GM Celebrity/Century/Ciera/6000 1982-1996 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION




CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2.2L Engine

See Figure 1

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Separate the air cleaner and air duct assembly from the vehicle.
  8.  
  9. Remove the lower air inlet.
  10.  
  11. Remove the serpentine drive belt.
  12.  
  13. Unsecure the alternator, and remove from the vehicle.
  14.  
  15. Remove the power steering pump, then position it aside without disconnecting the power steering lines.
  16.  
  17. Disconnect the spark plug wires, lay them aside.
  18.  
  19. Detach the control cables from the throttle body, then remove the cable bracket at the throttle body and valve cover.
  20.  

When removing the valve train components, they must be kept in order for installation, in the same locations as they were removed from.

  1. Remove the valve cover, rocker arm nuts, rocker arms and pushrods.
  2.  
  3. Disconnect the electrical harness from the intake manifold, throttle body and cylinder head.
  4.  
  5. Remove the O 2 sensor connection.
  6.  
  7. Unsecure the power steering pump bracket from the intake brace, located under the manifold.
  8.  
  9. Remove the torque strut and the engine side torque strut mounting bracket.
  10.  
  11. Unfasten the alternator rear bracket.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Tightening sequence for cylinder head bolts on 2.2L engines

  1. Tag and disconnect the vacuum lines at the intake manifold and cylinder head.
  2.  
  3. Disconnect the upper radiator hose from the engine.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Disconnect the exhaust pipe from the exhaust manifold.
  8.  
  9. Lower the vehicle.
  10.  
  11. Disconnect and cap the fuel lines at the quick disconnects.
  12.  
  13. Remove the transaxle fill tube.
  14.  
  15. Remove the cylinder head bolts.
  16.  
  17. Remove the cylinder head with both manifolds, then remove the intake and exhaust manifolds from the cylinder head.
  18.  

To install:
  1. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and the block threads.
  2.  
  3. Install the intake and exhaust manifolds on the cylinder head.
  4.  
  5. Place a new cylinder head gasket in position over the dowel pins on the block. Carefully guide the cylinder head into position.
  6.  
  7. Install the head bolts finger-tight. The long bolts go in bolts positions 1, 4, 5, 8, and 9. The short bolts are in the positions 2, 3, 6 and 7. The stud is in position 10.
  8.  
  9. Tighten the bolts in sequence. The long bolts to 23 ft. lbs. (32 Nm) and the short bolts and stud to 22 ft. lbs. (29 Nm). Make a second pass tightening the long bolts to 46 ft. lbs. (58 Nm). Maker a final pass over all the bolts tightening each an additional 100°.
  10.  
  11. Install the transaxle fill tube.
  12.  
  13. Connect the fuel lines to the throttle body.
  14.  
  15. Raise and support the vehicle.
  16.  
  17. Connect the exhaust pipe to the exhaust manifold. Tighten the mounting bolts to 22 ft. lbs. (30 Nm).
  18.  
  19. Lower the vehicle.
  20.  
  21. Attach the upper radiator hose.
  22.  
  23. Install the vacuum lines to the intake manifold.
  24.  
  25. Attach the engine side torque strut bracket and torque strut to the engine.
  26.  
  27. Install the alternator rear bracket.
  28.  
  29. Install the power steering pump bracket to the intake manifold brace, located under the intake manifold.
  30.  
  31. Connect the electrical harness at the intake manifold, throttle body and cylinder head.
  32.  
  33. Attach the O 2 sensor wiring harness.
  34.  
  35. Install the pushrods, rocker arms and rocker arm nuts, then tighten to 22 ft. lbs. (30 Nm).
  36.  
  37. Install the valve cover.
  38.  
  39. Connect the control cables to the throttle body, then install the cables brackets at the throttle body and valve cover.
  40.  
  41. Attach the spark plug wires to there proper locations.
  42.  
  43. Install the power steering pump in the mounting bracket.
  44.  
  45. Attach the alternator to the engine.
  46.  
  47. Install the serpentine drive belt.
  48.  
  49. Connect the lower air inlet duct.
  50.  
  51. Attach the air inlet resonator tie bar.
  52.  
  53. Install the air cleaner and duct assembly.
  54.  
  55. Refill the cooling system.
  56.  
  57. Connect the negative battery cable.
  58.  
  59. Start the vehicle, top off the coolant. Verify there are no leaks.
  60.  

