25 Nm).
     
    Exhaust crossover pipe. Torque the fastener to 18 ft. lbs. (25 Nm).
     
    Valve rocker arms and pushrods. Torque the fastener to 89 inch lbs. (10 Nm). Using a torque angle meter torque the fastener an additional 30 degrees.
     
    Lower intake manifold. Torque the bolts to 115 inch lbs. (13 Nm).
     
    Upper intake manifold. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Negative battery cable
     

  8.  
  9. Refill the coolant system.
  10.  
  11. Change the oil filter and fill the engine with clean oil.
  12.  
  13. Turn the ignition to the ON position several times to pressurize the fuel system. Start the engine and inspect for any leaks, repair if necessary. Check and top off the fluid levels if required.
  14.  

Right (Rear) Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Drain the coolant system.
  6.  
  7. Drain the oil from the engine.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Upper intake manifold
     
    Lower intake manifold
     
    Valve rocker arms and pushrods
     
    Exhaust crossover pipe
     
    Right side spark plug wires
     
    Right side exhaust manifold
     
    Right side cylinder head and gasket
     
    Right side spark plugs from the cylinder head
     

  10.  

To install:

  1. Clean all parts well. Clean all gasket surfaces. Carefully remove all varnish soot and carbon to the bare metal. DO NOT use a motorized wire brush on any gasket surface since the soft aluminum will be damaged. If necessary, the head can be disassembled for thorough inspection and reconditioning.
  2.  
  3. Inspect the cylinder head for cracks. Do not attempt to weld the cylinder head. If cracked, replace it. Check the cylinder head deck, intake and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by milling. If the surfaces are "out of flat" by more than 0.005 inch, the surface should be milled. If more than 0.010 inch of metal must be removed from the head, the head should be replaced.
  4.  
  5. Clean the cylinder head bolts and the bolt holes. Check the head bolts for damaged threads or stretching. New replacement head bolts are recommended.
  6.  
  7. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head on top of the gasket and make certain it is lined up properly with the dowel pins
     
    New cylinder head bolts coated with a sealant (such as GM 1052080). Torque the bolts in the proper sequence (1-8) to 37 ft. lbs. (50 Nm). Using a torque angle meter turn the bolts 90 degrees in the proper sequence.
     
    Right side exhaust manifold. Torque the bolts to 12 ft. lbs. (16 Nm).
     
    Spark plugs. Torque the plugs 11 ft. lbs. (15 Nm).
     
    Spark plug wires
     
    Exhaust crossover pipe. Torque the fastener to 18 ft. lbs. (25 Nm).
     
    Valve rocker arms and pushrods. Torque the fastener to 89 inch lbs. (10 Nm). Using a torque angle meter torque the fastener an additional 30 degrees.
     
    Lower intake manifold. Torque the bolts to 115 inch lbs. (13 Nm).
     
    Upper intake manifold. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Negative battery cable
     

  8.  
  9. Refill the coolant system.
  10.  
  11. Change the oil filter and fill the engine with clean oil.
  12.  
  13. Start the vehicle and verify no leaks, abnormal noises and correct engine operation.
  14.  
  15. Check the fluid levels and top off if necessary.
  16.  

3.6L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the upper and lower intake manifolds.
  4.  
  5. Remove the camshafts.
  6.  
  7. Remove the exhaust manifold.
  8.  
  9. Remove the two front M8 left cylinder head bolts.
  10.  
  11. Remove the left cylinder head bolts.
  12.  
  13. Remove the left cylinder head.
  14.  
  15. Remove and discard the left cylinder head gasket.
  16.  

To install:


WARNING
Ensure that the crankshaft is in the stage one timing drive assembly position using the EN 46111.



Click image to see an enlarged view

Fig. Cylinder head locating pins-3.6L engine

  1. Ensure the cylinder head locating pins are securely mounted in the cylinder block deck face.
  2.  
  3. Install a NEW left cylinder head gasket using the deck face locating pins for retention.
  4.  
  5. Align the left cylinder head with the deck face locating pins. Place the left cylinder head in position on the deck face.
    NOTE
    DO NOT allow oil on the cylinder head bolt bosses. DO NOT reuse the old M11 cylinder head bolts.



    Click image to see an enlarged view

    Fig. Left cylinder head bolt torque sequence-3.6L engine

  6.  
  7. Install new M11 cylinder head bolts.
    1. Tighten the M11 cylinder head bolts a first pass in sequence to 33 ft. lbs. (45 Nm).
    2.  
    3. Tighten the M11 cylinder head bolts a second pass in sequence an additional 120 degrees.
    4.  

  8.  
  9. Install the 2 front M8 left cylinder head bolts.
    1. Tighten the M8 cylinder head bolts a first pass to 11 ft. lbs. (15 Nm).
    2.  
    3. Tighten the M8 cylinder head bolts a second pass in sequence an additional 60 degrees.
    4.  

  10.  
  11. The remainder of installation is the reverse of removal.
  12.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the upper and lower intake manifolds.
  4.  
  5. Remove the camshafts.
  6.  
  7. Remove the exhaust manifold.
  8.  
  9. Remove the right cylinder head bolts.
  10.  
  11. Remove the right cylinder head.
  12.  
  13. Remove and discard the right cylinder head gasket.
  14.  

To install:

Click image to see an enlarged view

Fig. Right side cylinder head bolt torque sequence-3.6L engine


NOTE
Ensure that the crankshaft is in the timing drive assembly position using the EN 46111.

  1. Ensure the cylinder head locating pins are securely mounted in the cylinder block deck face.
  2.  
  3. Install a NEW right cylinder head gasket using the deck face locating pins for retention.
  4.  
  5. Align the right cylinder head with the deck face locating pins.
  6.  
  7. Place the right cylinder head in position on the deck face.
    NOTE
    DO NOT allow oil on the cylinder head bolt bosses. DO NOT reuse the old M11 cylinder head bolts.

  8.  
  9. Install new M11 cylinder head bolts.
    1. Tighten the M11 cylinder head bolts a first pass in sequence to 33 ft. lbs. (45 Nm).
    2.  
    3. Tighten the M11 cylinder head bolts a second pass in sequence an additional 120 degrees using the J 45059.
    4.  

  10.  
  11. The remainder of installation is the reverse of removal.
  12.  

 
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