Century, Grand Prix, Impala, Intrigue, Lumina, Monte Carlo, Regal 2001-2005

Cylinder Head

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Removal & Installation



3.1L & 3.4L Engines
Left (Front) Cylinder Head
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Upper half of the air cleaner
     
    Throttle body air inlet duct
     
    Upper intake manifold
     
    Spark plug wires from the spark plugs
     
    Rocker arm covers
     
    Lower intake manifold
     
    Rocker arm bolt, rocker arms, balls and pushrods
     
    Exhaust crossover pipe
     
    Engine mount strut bracket from the cylinder head
     
    Left side exhaust manifold
     
    Oil level indicator tube
     
    Cylinder head bolts evenly
     
    Cylinder head and discard the gasket
     

  10.  

To install:

Click image to see an enlarged view

Fig. Tighten the cylinder head bolts using the following sequence-31L and 3.4L engines

  1. Install the cylinder head with a new gasket.
  2.  
  3. Apply thread sealer to the head bolts.
  4.  
  5. Tighten the cylinder head bolts to 37 ft. lbs. (50 Nm) plus an additional 90 degree turn.
  6.  
  7. Install or connect the following:

    Left side exhaust manifold and torque the nuts to 12 ft. lbs. (16 Nm)
     
    Oil level indicator tube
     
    Engine mount strut bracket and torque the bolts to 52 ft. lbs. (70 Nm)
     
    Exhaust crossover pipe and torque the nuts to 18 ft. lbs. (25 Nm)
     
    Exhaust crossover pipe heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Pushrods, rocker arms, balls and bolts and tighten the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn
     
    Lower intake manifold and torque the bolts to 115 inch lbs. (13 Nm)
     
    Upper intake plenum and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Spark the plug wires
     
    Upper half of the air cleaner assembly
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Refill the engine with clean oil.
    NOTE
    A filter change is also recommended.

  12.  
  13. Start the engine and check for leaks, repair if necessary.
  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 engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Upper half of the air cleaner
     
    Throttle body air inlet duct
     
    Upper intake manifold
     
    Spark plug wires from the spark plugs
     
    Rocker arm covers
     
    Lower intake manifold
     
    Rocker arm bolt, rocker arms, balls and pushrods
     
    Exhaust crossover pipe
     
    Engine mount strut bracket from the cylinder head
     
    Left side exhaust manifold
     
    Oil level indicator tube
     
    Cylinder head bolts evenly
     
    Cylinder head and discard the gasket
     

  10.  

To install:

Click image to see an enlarged view

Fig. Tighten the cylinder head bolts using the following sequence-31L and 3.4L engines

  1. Install the cylinder head with a new gasket.
  2.  
  3. Apply thread sealer to the head bolts.
  4.  
  5. Tighten the cylinder head bolts to 37 ft. lbs. (50 Nm) plus an additional 90 degree turn.
  6.  
  7. Install or connect the following:

    Left side exhaust manifold and torque the nuts to 12 ft. lbs. (16 Nm)
     
    Oil level indicator tube
     
    Engine mount strut bracket and torque the bolts to 52 ft. lbs. (70 Nm)
     
    Exhaust crossover pipe and torque the nuts to 18 ft. lbs. (25 Nm)
     
    Exhaust crossover pipe heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Pushrods, rocker arms, balls and bolts and tighten the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn
     
    Lower intake manifold and torque the bolts to 115 inch lbs. (13 Nm)
     
    Upper intake plenum and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Spark the plug wires
     
    Upper half of the air cleaner assembly
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Refill the engine with clean oil.
    NOTE
    A filter change is also recommended.

  12.  
  13. Start the engine and check for leaks, repair if necessary.
  14.  

Right (Rear) Cylinder Head
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Upper half of the air cleaner
     
    Throttle body air inlet duct
     
    Upper intake plenum
     
    Lower intake manifold
     
    Spark plug wires from the spark plugs
     
    Rocker arm covers
     
    Exhaust crossover pipe heat shield
     
    Crossover pipe
     
    Right side exhaust manifold
     
    Fuel line bracket
     
    Alternator and bracket
     
    Rocker arms bolt, rocker arms, balls and pushrods
     
    Cylinder head bolts evenly
     
    Cylinder head
     

  10.  

To install:

  1. Install the cylinder head with a new gasket.
  2.  
  3. Apply thread sealer to the head bolts.
  4.  
  5. Tighten the cylinder head bolts to 37 ft. lbs. (50 Nm) plus an additional 90 degree turn.
  6.  
  7. Install or connect the following:

    Pushrods, rocker arms, balls and rocker arm bolts and tighten the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degrees
     
    Exhaust manifold and torque the nuts to 12 ft. lbs. (16 Nm)
     
    Alternator bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Spark plug wires
     
    Exhaust crossover pipe and torque the nuts to 18 ft. lbs. (25 Nm)
     
    Exhaust crossover pipe heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Pushrods, rocker arms, balls and bolts and tighten the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn
     
    Lower intake manifold and torque the bolts to 115 inch lbs. (13 Nm)
     
    Upper intake plenum and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Upper half of the air cleaner assembly
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Refill the engine with clean oil.
    NOTE
    An oil filter change is recommended.

  12.  
  13. Start the engine and check for leaks, repair if necessary.
  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 engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Upper half of the air cleaner
     
    Throttle body air inlet duct
     
    Upper intake plenum
     
    Lower intake manifold
     
    Spark plug wires from the spark plugs
     
    Rocker arm covers
     
    Exhaust crossover pipe heat shield
     
    Crossover pipe
     
    Right side exhaust manifold
     
    Fuel line bracket
     
    Alternator and bracket
     
    Rocker arms bolt, rocker arms, balls and pushrods
     
    Cylinder head bolts evenly
     
    Cylinder head
     

  10.  