2.5L Engine

See Figure 2


CAUTION
On fuel injected engines, relieve the pressure in the fuel system before disconnecting any fuel line connections.

The engine should be not be warm, it is best to leave engine sit overnight to cool before removing the cylinder head.

  1. Drain the cooling system into a clean container.
  2.  
  3. Remove the air cleaner, the negative battery cable, the oil dipstick tube, the ignition coil, the engine-to-upper strut rod bolt and the power steering pump bracket.
  4.  
  5. Remove the intake and exhaust manifolds as previously outlined.
  6.  
  7. Remove the alternator bracket bolts.
  8.  
  9. Remove the air conditioning compressor bracket bolts and position the compressor to one side. Do not disconnect any of the refrigerant lines.
  10.  



Click image to see an enlarged view

Fig. Fig. 2: Tightening sequence for cylinder head bolts on 2.5L engines

  1. Disconnect and tag all vacuum and electrical connections from the cylinder head.
  2.  
  3. Disconnect the upper radiator hose.
  4.  
  5. Disconnect the spark plug wires and remove the plugs.
  6.  
  7. Remove the valve cover, rocker arms, and pushrods.
  8.  
  9. Unbolt and remove the cylinder head.
  10.  
  11. Clean the gasket surfaces thoroughly.
  12.  
  13. Install a new gasket over the dowels with the right side facing up.
  14.  
  15. Coat the head bolt threads with sealer and install finger-tight.
  16.  
  17. Tighten the bolts in sequence, in equal steps to the specified torque.
  18.  
  19. On vehicles from:
    1. 1982-84 final torque is 85 ft. lbs. (115 Nm).
    2.  
    3. 1985-86 final torque is 92 ft. lbs. (125 Nm).
    4.  
    5. 1987-92 first torque to 18 ft. lbs. (25 Nm), then repeat 26 ft. lbs. (35 Nm) excluding No. 9, which is 18 ft. lbs. (25 Nm).
    6.  

  20.  
  21. Reverse the removal procedure to install.
  22.  

2.8L Engine

See Figures 3 and 4

LEFT SIDE
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the car.
  4.  
  5. Drain the coolant and lower the car.
  6.  
  7. Remove the valve covers.
  8.  
  9. Remove the intake manifold and plenum.
  10.  
  11. Remove the crossover pipe.
  12.  
  13. Remove the left exhaust manifold.
  14.  
  15. Remove the oil dipstick.
  16.  
  17. Remove the alternator and AIR pump brackets.
  18.  
  19. Remove the dipstick tube.
  20.  
  21. Loosen the rocker arm bolts and remove the pushrods. Keep the pushrods in the same order as removed.
  22.  
  23. Remove the cylinder head bolts in stages using the reverse order of the tightening sequence.
  24.  
  25. Remove the cylinder head. Do not pry on the head to loosen it.
  26.  

To install:
  1. Clean all mating surfaces on the cylinder head block and intake manifold.
  2.  
  3. Place the gasket into position over the dowel pins, with the correct side facing up, if marked.
  4.  
  5. Install the cylinder head.
  6.  
  7. Coat the head bolt threads with GM part no. 1052080 sealer or an equivalent.
  8.  
  9. Tighten the head bolts in proper sequence to 70 ft. lbs. (90 Nm) on 1982-86 models and 1987-89 models to 33 ft. lbs. (45 Nm).
  10.  
  11. Attach the intake manifold gasket.
  12.  
  13. Install the pushrods loosely retained with the rocker arms. Make sure the pushrods seat in the lifter.
  14.  
  15. Install the rocker arm nuts.
  16.  
  17. Attach the intake manifold and plenum.
  18.  
  19. Install the valve covers, then connect the oil level indicator tube bracket.
  20.  
  21. Install the crossover pipe and the left exhaust manifold.
  22.  
  23. Connect the engine strut bracket top the engine.
  24.  
  25. Fill the cooling system, connect the negative battery cable.
  26.  
  27. Double check no connections have been missed.
  28.  
  29. Start the vehicle, top off the coolant, then check for leaks.
  30.  