To install:

  1. Install the cylinder head with a new gasket.
  2.  
  3. Apply thread sealer to the head bolts.
  4.  
  5. Tighten the cylinder head bolts to 37 ft. lbs. (50 Nm) plus an additional 90 degree turn.
  6.  
  7. Install or connect the following:

    Pushrods, rocker arms, balls and rocker arm bolts and tighten the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degrees
     
    Exhaust manifold and torque the nuts to 12 ft. lbs. (16 Nm)
     
    Alternator bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Spark plug wires
     
    Exhaust crossover pipe and torque the nuts to 18 ft. lbs. (25 Nm)
     
    Exhaust crossover pipe heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Pushrods, rocker arms, balls and bolts and tighten the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn
     
    Lower intake manifold and torque the bolts to 115 inch lbs. (13 Nm)
     
    Upper intake plenum and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Upper half of the air cleaner assembly
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Refill the engine with clean oil.
    NOTE
    An oil filter change is recommended.

  12.  
  13. Start the engine and check for leaks, repair if necessary.
  14.  

3.4L Engine
Left (Front) Cylinder Head
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Upper half of the air cleaner
     
    Throttle body air inlet duct
     
    Upper intake manifold
     
    Spark plug wires from the spark plugs
     
    Rocker arm covers
     
    Lower intake manifold
     
    Rocker arm bolt, rocker arms, balls and pushrods
     
    Exhaust crossover pipe
     
    Engine mount strut bracket from the cylinder head
     
    Left side exhaust manifold
     
    Oil level indicator tube
     
    Cylinder head bolts evenly
     
    Cylinder head and discard the gasket
     

  10.  

To install:

Click image to see an enlarged view

Fig. Tighten the cylinder head bolts using the following sequence-31L and 3.4L engines

  1. Install the cylinder head with a new gasket.
  2.  
  3. Apply thread sealer to the head bolts.
  4.  
  5. Tighten the cylinder head bolts to 37 ft. lbs. (50 Nm) plus an additional 90 degree turn.
  6.  
  7. Install or connect the following:

    Left side exhaust manifold and torque the nuts to 12 ft. lbs. (16 Nm)
     
    Oil level indicator tube
     
    Engine mount strut bracket and torque the bolts to 52 ft. lbs. (70 Nm)
     
    Exhaust crossover pipe and torque the nuts to 18 ft. lbs. (25 Nm)
     
    Exhaust crossover pipe heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Pushrods, rocker arms, balls and bolts and tighten the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn
     
    Lower intake manifold and torque the bolts to 115 inch lbs. (13 Nm)
     
    Upper intake plenum and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Spark the plug wires
     
    Upper half of the air cleaner assembly
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Refill the engine with clean oil.
    NOTE
    A filter change is also recommended.

  12.  
  13. Start the engine and check for leaks, repair if necessary.
  14.  

Right (Rear) Cylinder Head
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Upper half of the air cleaner
     
    Throttle body air inlet duct
     
    Upper intake plenum
     
    Lower intake manifold
     
    Spark plug wires from the spark plugs
     
    Rocker arm covers
     
    Exhaust crossover pipe heat shield
     
    Crossover pipe
     
    Right side exhaust manifold
     
    Fuel line bracket
     
    Alternator and bracket
     
    Rocker arms bolt, rocker arms, balls and pushrods
     
    Cylinder head bolts evenly
     
    Cylinder head
     

  10.  

To install:

  1. Install the cylinder head with a new gasket.
  2.  
  3. Apply thread sealer to the head bolts.
  4.  
  5. Tighten the cylinder head bolts to 37 ft. lbs. (50 Nm) plus an additional 90 degree turn.
  6.  
  7. Install or connect the following:

    Pushrods, rocker arms, balls and rocker arm bolts and tighten the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degrees
     
    Exhaust manifold and torque the nuts to 12 ft. lbs. (16 Nm)
     
    Alternator bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Spark plug wires
     
    Exhaust crossover pipe and torque the nuts to 18 ft. lbs. (25 Nm)
     
    Exhaust crossover pipe heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Pushrods, rocker arms, balls and bolts and tighten the bolts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn
     
    Lower intake manifold and torque the bolts to 115 inch lbs. (13 Nm)
     
    Upper intake plenum and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Upper half of the air cleaner assembly
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Refill the engine with clean oil.
    NOTE
    An oil filter change is recommended.

  12.  
  13. Start the engine and check for leaks, repair if necessary.
  14.  

3.5L & 3.9L Engine
Front
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Water outlet housing
     
    Engine mount strut bracket
     
    Coolant crossover pipe
     
    Front exhaust manifold
     
    Camshaft cover
     

  8.  
  9. Install a holding tool on the camshafts to hold them in position.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Be sure to keep the arms and lifters in order so they can be installed the their original locations.



    Camshaft primary chain
     
    Camshafts from the front cylinder head
     
    Rocker arms and valve lifters
     



    M6 bolts from the front of the cylinder head
     
    M11 cylinder head bolts and discard
     
    Cylinder head
     

  12.  

To install:

Click image to see an enlarged view

Fig. Front cylinder head bolt torque sequence-3.5L engine

  1. Be sure the dowels are securely mounted in the engine block.
  2.  
  3. Install or connect the following:

    New gasket
     
    Cylinder head
     
    New M11 bolts
     
    M6 bolts in the front of the cylinder head
     

  4.  
  5. Torque the M11 bolts in sequence to:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  
    3. Step 2: 100 degree turn.
    4.  
    5. Step 3: 100 degree turn.
    6.  

  6.  
  7. Torque the long M6 bolt to 106 inch lbs. (12 Nm).
  8.  
  9. Torque both shorter M6 bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Install or connect the following:

    Lifters and rocker arms in their original positions
     
    Camshafts and torque the bearing cap bolts to 71 inch lbs. (8 Nm) plus an additional 22 degree turn
     
    Primary camshaft drive chain
     
    Camshaft cover and torque the bolts to 80 inch lbs. (9 Nm)
     
    Exhaust manifold and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Coolant crossover pipe and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Engine mount strut bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Water outlet housing and torque the bolts to 80 inch lbs. (9 Nm)
     
    Intake manifold and torque the bolts to 62 inch lbs. (7 Nm)
     
    New oil filter
     
    Negative battery cable
     

  12.  
  13. Refill the engine with clean oil.
  14.  
  15. Refill the cooling system.
  16.  
  17. Start the engine and check for leaks, repair if necessary.

    Click image to see an enlarged view

    Fig. Camshaft holding fixture J-42038-3.5L engine

  18.  

Rear
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do not remove the rear exhaust manifold. Detach it from the cylinder head and the connection from the front manifold; then, move it aside.