Click image to see an enlarged view

Fig. Fig. 3: Remove the cylinder head. Do not pry on the head to loosen it



Click image to see an enlarged view

Fig. Fig. 4: Tightening sequence for cylinder head bolts on 2.8L engines

RIGHT SIDE
  1. Raise the car and drain the coolant from the block.
  2.  
  3. Disconnect the exhaust pipe and lower the car.
  4.  
  5. If equipped, remove the cruise control servo bracket.
  6.  
  7. Remove the air management valve and hose.
  8.  
  9. Remove the intake manifold.
  10.  
  11. Remove the exhaust crossover.
  12.  
  13. Loosen the rocker arm nuts and remove the pushrods. Keep the pushrods in the order in which they were removed.
  14.  
  15. Remove the cylinder head bolts in stages using the reverse order of the tightening sequence.
  16.  
  17. Remove the cylinder head. Do not pry on the cylinder head to loosen it.
  18.  

To install:
  1. Clean all mating surfaces on the cylinder head block and intake manifold.
  2.  
  3. Place the gasket into position over the dowel pins, with the correct side facing up, if marked.
  4.  
  5. Install the cylinder head.
  6.  
  7. Coat the head bolt threads with GM part no. 1052080 sealer or an equivalent.
  8.  
  9. Tighten the head bolts in proper sequence to 70 ft. lbs. (90 Nm) on 1982-86 models and 1987-89 models to 33 ft. lbs. (45 Nm).
  10.  
  11. Attach the intake manifold gasket.
  12.  
  13. Install the pushrods loosely retained with the rocker arms. Make sure the pushrods seat in the lifter.
  14.  
  15. Install the rocker arm nuts.
  16.  
  17. Attach the intake manifold and plenum.
  18.  
  19. Install the valve covers, then connect the spark plug wires.
  20.  
  21. Install the crossover pipe and the right exhaust manifold. The crossover heat shield needs to be installed.
  22.  
  23. Raise and support the vehicle.
  24.  
  25. Install the exhaust at the crossover. Lower the vehicle.
  26.  
  27. Attach the cruise control servo bracket, if removed.
  28.  
  29. Fill the cooling system, connect the negative battery cable.
  30.  
  31. Double check no connections have not been missed.
  32.  
  33. Start the vehicle, top off the coolant, then check for leaks.
  34.  

3.0L Engine

See Figure 5

  1. Disconnect negative battery cable.
  2.  
  3. Remove intake manifold.
  4.  
  5. Loosen and remove the belt(s).
  6.  
  7. When removing LEFT cylinder head;
    1. Remove oil dipstick.
    2.  
    3. Remove air and vacuum pumps with mounting bracket if present, and move out of the way with hoses attached.
    4.  

  8.  
  9. When removing RIGHT cylinder head:
    1. Remove alternator.
    2.  
    3. Disconnect power steering gear pump and brackets attached to cylinder head.
    4.  

  10.  
  11. Disconnect wires from spark plugs, and remove the spark plug wire clips from the valve cover studs.
  12.  



Click image to see an enlarged view

Fig. Fig. 5: Tightening sequence for cylinder head bolts on 3.0L engines

  1. Remove exhaust manifold bolts from head being removed.
  2.  
  3. Clean dirt off cylinder head and adjacent area to avoid getting dirt into engine. It is extremely important to avoid getting dirt into the hydraulic valve lifters.
  4.  
  5. Remove valve cover and rocker arm and shaft assembly from cylinder head. Lift out pushrods.
  6.  
  7. Loosen all cylinder head bolts, then remove bolts and lift off the cylinder head.
  8.  
  9. With cylinder head on bench, remove all spark plugs for cleaning and to avoid damaging them during work on the head.
  10.  
  11. Installation is the reverse of removal. Clean all gasket surfaces thoroughly. Always use a new head gasket. The head gasket is installed with the bead downward. Coat the head bolt threads with heavy-bodied thread sealer. Tighten the head bolts in equal stages. Recheck head bolt torque after the engine has been warmed to operating temperature.
  12.  

3.1L Engine (VIN T)

See Figure 6

LEFT SIDE

CAUTION
Care should be taken when working around the fuel system. DO NOT smoke or expose the fuel system to any flames or sparks. The fuel system is under pressure and must be relieved prior to performing any service work on the system components. Failure to properly bleed the system can lead to personal injury or component damage. Always keep a suitable fire extinguisher handy when servicing the fuel system.