    Negative battery cable
     
    Intake manifold
     



    Exhaust manifold
     
    Coolant crossover pipe
     
    Camshaft cover
     

  8.  
  9. Install a holding tool on the camshafts to hold them in position.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Keep the valve train parts in order so they can be installed in their original positions.



    Primary camshaft drive chain
     
    Camshafts
     
    Rocker arms and valve lifters
     



    Engine Coolant Temperature (ECT) sensor from the cylinder head
     
    M6 bolts from the front of the cylinder head, note the location of the longer bolt
     
    M11 cylinder head bolts and discard the bolts
     
    Cylinder head
     

  12.  

To install:

Click image to see an enlarged view

Fig. Rear cylinder head bolt torque sequence-3.5L engine

  1. Be sure the dowels are securely mounted in the engine block.
  2.  
  3. Install or connect the following:

    New gasket
     
    Cylinder head
     
    New M11 bolts
     
    M6 bolts in the front of the cylinder head
     

  4.  
  5. Torque the M11 bolts in sequence to:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  
    3. Step 2: 100 degree turn.
    4.  
    5. Step 3: 100 degree turn.
    6.  

  6.  
  7. Torque the long M6 bolt to 106 inch lbs. (12 Nm).
  8.  
  9. Torque both shorter M6 bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Install or connect the following:

    ECT sensor and torque the fastener to 15 ft. lbs. (20 Nm)
     
    Lifters and rocker arms in their original positions
     
    Camshafts and torque the bearing cap bolts to 71 inch lbs. (8 Nm) plus an additional 22 degree turn
     
    Primary camshaft drive chain
     
    Camshaft cover and torque the bolts to 80 inch lbs. (9 Nm)
     
    Coolant crossover pipe and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Exhaust manifold and torque the bolts to18 ft. lbs. (25 Nm)
     
    Intake manifold and torque the bolts to 62 inch lbs. (7 Nm)
     
    New oil filter
     
    Negative battery cable
     

  12.  
  13. Refill the engine with clean oil.
  14.  
  15. Refill the cooling system.
  16.  
  17. Start the engine and check for leaks, repair if necessary.
  18.  

3.5L Engine
Front
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Water outlet housing
     
    Engine mount strut bracket
     
    Coolant crossover pipe
     
    Front exhaust manifold
     
    Camshaft cover
     

  8.  
  9. Install a holding tool on the camshafts to hold them in position.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Be sure to keep the arms and lifters in order so they can be installed the their original locations.



    Camshaft primary chain
     
    Camshafts from the front cylinder head
     
    Rocker arms and valve lifters
     



    M6 bolts from the front of the cylinder head
     
    M11 cylinder head bolts and discard
     
    Cylinder head
     

  12.  

To install:

Click image to see an enlarged view

Fig. Front cylinder head bolt torque sequence-3.5L engine

  1. Be sure the dowels are securely mounted in the engine block.
  2.  
  3. Install or connect the following:

    New gasket
     
    Cylinder head
     
    New M11 bolts
     
    M6 bolts in the front of the cylinder head
     

  4.  
  5. Torque the M11 bolts in sequence to:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  
    3. Step 2: 100 degree turn.
    4.  
    5. Step 3: 100 degree turn.
    6.  

  6.  
  7. Torque the long M6 bolt to 106 inch lbs. (12 Nm).
  8.  
  9. Torque both shorter M6 bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Install or connect the following:

    Lifters and rocker arms in their original positions
     
    Camshafts and torque the bearing cap bolts to 71 inch lbs. (8 Nm) plus an additional 22 degree turn
     
    Primary camshaft drive chain
     
    Camshaft cover and torque the bolts to 80 inch lbs. (9 Nm)
     
    Exhaust manifold and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Coolant crossover pipe and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Engine mount strut bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Water outlet housing and torque the bolts to 80 inch lbs. (9 Nm)
     
    Intake manifold and torque the bolts to 62 inch lbs. (7 Nm)
     
    New oil filter
     
    Negative battery cable
     

  12.  
  13. Refill the engine with clean oil.
  14.  
  15. Refill the cooling system.
  16.  
  17. Start the engine and check for leaks, repair if necessary.

    Click image to see an enlarged view

    Fig. Camshaft holding fixture J-42038-3.5L engine

  18.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Water outlet housing
     
    Engine mount strut bracket
     
    Coolant crossover pipe
     
    Front exhaust manifold
     
    Camshaft cover
     

  8.  
  9. Install a holding tool on the camshafts to hold them in position.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Be sure to keep the arms and lifters in order so they can be installed the their original locations.



    Camshaft primary chain
     
    Camshafts from the front cylinder head
     
    Rocker arms and valve lifters
     



    M6 bolts from the front of the cylinder head
     
    M11 cylinder head bolts and discard
     
    Cylinder head
     

  12.  

To install:

Click image to see an enlarged view

Fig. Front cylinder head bolt torque sequence-3.5L engine

  1. Be sure the dowels are securely mounted in the engine block.
  2.  
  3. Install or connect the following:

    New gasket
     
    Cylinder head
     
    New M11 bolts
     
    M6 bolts in the front of the cylinder head
     

  4.  
  5. Torque the M11 bolts in sequence to:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  
    3. Step 2: 60 degree turn.
    4.  
    5. Step 3: 60 degree turn.
    6.  
    7. Step 4: 60 degree turn.
    8.  

  6.  
  7. Torque the long M6 bolt to 22 ft. lbs. (30 Nm).
  8.  
  9. Torque both shorter M6 bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Install or connect the following:

    Lifters and rocker arms in their original positions
     
    Camshafts and torque the bearing cap bolts to 71 inch lbs. (8 Nm) plus an additional 22 degree turn
     
    Primary camshaft drive chain
     
    Camshaft cover and torque the bolts to 80 inch lbs. (9 Nm)
     
    Exhaust manifold and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Coolant crossover pipe and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Engine mount strut bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Water outlet housing and torque the bolts to 80 inch lbs. (9 Nm)
     
    Intake manifold and torque the bolts to 62 inch lbs. (7 Nm)
     
    New oil filter
     
    Negative battery cable
     

  12.  
  13. Refill the engine with clean oil.
  14.  
  15. Refill the cooling system.
  16.  
  17. Start the engine and check for leaks, repair if necessary.

    Click image to see an enlarged view

    Fig. Camshaft holding fixture J-42038-3.5L engine

  18.  

Rear
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do not remove the rear exhaust manifold. Detach it from the cylinder head and the connection from the front manifold; then, move it aside.



    Negative battery cable
     
    Intake manifold
     



    Exhaust manifold
     
    Coolant crossover pipe
     
    Camshaft cover
     

  8.  
  9. Install a holding tool on the camshafts to hold them in position.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Keep the valve train parts in order so they can be installed in their original positions.



    Primary camshaft drive chain
     
    Camshafts
     
    Rocker arms and valve lifters
     



    Engine Coolant Temperature (ECT) sensor from the cylinder head
     
    M6 bolts from the front of the cylinder head, note the location of the longer bolt
     
    M11 cylinder head bolts and discard the bolts
     
    Cylinder head
     

  12.  

To install:

Click image to see an enlarged view

Fig. Rear cylinder head bolt torque sequence-3.5L engine

  1. Be sure the dowels are securely mounted in the engine block.
  2.  
  3. Install or connect the following:

    New gasket
     
    Cylinder head
     
    New M11 bolts
     
    M6 bolts in the front of the cylinder head
     

  4.  
  5. Torque the M11 bolts in sequence to:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  
    3. Step 2: 100 degree turn.
    4.  
    5. Step 3: 100 degree turn.
    6.  

  6.  
  7. Torque the long M6 bolt to 106 inch lbs. (12 Nm).
  8.  
  9. Torque both shorter M6 bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Install or connect the following:

    ECT sensor and torque the fastener to 15 ft. lbs. (20 Nm)
     
    Lifters and rocker arms in their original positions
     
    Camshafts and torque the bearing cap bolts to 71 inch lbs. (8 Nm) plus an additional 22 degree turn
     
    Primary camshaft drive chain
     
    Camshaft cover and torque the bolts to 80 inch lbs. (9 Nm)
     
    Coolant crossover pipe and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Exhaust manifold and torque the bolts to18 ft. lbs. (25 Nm)
     
    Intake manifold and torque the bolts to 62 inch lbs. (7 Nm)
     
    New oil filter
     
    Negative battery cable
     

  12.  
  13. Refill the engine with clean oil.
  14.  
  15. Refill the cooling system.
  16.  
  17. Start the engine and check for leaks, repair if necessary.
  18.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do not remove the rear exhaust manifold. Detach it from the cylinder head and the connection from the front manifold; then, move it aside.



    Negative battery cable
     
    Intake manifold
     



    Exhaust manifold
     
    Coolant crossover pipe
     
    Camshaft cover
     

  8.  
  9. Install a holding tool on the camshafts to hold them in position.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Keep the valve train parts in order so they can be installed in their original positions.



    Primary camshaft drive chain
     
    Camshafts
     
    Rocker arms and valve lifters
     



    Engine Coolant Temperature (ECT) sensor from the cylinder head
     
    M6 bolts from the front of the cylinder head, note the location of the longer bolt
     
    M11 cylinder head bolts and discard the bolts
     
    Cylinder head
     

  12.  

To install:

Click image to see an enlarged view

Fig. Rear cylinder head bolt torque sequence-3.5L engine

  1. Be sure the dowels are securely mounted in the engine block.
  2.  
  3. Install or connect the following:

    New gasket
     
    Cylinder head
     
    New M11 bolts
     
    M6 bolts in the front of the cylinder head
     

  4.  
  5. Torque the M11 bolts in sequence as follows:
    1. Step 1: 22 ft. lbs. (30 Nm).
    2.  
    3. Step 2: 60 degree turn.
    4.  
    5. Step 3: 60 degree turn.
    6.  
    7. Step 4: 60 degree turn.
    8.  

  6.  
  7. Torque the long M6 bolt to 22 ft. lbs. (30 Nm).
  8.  
  9. Torque both short M6 bolts to 106 inch lbs. (12 Nm).
  10.  
  11. Install or connect the following:

    ECT sensor and torque the fastener to 15 ft. lbs. (20 Nm)
     
    Lifters and rocker arms in their original positions
     
    Camshafts and torque the bearing cap bolts to 71 inch lbs. (8 Nm) plus an additional 22 degree turn
     
    Primary camshaft drive chain
     
    Camshaft cover and torque the bolts to 80 inch lbs. (9 Nm)
     
    Coolant crossover pipe and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Exhaust manifold and torque the bolts to18 ft. lbs. (25 Nm)
     
    Intake manifold and torque the bolts to 62 inch lbs. (7 Nm)
     
    New oil filter
     
    Negative battery cable
     

  12.  
  13. Refill the engine with clean oil.
  14.  
  15. Refill the cooling system.
  16.  
  17. Start the engine and check for leaks, repair if necessary.
  18.  

3.8L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Fuel injector sight shield
     
    Throttle body air inlet duct
     
    Right and left engine mount strut brackets
     
    Fuel lines from the fuel rail
     
    Upper intake manifold
     
    Lower intake manifold
     
    Left exhaust manifold
     
    Rocker arm cover
     
    Rocker arms and pushrods
     
    Cylinder head bolts
     
    Cylinder head
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.8L engine

  1. Install the new cylinder head gasket with the arrow pointing to the front of the engine.
  2.  
  3. Install the cylinder head.
  4.  
  5. Install NEW cylinder head bolts. Torque the bolts in sequence, as follows:
    1. Step 1: 37 ft. lbs. (50 Nm).
    2.  
    3. Step 2: Plus 120 degree turn.
    4.  