  1. Relieve the pressure in the fuel system before disconnecting any fuel line connections. Disconnect the fuel lines.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner assembly. Raise and safely support the vehicle.
  6.  
  7. Drain the cylinder block and lower the vehicle.
  8.  
  9. Remove the oil level indicator tube, valve cover, intake manifold and plenum, as required.
  10.  
  11. Remove the exhaust crossover, alternator bracket, AIR pump and brackets.
  12.  
  13. Disconnect and tag all electrical wiring and vacuum hoses that may interfere with the removal of the left cylinder head.
  14.  
  15. Loosen the rocker arm until the pushrods can be removed. Remove the pushrods. Keep the pushrods in the same order as removed.
  16.  
  17. Remove the cylinder head bolts. Remove the cylinder head. Do not pry on the head to loosen it.
  18.  

To install:
  1. Clean the cylinder head and block from any foreign matter, nicks or heavy scratches. Clean the cylinder head bolt threads and threads in the cylinder block.
  2.  
  3. Place the gasket into position over the dowel pins, with the correct side facing up, if marked.
  4.  
  5. Install the cylinder head bolts and tighten in sequence to 33 ft. lbs. (45 Nm). Turn an additional 90° in sequence.
  6.  
  7. Install the pushrods. Make sure the lower ends of the pushrods are in the lifter seats. Install the rocker arm nuts and tighten the nuts to 14-20 ft. lbs. (20-27 Nm).
  8.  
  9. Install the intake manifold.
  10.  
  11. Connect all electrical wiring and vacuum hoses.
  12.  
  13. Install the exhaust crossover, alternator and AIR pump brackets, alternator and AIR pump.
  14.  
  15. If removed, install the oil level indicator tube, valve cover, intake manifold and plenum.
  16.  
  17. Connect the fuel lines.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Adjust the valve lash, as required.
  22.  
  23. Install the air cleaner assembly.
  24.  

RIGHT SIDE
  1. Relieve the pressure in the fuel system before disconnecting any fuel line connections.
  2.  
  3. Disconnect the negative battery cable. Remove the air cleaner assembly. Raise the vehicle and support it safely.
  4.  
  5. Drain the cylinder block and lower the vehicle.
  6.  
  7. If equipped, remove the cruise control servo bracket, the air management valve and hose and the intake manifold.
  8.  
  9. Remove the exhaust pipe at crossover, crossover and heat shield, as required.
  10.  
  11. Disconnect and tag all electrical wiring and vacuum hoses that may interfere with the removal of the right cylinder head.
  12.  
  13. Remove the rocker cover. Loosen the rocker arm nuts and remove the pushrods. Keep the pushrods in the order in which they were removed.
  14.  
  15. Remove the cylinder head bolts. Remove the cylinder head. Do not pry on the head to loosen it.
  16.  

To install:
  1. Clean the cylinder head and block from any foreign matter, nicks or heavy scratches. Clean the cylinder head bolt threads and threads in the cylinder block.
  2.  
  3. Place the gasket into position over the dowel pins, with the correct side facing up, if marked.
  4.  
  5. Install the cylinder head bolts and tighten in sequence to 33 ft. lbs. (45 Nm). Turn an additional 90° in sequence.
  6.  
  7. Install the pushrods. Make sure the lower ends of the pushrods are in the lifter seats. Install the rocker arm nuts and tighten the nuts to 14-20 ft. lbs. (20-27 Nm).
  8.  
  9. Install the intake manifold.
  10.  
  11. Install the rocker cover.
  12.  
  13. Connect all electrical wiring and vacuum hoses.
  14.  
  15. If removed, install the crossover exhaust pipe and heat shield.
  16.  
  17. If equipped, install the cruise control servo bracket, the air management valve and hose.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Recheck for leaks.
  22.  
  23. Adjust the valve lash, as required.
  24.  
  25. Install the air cleaner assembly.
  26.  