  6.  
  7. Install or connect the following:

    Push rods and rocker arms
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Left exhaust manifold and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Upper intake manifold and torque the bolts to 89 inch lbs. (10 Nm)
     
    Left and right engine mount strut brackets and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Throttle body air inlet duct
     
    Fuel injector sight shield and torque the bolts to 27 inch lbs. (3 Nm)
     
    Negative battery cable
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  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 cooling system.
  6.  
  7. Remove or disconnect the following:

    Fuel injector sight shield
     
    Throttle body air inlet duct
     
    Right and left engine mount strut brackets
     
    Fuel lines from the fuel rail
     
    Upper intake manifold
     
    Lower intake manifold
     
    Left exhaust manifold
     
    Rocker arm cover
     
    Rocker arms and pushrods
     
    Cylinder head bolts
     
    Cylinder head
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.8L engine

  1. Install the new cylinder head gasket with the arrow pointing to the front of the engine.
  2.  
  3. Install the cylinder head.
  4.  
  5. Install NEW cylinder head bolts. Torque the bolts in sequence, as follows:
    1. Step 1: 37 ft. lbs. (50 Nm).
    2.  
    3. Step 2: Plus 120 degree turn.
    4.  
    5. Step 3: Rotate the 4 center bolts an additional 30 degrees.
    6.  

  6.  
  7. Install or connect the following:

    Push rods and rocker arms
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Left exhaust manifold and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Upper intake manifold and torque the bolts to 89 inch lbs. (10 Nm)
     
    Left and right engine mount strut brackets and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Throttle body air inlet duct
     
    Fuel injector sight shield and torque the bolts to 27 inch lbs. (3 Nm)
     
    Negative battery cable
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Fuel injector sight shield
     
    Throttle body air inlet duct
     
    Right and left engine mount strut brackets
     
    Fuel lines from the fuel rail
     
    Upper intake manifold
     
    Lower intake manifold
     
    Left exhaust manifold
     
    Rocker arm cover
     
    Rocker arms and pushrods
     
    Cylinder head bolts
     
    Cylinder head
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.8L engine

  1. Install the new cylinder head gasket with the arrow pointing to the front of the engine.
  2.  
  3. Install the cylinder head.
  4.  
  5. Install NEW cylinder head bolts. Torque the bolts in sequence, as follows:
    1. Step 1: 37 ft. lbs. (50 Nm).
    2.  
    3. Step 2: Plus 120 degree turn.
    4.  

  6.  
  7. Install or connect the following:

    Push rods and rocker arms
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Left exhaust manifold and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Upper intake manifold and torque the bolts to 89 inch lbs. (10 Nm)
     
    Left and right engine mount strut brackets and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Throttle body air inlet duct
     
    Fuel injector sight shield and torque the bolts to 27 inch lbs. (3 Nm)
     
    Negative battery cable
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Throttle body air inlet duct
     
    Fuel injector sight shield
     
    Accessory drive belt
     
    Alternator
     
    Catalytic converter from the exhaust manifold
     
    Engine mount struts
     

  8.  
  9. Place the transmission in neutral and rotate the engine forward for access.
  10.  
  11. Remove or disconnect the following:

    Drive belt tensioner
     
    Power steering pump without disconnecting the lines
     
    Heater hoses from the engine
     
    Spark plug wires
     
    Oxygen Sensor (O 2 S) electrical connector
     
    Throttle and cruise control cables
     
    Fuel lines from the fuel rail
     
    Fuel rail
     
    Exhaust Gas Recirculation (EGR) valve heat shield
     
    EGR valve
     
    EGR valve outlet pipe
     
    EGR valve adapter
     
    Upper intake manifold
     
    Lower intake manifold
     
    Exhaust crossover pipe
     
    Right exhaust manifold
     
    Rocker arm cover
     
    Rocker arms and pushrods
     
    Cylinder head
     

  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.8L engine

  1. Install a new cylinder head gasket with the arrow pointing to the front of the engine.
  2.  
  3. Install the cylinder head and secure with NEW head bolts. Torque the bolts, in sequence, as follows:
    1. Step 1: 37 ft. lbs. (50 Nm).
    2.  
    3. Step 2: Plus a 120 degree turn.
    4.  

  4.  
  5. Install or connect the following:

    Push rods and rocker arms
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Right exhaust manifold and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Exhaust crossover pipe and torque the nuts to 18 ft. lbs. (25 Nm)
     
    Lower intake manifold and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Upper intake manifold and torque the bolts to 89 inch lbs. (10 Nm)
     
    EGR valve adapter and torque the bolts to 37 ft. lbs. (50 Nm)
     
    EGR valve outlet pipe and torque the bolts to 21 ft. lbs. (29 Nm)
     
    EGR valve and torque the nuts to 21 ft. lbs. (29 Nm)
     
    EGR valve heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Fuel rail
     
    Fuel lines to the fuel rail
     
    Throttle and cruise control cables
     
    O 2 S electrical connector
     
    Spark plugs and torque them to 20 ft. lbs. (27 Nm)
     
    Spark plug wires
     
    Heater hoses
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Drive belt tensioner and torque the bolts to 37 ft. lbs. (50 Nm)
     

  6.  
  7. Carefully return the engine to its proper position.
  8.  
  9. Place the transmission in park.
  10.  
  11. Install or connect the following:

    Throttle body air inlet duct
     
    Engine mount struts and torque the bolts to 35 ft. lbs. (48 Nm)
     
    Catalytic converter and torque the bolts to 26 ft. lbs. (35 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Accessory drive belt
     
    Fuel injector sight shield
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Start the engine and check for leaks.
  16.  

  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 cooling system.
  6.  
  7. Remove or disconnect the following:

    Throttle body air inlet duct
     
    Fuel injector sight shield
     
    Accessory drive belt
     
    Alternator
     
    Catalytic converter from the exhaust manifold
     
    Engine mount struts
     

  8.  
  9. Place the transmission in neutral and rotate the engine forward for access.
  10.  
  11. Remove or disconnect the following:

    Drive belt tensioner
     
    Power steering pump without disconnecting the lines
     
    Heater hoses from the engine
     
    Spark plug wires
     
    Oxygen (O 2 S) sensor electrical connector
     
    Throttle and cruise control cables
     
    Fuel lines from the fuel rail
     
    Fuel rail
     
    Exhaust Gas Recirculation (EGR) valve heat shield
     
    EGR valve
     
    EGR valve outlet pipe
     
    EGR valve adapter
     
    Upper intake manifold
     
    Lower intake manifold
     
    Exhaust crossover pipe
     
    Right exhaust manifold
     
    Rocker arm cover
     
    Rocker arms and pushrods
     
    Cylinder head
     

  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.8L engine

  1. Install a new cylinder head gasket with the arrow pointing to the front of the engine.
  2.  
  3. Install the cylinder head and secure with NEW head bolts. Torque the bolts, in sequence, as follows:
    1. Step 1: 37 ft. lbs. (50 Nm).
    2.  
    3. Step 2: Plus a 120 degree turn.
    4.  
    5. Step 3: Rotate the 4 center bolts an additional 30 degrees.
    6.  

  4.  
  5. Install or connect the following:

    Push rods and rocker arms
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Right exhaust manifold and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Exhaust crossover pipe and torque the nuts to 18 ft. lbs. (25 Nm)
     
    Lower intake manifold and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Upper intake manifold and torque the bolts to 89 inch lbs. (10 Nm)
     
    EGR valve adapter and torque the bolts to 37 ft. lbs. (50 Nm)
     
    EGR valve outlet pipe and torque the bolts to 21 ft. lbs. (29 Nm)
     
    EGR valve and torque the nuts to 21 ft. lbs. (29 Nm)
     
    EGR valve heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Fuel rail
     
    Fuel lines to the fuel rail
     
    Throttle and cruise control cables
     
    O 2 S electrical connector
     
    Spark plugs and torque them to 20 ft. lbs. (27 Nm)
     
    Spark plug wires
     
    Heater hoses
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Drive belt tensioner and torque the bolts to 37 ft. lbs. (50 Nm)
     

  6.  
  7. Carefully return the engine to its proper position.
  8.  
  9. Place the transmission in park.
  10.  
  11. Install or connect the following:

    Throttle body air inlet duct
     
    Engine mount struts and torque the bolts to 35 ft. lbs. (48 Nm)
     
    Catalytic converter and torque the bolts to 26 ft. lbs. (35 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Accessory drive belt
     
    Fuel injector sight shield
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Start the engine and check for leaks.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Throttle body air inlet duct
     
    Fuel injector sight shield
     
    Accessory drive belt
     
    Alternator
     
    Catalytic converter from the exhaust manifold
     
    Engine mount struts
     

  8.  
  9. Place the transmission in neutral and rotate the engine forward for access.
  10.  
  11. Remove or disconnect the following:

    Drive belt tensioner
     
    Power steering pump without disconnecting the lines
     
    Heater hoses from the engine
     
    Spark plug wires
     
    Oxygen Sensor (O 2 S) electrical connector
     
    Throttle and cruise control cables
     
    Fuel lines from the fuel rail
     
    Fuel rail
     
    Exhaust Gas Recirculation (EGR) valve heat shield
     
    EGR valve
     
    EGR valve outlet pipe
     
    EGR valve adapter
     
    Upper intake manifold
     
    Lower intake manifold
     
    Exhaust crossover pipe
     
    Right exhaust manifold
     
    Rocker arm cover
     
    Rocker arms and pushrods
     
    Cylinder head
     

  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.8L engine

  1. Install a new cylinder head gasket with the arrow pointing to the front of the engine.
  2.  
  3. Install the cylinder head and secure with NEW head bolts. Torque the bolts, in sequence, as follows:
    1. Step 1: 37 ft. lbs. (50 Nm).
    2.  
    3. Step 2: Plus a 120 degree turn.
    4.  

  4.  
  5. Install or connect the following:

    Push rods and rocker arms
     
    Rocker arm cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Right exhaust manifold and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Exhaust crossover pipe and torque the nuts to 18 ft. lbs. (25 Nm)
     
    Lower intake manifold and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Upper intake manifold and torque the bolts to 89 inch lbs. (10 Nm)
     
    EGR valve adapter and torque the bolts to 37 ft. lbs. (50 Nm)
     
    EGR valve outlet pipe and torque the bolts to 21 ft. lbs. (29 Nm)
     
    EGR valve and torque the nuts to 21 ft. lbs. (29 Nm)
     
    EGR valve heat shield and torque the bolts to 89 inch lbs. (10 Nm)
     
    Fuel rail
     
    Fuel lines to the fuel rail
     
    Throttle and cruise control cables
     
    O 2 S electrical connector
     
    Spark plugs and torque them to 20 ft. lbs. (27 Nm)
     
    Spark plug wires
     
    Heater hoses
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Drive belt tensioner and torque the bolts to 37 ft. lbs. (50 Nm)
     

  6.  
  7. Carefully return the engine to its proper position.
  8.  
  9. Place the transmission in park.
  10.  
  11. Install or connect the following:

    Throttle body air inlet duct
     
    Engine mount struts and torque the bolts to 35 ft. lbs. (48 Nm)
     
    Catalytic converter and torque the bolts to 26 ft. lbs. (35 Nm)
     
    Alternator and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Accessory drive belt
     
    Fuel injector sight shield
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Start the engine and check for leaks.
  16.  

5.3L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Disconnect the hose clamp and hose from the coolant fill neck.
  6.  
  7. Remove the coolant air bleed pipe bolts.
  8.  
  9. Remove the coolant air bleed pipe (1) with hose and seals.
  10.  
  11. Remove the hose (2) and clamps (3) from the coolant air bleed pipe as required.

    Click image to see an enlarged view

    Fig. Coolant air bleed pipe-5.3L engine

  12.  
  13. Remove the engine coolant air bleed cover bolts.
  14.  
  15. Remove the covers with seals.
  16.  
  17. Remove the seals from the pipe and covers. Discard the seals.
  18.  
  19. Remove the left exhaust manifold.
  20.  
  21. Remove the pushrods.
  22.  
  23. Remove the power steering pump pulley.
  24.  
  25. Remove the 3 coolant manifold bolts to the cylinder head.
  26.  
  27. Remove the forward engine mount strut bolt and nut.
  28.  
  29. Remove the rear engine mount strut bolt and nut.
  30.  
  31. Remove the engine mount strut.
  32.  
  33. Inspect the rubber in the engine mount strut for the following conditions:
  34.  
  35. If necessary, remove the engine mount strut bracket bolts (body side).
  36.  
  37. If necessary, remove the engine mount strut bracket (body side).
  38.  
  39. Remove the heater pipe bracket bolt from the engine mount.
  40.  
  41. If necessary, remove the engine mount strut bracket bolts (engine side).
  42.  
  43. If necessary, remove the engine mount strut bracket (engine side).
    NOTE
    The cylinder head bolts are of a torque to yield design and are NOT to be used again.