Click image to see an enlarged view

Fig. Fig. 6: Tightening sequence for cylinder head bolts on 3.1L engines

3.1L Engine (VIN M)
LEFT SIDE (FRONT)

See Figure 6


CAUTION
Fuel Injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the top half of the air cleaner assembly and remove the throttle body air inlet duct.
  8.  
  9. Remove the exhaust crossover pipe heat shield and crossover pipe.
  10.  
  11. Disconnect the spark plug wires from spark plugs and wire looms and route the wires out of the way.
  12.  
  13. Remove the rocker arm covers.
  14.  
  15. Remove upper intake plenum and lower intake manifold.
  16.  
  17. Remove the left side exhaust manifold.
  18.  
  19. Remove oil level indicator tube.
  20.  

When removing the valve train components they must be kept in order for installation in the same locations they were removed from.

  1. Remove rocker arms nut, rocker arms, balls and pushrods.
  2.  
  3. Remove the cylinder head bolts evenly.
  4.  
  5. Remove the cylinder head.
  6.  

To install:
  1. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads.
  2.  
  3. Place the gasket into position over the dowel pins, with the correct side facing up, if marked.
  4.  
  5. Coat the bolt threads with sealer and install finger-tight.
  6.  
  7. Tighten the cylinder head bolts in sequence to 33 ft. lbs. (45 Nm). With all the bolts tightened make a second pass tightening all the bolts an additional 90°.
  8.  
  9. Install the pushrods, rocker arms, balls and rocker arm nuts. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the lower intake manifold and upper intake plenum.
  12.  
  13. Install the rocker arm covers.
  14.  
  15. Install the oil level indicator tube.
  16.  
  17. Connect the spark plug wires to spark plugs and wire looms.
  18.  
  19. Install the left side exhaust manifold.
  20.  
  21. Install the exhaust crossover pipe and crossover pipe heat shield.
  22.  
  23. Refill the cooling system.
  24.  
  25. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
  26.  
  27. Connect negative battery cable.
  28.  
  29. Start vehicle and verify no leaks.
  30.  

RIGHT SIDE (REAR)

CAUTION
Fuel Injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the top half of the air cleaner assembly and remove the throttle body air inlet duct.
  8.  
  9. Remove the exhaust crossover pipe heat shield and crossover pipe.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Disconnect the oxygen (O 2 ) sensor connector.
  14.  
  15. Disconnect the exhaust pipe from the exhaust manifold.
  16.  
  17. Remove the right side exhaust manifold.
  18.  
  19. Lower the vehicle.
  20.  
  21. Disconnect the spark plug wires from spark plugs and wire looms and route the wires out of the way.
  22.  
  23. Remove the rocker arm covers.
  24.  
  25. Remove upper intake plenum and lower intake manifold.
  26.  

When removing the valve train components they must be kept in order for installation in the same locations they were removed from.

  1. Remove rocker arms nut, rocker arms, balls and pushrods.
  2.  
  3. Remove the cylinder head bolts evenly.
  4.  
  5. Remove the cylinder head.
  6.  

To install:
  1. Clean all the gasket surfaces completely. Clean the threads on the cylinder head bolts and block threads.
  2.  
  3. Place the gasket into position over the dowel pins, with the correct side facing up, if marked.
  4.  
  5. Coat the bolt threads with sealer and install finger-tight.
  6.  
  7. Tighten the cylinder head bolts in sequence to 33 ft. lbs. (45 Nm). With all the bolts tightened make a second pass tightening all the bolts an additional 90°.
  8.  
  9. Install the pushrods, rocker arms, balls and rocker arm nuts. Tighten the rocker arm nuts to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the lower intake manifold and upper intake plenum.
  12.  
  13. Install the rocker arm covers.
  14.  
  15. Connect the spark plug wires to spark plugs and wire looms.
  16.  
  17. Raise vehicle and safely support.
  18.  
  19. Install the exhaust manifold.
  20.  
  21. Connect the exhaust pipe to the exhaust manifold.
  22.  
  23. Lower the vehicle.
  24.  
  25. Connect the oxygen (O 2 ) sensor connector.
  26.  
  27. Install the exhaust crossover pipe and heat shield.
  28.  
  29. Refill the cooling system.
  30.  
  31. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
  32.  
  33. Connect negative battery cable.
  34.  
  35. Start vehicle and verify no leaks.
  36.  