  44.  
  45. Remove and discard the cylinder head bolts.
    WARNING
    After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.

  46.  
  47. Remove the cylinder head.
  48.  
  49. Remove and discard the cylinder head gasket.
  50.  
  51. Clean and inspect the cylinder head.
  52.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-5.3L engine


CAUTION
Wear safety glasses in order to avoid eye damage.


WARNING
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.


NOTE
Do not reuse the cylinder head bolts. Install NEW cylinder head bolts during assembly. 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 cylinder head bolt holes, if required.
  2.  
  3. Clean the engine block bolt holes, if required.
  4.  
  5. Use spray cleaner GM P/N 12346139 or P/N 12377981, Canadian P/N 10953463), or equivalent into the hole.
  6.  
  7. Clean the cylinder head bolt holes with compressed air.
  8.  
  9. Check the cylinder head locating pins for proper installation.
  10.  
  11. Inspect the displacement markings on the cylinder head gasket, for the proper usage.
  12.  
  13. Install the NEW cylinder head gasket onto the locating pins.
  14.  
  15. Install the cylinder head onto the locating pins.
  16.  
  17. Install the NEW cylinder head bolts.
  18.  
  19. Tighten the cylinder head bolts. Tighten the M11 bolts (1-10) a first pass in sequence to 22 ft. lbs. (30 Nm).
    1. Tighten the M11 bolts (1-10) a second pass in sequence to 90 degrees.
    2.  
    3. Tighten the M11 bolts (1-10) a final pass in sequence to 70 degrees.
    4.  
    5. Tighten the M8 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.
    6.  

  20.  
  21. If necessary, position the engine mount strut bracket (engine side) to the cylinder head.
  22.  
  23. If necessary, install the engine mount strut bracket bolts (engine side). Tighten the bolts to 48 Nm (35 ft. lbs.).
  24.  
  25. Install the heater pipe bracket bolt. Tighten the bolt to 16 Nm (12 ft. lbs.).
  26.  
  27. If necessary, position the engine mount strut bracket (body side) to the vehicle.
  28.  
  29. If necessary, install the engine mount strut bracket bolts (body side). Tighten the bolt to 48 Nm (35 ft. lbs.).
  30.  
  31. Install the engine mount strut.
  32.  
  33. Install the rear engine mount strut bolt and nut. Tighten the bolt/nut to 48 Nm (35 ft. lbs.).
  34.  
  35. Install the forward engine mount strut bolt and nut. Tighten the bolt/nut to 48 Nm (35 ft. lbs.).
  36.  
  37. Install the 3 coolant manifold bolts to the cylinder head. Tighten the bolts to 37 ft. lbs. (50 Nm).
  38.  
  39. Install the power steering pump pulley.
  40.  
  41. Install the pushrods.
  42.  
  43. Install the left exhaust manifold.
  44.  
  45. Install the coolant air bleed pipe.
  46.  
  47. Install the intake manifold.
  48.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Disconnect the hose clamp and hose from the coolant fill neck.
  6.  
  7. Remove the coolant air bleed pipe bolts.
  8.  
  9. Remove the coolant air bleed pipe (1) with hose and seals.
  10.  
  11. Remove the hose (2) and clamps (3) from the coolant air bleed pipe as required.

    Click image to see an enlarged view

    Fig. Coolant air bleed pipe-5.3L engine

  12.  
  13. Remove the engine coolant air bleed cover bolts.
  14.  
  15. Remove the covers with seals.
  16.  
  17. Remove the seals from the pipe and covers. Discard the seals.
  18.  
  19. Remove the left exhaust manifold.
  20.  
  21. Remove the pushrods.
  22.  
  23. Remove the power steering pump pulley.
  24.  
  25. Remove the 3 coolant manifold bolts to the cylinder head.
  26.  
  27. Remove the forward engine mount strut bolt and nut.
  28.  
  29. Remove the rear engine mount strut bolt and nut.
  30.  
  31. Remove the engine mount strut.
  32.  
  33. Inspect the rubber in the engine mount strut for the following conditions:
  34.  
  35. If necessary, remove the engine mount strut bracket bolts (body side).
  36.  
  37. If necessary, remove the engine mount strut bracket (body side).
  38.  
  39. Remove the heater pipe bracket bolt from the engine mount.
  40.  
  41. If necessary, remove the engine mount strut bracket bolts (engine side).
  42.  
  43. If necessary, remove the engine mount strut bracket (engine side).
    NOTE
    The cylinder head bolts are of a torque to yield design and are NOT to be used again.

  44.  
  45. Remove and discard the cylinder head bolts.
    WARNING
    After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.

  46.  
  47. Remove the cylinder head.
  48.  
  49. Remove and discard the cylinder head gasket.
  50.  
  51. Clean and inspect the cylinder head.
  52.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-5.3L engine


CAUTION
Wear safety glasses in order to avoid eye damage.


WARNING
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.


NOTE
Do not reuse the cylinder head bolts. Install NEW cylinder head bolts during assembly. 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 cylinder head bolt holes, if required.
  2.  
  3. Clean the engine block bolt holes, if required.
  4.  
  5. Use spray cleaner GM P/N 12346139 or P/N 12377981, Canadian P/N 10953463), or equivalent into the hole.
  6.  
  7. Clean the cylinder head bolt holes with compressed air.
  8.  
  9. Check the cylinder head locating pins for proper installation.
  10.  
  11. Inspect the displacement markings on the cylinder head gasket, for the proper usage.
  12.  
  13. Install the NEW cylinder head gasket onto the locating pins.
  14.  
  15. Install the cylinder head onto the locating pins.
  16.  
  17. Install the NEW cylinder head bolts.
  18.  
  19. Tighten the cylinder head bolts. Tighten the M11 bolts (1-10) a first pass in sequence to 22 ft. lbs. (30 Nm).
    1. Tighten the M11 bolts (1-10) a second pass in sequence to 90 degrees.
    2.  
    3. Tighten the M11 bolts (1-10) a final pass in sequence to 70 degrees.
    4.  
    5. Tighten the M8 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.
    6.  