3.3L Engine

See Figure 7

RIGHT SIDE
  1. Relieve the pressure in the fuel system before disconnecting any fuel line connections.
  2.  
  3. Disconnect the negative battery cable. Raise the vehicle and support it safely.
  4.  
  5. Drain the cylinder block and lower the vehicle.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Remove the exhaust crossover pipe.
  10.  
  11. Disconnect the heater pipe retaining nut, then slide the pipe from the front of the cover housing.
  12.  
  13. Unsecure the power steering pump bolts at the mounting bracket, then remove the ground wires.
  14.  
  15. Unsecure the engine lift bracket and coolant pipe.
  16.  
  17. Remove the exhaust manifold heat shield.
  18.  
  19. Unbolt the transaxle fill tube.
  20.  
  21. Remove the spark plug loom, wires and spark plugs.
  22.  
  23. Raise and support the vehicle.
  24.  
  25. Disconnect the exhaust pipe to the manifold.
  26.  
  27. Lower the vehicle.
  28.  
  29. Unbolt the exhaust manifold and the heat shield, then remove.
  30.  
  31. Remove the valve cover, then remove the rocker arm assemblies.
  32.  
  33. Disconnect and tag all electrical wiring and vacuum hoses, as necessary.
  34.  
  35. If equipped with air conditioning, remove the air conditioning compressor and position to the side.
  36.  
  37. Remove the cylinder head bolts, then remove the cylinder head.
  38.  

To install:
  1. Clean the cylinder head and block of any foreign matter, nicks or heavy scratches. Clean the cylinder head bolt threads and threads in the cylinder block.
  2.  
  3. Position the new cylinder head gasket on the block. Apply sealant GM part no. 1052080, to the under side of the bolt heads, and thread locker GM part no. 12345382, to the bolt threads.
  4.  
  5. Carefully guide the cylinder head into place.
  6.  
  7. Coat the cylinder head bolts with sealing compound and install into the head. Tighten the cylinder head bolts according to the following procedure:
    1. Tighten in sequence to 35 ft. lbs. (47 Nm).
    2.  
    3. Using an appropriate torque angle gauge, rotate each bolt in sequence an additional 130°.
    4.  
    5. Rotate the center 4 bolts an additional 30° in sequence.
    6.  

  8.  
  9. Install the pushrods, guide plate and rocker arm assembly. Tighten the rocker arm pivot bolts to 28 ft. lbs. (38 Nm).
  10.  
  11. Install the exhaust manifold and heat shield, tighten the mounting bolts to 38 ft. lbs. (52 Nm).
  12.  
  13. Raise and support the vehicle.
  14.  
  15. Attach the exhaust pipe to the manifold.
  16.  
  17. Lower the vehicle.
  18.  
  19. Install the spark plug, wires and looms to the engine.
  20.  
  21. Bolt the transaxle fill tube to the engine.
  22.  
  23. Attach the exhaust manifold heat shield.
  24.  
  25. Install the coolant pipe and the engine lift bracket.
  26.  
  27. Connect the ground wires, then install the power steering pump bolts to the mounting bracket.
  28.  
  29. Slide the heater pipe to the front of the cover housing, then install the pipe retaining nut.
  30.  
  31. Attach the exhaust crossover pipe.
  32.  
  33. Install the intake manifold.
  34.  
  35. Connect all electrical wiring and vacuum hoses.
  36.  
  37. If equipped with air conditioning, install the air conditioning compressor.
  38.  
  39. Connect the negative battery cable.
  40.  
  41. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Recheck for leaks.
  42.  



Click image to see an enlarged view

Fig. Fig. 7: Tightening sequence for cylinder head bolts on 3.3L engines

LEFT SIDE
  1. Relieve the pressure in the fuel system before disconnecting any fuel lines.
  2.  
  3. Disconnect the negative battery cable. Raise the vehicle and support it safely.
  4.  
  5. Drain the cylinder block and lower the vehicle.
  6.  
  7. Unbolt the intake manifold.
  8.  
  9. Remove the spark plug loom and wires.
  10.  
  11. Unsecure the engine lift bracket and coolant pipe.
  12.  
  13. Unbolt the valve cover.
  14.  
  15. Remove the spark plugs.
  16.  
  17. Unfasten the exhaust crossover pipe.
  18.  
  19. Remove the oil level indicator.
  20.  
  21. Remove the cooling fan assembly.
  22.  
  23. Disconnect the exhaust manifold heat shield.
  24.  
  25. Remove the exhaust manifold support bracket.
  26.  
  27. Unbolt the exhaust manifold.
  28.  
  29. Remove the rocker arm assemblies.
  30.  
  31. Disconnect the A/C bracket bolt from the cylinder head.
  32.  
  33. Disconnect the bolts holding the alternator and ignition coil mounting bracket, push aside.
  34.  
  35. Remove the vacuum line bolt at the cylinder head (rear).
  36.  
  37. Remove the cylinder head bolts, then remove the cylinder head.
  38.  

To install:
  1. Clean the cylinder head and block of any foreign matter, nicks or heavy scratches. Clean the cylinder head bolt threads and threads in the cylinder block.
  2.  
  3. Position the new cylinder head gasket on the block. Apply sealant GM part no. 1052080, to the under side of the bolt heads, and thread locker GM part no. 12345382, to the bolt threads.
  4.  
  5. Carefully guide the cylinder head into place.
  6.  
  7. Coat the cylinder head bolts with sealing compound and install into the head. Tighten the cylinder head bolts according to the following procedure:
    1. Tighten in sequence to 35 ft. lbs. (47 Nm).
    2.  
    3. Using an appropriate torque angle gauge, rotate each bolt in sequence an additional 130°.
    4.  
    5. Rotate the center 4 bolts an additional 30° in sequence.
    6.  

  8.  
  9. Attach the vacuum line bolt at the cylinder head.
  10.  
  11. Connect the A/C bracket bolt from the head.
  12.  
  13. Install the pushrods, guide plate and rocker arm assembly. Tighten the rocker arm pivot bolts to 28 ft. lbs. (38 Nm).
  14.  
  15. Install the exhaust manifold, gasket and heat shield, tighten the mounting bolts to 38 ft. lbs. (52 Nm).
  16.  
  17. Attach the manifold support bracket and the heat shield, tighten the nuts fro the heat shield to 20 ft. lbs. (27 Nm).
  18.  
  19. Install the cooling fan assembly.
  20.  
  21. Attach the oil level indicator, tighten to 20 ft. lbs. (27 Nm).
  22.  
  23. Install the exhaust crossover.
  24.  
  25. Install the spark plugs.
  26.  
  27. Attach the intake manifold and gasket.
  28.  

3.8L Engine

See Figure 8

  1. Relieve the pressure in the fuel system before disconnecting any fuel lines.
  2.  
  3. Disconnect the negative battery cable. Raise the vehicle and support it safely.
  4.  
  5. Drain the cylinder block and lower the vehicle.
  6.  
  7. Remove the serpentine belt.
  8.  
  9. Remove the alternator, AIR pump, oil indicator and power steering pump, as required. Position to the side.
  10.  
  11. Remove the throttle cable. Remove the cruise control cable, if equipped.
  12.  
  13. Disconnect the fuel lines and fuel rail, as required.
  14.  
  15. Loosen and remove the heater hoses and radiator hoses.
  16.  
  17. Disconnect and tag all vacuum and electrical wiring.
  18.  
  19. Remove the radiator and cooling fan, if necessary.
  20.  
  21. Remove the intake manifold and valve cover.
  22.  
  23. Disconnect the exhaust manifold(s).
  24.  
  25. Remove the rocker arm assembly and pushrods.
  26.  
  27. Unbolt the cylinder head, then remove the cylinder head and gasket.
  28.  



Click image to see an enlarged view

Fig. Fig. 8: Tightening sequence for cylinder head bolts on 3.8L engines

To install:
  1. Clean the cylinder head and block from any foreign matter, nicks or heavy scratches. Clean the cylinder head bolt threads and threads in the cylinder block.
  2.  
  3. Position the new cylinder head gasket on the block.
  4.  
  5. Carefully guide the cylinder head into place. Coat the cylinder head bolts with sealing compound and install.
  6.  
  7. Tighten the cylinder head bolts according to the following procedure:
    1. Tighten the cylinder head bolts in sequence to 25 ft. lbs. (34 Nm).
    2.  
    3. Do not exceed 60 ft. lbs. (81 Nm) at any point during the next 2 steps.
    4.  
    5. Using a torque angle gauge, tighten each bolt an additional 90° in sequence.
    6.  