  20.  
  21. If necessary, position the engine mount strut bracket (engine side) to the cylinder head.
  22.  
  23. If necessary, install the engine mount strut bracket bolts (engine side). Tighten the bolts to 48 Nm (35 ft. lbs.).
  24.  
  25. Install the heater pipe bracket bolt. Tighten the bolt to 16 Nm (12 ft. lbs.).
  26.  
  27. If necessary, position the engine mount strut bracket (body side) to the vehicle.
  28.  
  29. If necessary, install the engine mount strut bracket bolts (body side). Tighten the bolt to 48 Nm (35 ft. lbs.).
  30.  
  31. Install the engine mount strut.
  32.  
  33. Install the rear engine mount strut bolt and nut. Tighten the bolt/nut to 48 Nm (35 ft. lbs.).
  34.  
  35. Install the forward engine mount strut bolt and nut. Tighten the bolt/nut to 48 Nm (35 ft. lbs.).
  36.  
  37. Install the 3 coolant manifold bolts to the cylinder head. Tighten the bolts to 37 ft. lbs. (50 Nm).
  38.  
  39. Install the power steering pump pulley.
  40.  
  41. Install the pushrods.
  42.  
  43. Install the left exhaust manifold.
  44.  
  45. Install the coolant air bleed pipe.
  46.  
  47. Install the intake manifold.
  48.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Disconnect the hose clamp and hose from the coolant fill neck.
  6.  
  7. Remove the coolant air bleed pipe bolts.
  8.  
  9. Remove the coolant air bleed pipe (1) with hose and seals.
  10.  
  11. Remove the hose (2) and clamps (3) from the coolant air bleed pipe as required.
  12.  
  13. Remove the engine coolant air bleed cover bolts.
  14.  
  15. Remove the covers with seals.
  16.  
  17. Remove the seals from the pipe and covers. Discard the seals.
  18.  
  19. Remove the generator bracket.
  20.  
  21. Remove the right exhaust manifold.
  22.  
  23. Remove the pushrods.
    NOTE
    The cylinder head bolts are of a torque to yield design and are NOT to be used again.

  24.  
  25. Remove and discard the cylinder head bolts.
    WARNING
    After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.

  26.  
  27. Remove the cylinder head.
  28.  
  29. Remove and discard the cylinder head gasket.
  30.  
  31. Clean and inspect the cylinder head.
  32.  

To install


CAUTION
Wear safety glasses in order to avoid eye damage.


WARNING
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.


NOTE
Do not reuse the cylinder head bolts. Install NEW cylinder head bolts during assembly. 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 cylinder head bolt holes, if required.
  2.  
  3. Clean the engine block bolt holes, if required.
  4.  
  5. Use spray cleaner GM P/N 12346139 or P/N 12377981, Canadian P/N 10953463), or equivalent into the hole.
  6.  
  7. Clean the cylinder head bolt holes with compressed air.
  8.  
  9. Check the cylinder head locating pins for proper installation.
  10.  
  11. Inspect the displacement markings on the cylinder head gasket, for the proper usage.
  12.  
  13. Install the NEW cylinder head gasket onto the locating pins.
  14.  
  15. Install the cylinder head onto the locating pins.
  16.  
  17. Install the NEW cylinder head bolts.
  18.  
  19. Tighten the cylinder head bolts.
    1. Tighten the M11 bolts (1-10) a first pass in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten the M11 bolts (1-10) a second pass in sequence to 90 degrees.
    4.  
    5. Tighten the M11 bolts (1-10) a final pass in sequence to 70 degrees.
    6.  
    7. Tighten the M8 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.
    8.  

  20.  
  21. Install the pushrods.
  22.  
  23. Install the right exhaust manifold.
  24.  
  25. Install the generator bracket.
  26.  
  27. Install the coolant air bleed pipe.
  28.  
  29. Install the intake manifold.
  30.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Disconnect the hose clamp and hose from the coolant fill neck.
  6.  
  7. Remove the coolant air bleed pipe bolts.
  8.  
  9. Remove the coolant air bleed pipe (1) with hose and seals.
  10.  
  11. Remove the hose (2) and clamps (3) from the coolant air bleed pipe as required.
  12.  
  13. Remove the engine coolant air bleed cover bolts.
  14.  
  15. Remove the covers with seals.
  16.  
  17. Remove the seals from the pipe and covers. Discard the seals.
  18.  
  19. Remove the generator bracket.
  20.  
  21. Remove the right exhaust manifold.
  22.  
  23. Remove the pushrods.
    NOTE
    The cylinder head bolts are of a torque to yield design and are NOT to be used again.

  24.  
  25. Remove and discard the cylinder head bolts.
    WARNING
    After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.

  26.  
  27. Remove the cylinder head.
  28.  
  29. Remove and discard the cylinder head gasket.
  30.  
  31. Clean and inspect the cylinder head.
  32.  

To install


CAUTION
Wear safety glasses in order to avoid eye damage.


WARNING
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.


NOTE
Do not reuse the cylinder head bolts. Install NEW cylinder head bolts during assembly. 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 cylinder head bolt holes, if required.
  2.  
  3. Clean the engine block bolt holes, if required.
  4.  
  5. Use spray cleaner GM P/N 12346139 or P/N 12377981, Canadian P/N 10953463), or equivalent into the hole.
  6.  
  7. Clean the cylinder head bolt holes with compressed air.
  8.  
  9. Check the cylinder head locating pins for proper installation.
  10.  
  11. Inspect the displacement markings on the cylinder head gasket, for the proper usage.
  12.  
  13. Install the NEW cylinder head gasket onto the locating pins.
  14.  
  15. Install the cylinder head onto the locating pins.
  16.  
  17. Install the NEW cylinder head bolts.
  18.  
  19. Tighten the cylinder head bolts.
    1. Tighten the M11 bolts (1-10) a first pass in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten the M11 bolts (1-10) a second pass in sequence to 90 degrees.
    4.  
    5. Tighten the M11 bolts (1-10) a final pass in sequence to 70 degrees.
    6.  
    7. Tighten the M8 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.
    8.  

  20.  
  21. Install the pushrods.
  22.  
  23. Install the right exhaust manifold.
  24.  
  25. Install the generator bracket.
  26.  
  27. Install the coolant air bleed pipe.
  28.  
  29. Install the intake manifold.
  30.  

 
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