  8.  
  9. Install the exhaust manifold.
  10.  
  11. Install the intake manifold, pushrods and rocker arm assembly.
  12.  
  13. Install the valve cover.
  14.  
  15. Install the radiator and cooling fan, as required.
  16.  
  17. Connect all vacuum and electrical wiring.
  18.  
  19. Install the heater hoses and radiator hoses.
  20.  
  21. Connect the fuel lines and fuel rail.
  22.  
  23. Attach the throttle cable. Install the cruise control cable, if equipped.
  24.  
  25. Install the alternator, AIR pump, oil indicator and power steering pump.
  26.  
  27. Install the serpentine belt.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Check for leaks and top off the coolant.
  32.  

4.3L Diesel Engine

See Figure 9

  1. Remove intake manifold.
  2.  
  3. Remove valve cover. Loosen or remove any accessory brackets or pipe clamps which interfere.
  4.  

If removing the left cylinder head, remove the oil level indicator guide.

  1. Disconnect glow plug wiring (and block heater lead if so equipped on rear bank).
  2.  
  3. Remove the ground strap from the rear cylinder head. Remove the fuel lines at the injector nozzles.
  4.  
  5. Remove rocker arm nuts, pivots, rocker arms and pushrods. Scribe pivots and keep rocker arms separated so they can be installed in their original locations.
  6.  
  7. Disconnect the exhaust crossover pipe from the exhaust manifold on the side being worked on and loosen it on the other.
  8.  
  9. Remove engine block drain plug, from side of the block where head is being removed.
  10.  
  11. Remove the plugs covering the upper cylinder head bolts.
  12.  
  13. Remove all the cylinder head bolts and remove the cylinder head.
  14.  
  15. If necessary to remove the prechamber, remove the glow plug and injection nozzle, then tap out with a small blunt 1 / 8 in. (3mm) drift. Do not use a tapered drift.
  16.  

To install:
  1. Install the cylinder head gaskets using a special composition gasket that must be used without a sealer.
  2.  
  3. Attach the cylinder head, head bolts, pipe thread plugs. Coat the plug threads, bolt threads and the area under the bolt heads with GM part no. 1052080 sealer or equivalent.
  4.  


WARNING
Failure to coat the bolts with the correct sealer will result in coolant leaks and loss of clamping force on the cylinder head gasket due to thread and bolt-to-head friction. This will cause cylinder head damage.

  1. Tighten the cylinder head bolts to:
  2.  



Except No. 5, 6, 11, 12, 13 and 14 - 100 ft. lbs. (135 Nm)
 
No. 5, 6, 11, 12, 13 and 14 - 41 ft. lbs. (55 Nm)
 

Then retighten the cylinder head bolts to:



Except No. 5, 6, 11, 12, 13 and 14 - 142 ft. lbs. (193 Nm)
 
No. 5, 6, 11, 12, 13 and 14 - 59 ft. lbs. (80 Nm)
 



Click image to see an enlarged view

Fig. Fig. 9: Cylinder head bolt tightening sequence on 4.3L engines

  1. Install the pipe thread plugs, install the plug so that the bottom of the plug is flush with the bottom of the hole to 0.250 in. (6.35mm) above.
  2.  
  3. Install the engine coolant drain plug.
  4.  
  5. Attach the engine crossover pipe to the vehicle.
  6.  
  7. Install the pushrods and rocker arms.
  8.  
  9. Bleed the valve lifters. Refer to the procedure outlined in this section.
  10.  
  11. Attach the ground strap.
  12.  
  13. Connect the glow plug wiring.
  14.  
  15. Install the fuel lines to injection nozzles.
  16.  
  17. Bolt on the oil level indicator tube.
  18.  
  19. Install the valve covers.
  20.  
  21. Install the intake manifold.
  22.  
  23. Fill the cooling system, start the vehicle, top off the coolant.
  24.  
  25. Check for leaks.
  26.  

CLEANING & INSPECTION



See Figures 10 and 11

Chip carbon away from the valve heads, combustion chambers, and ports, using a chisel made of hardwood. Remove the remaining deposits with a stiff wire brush.



Click image to see an enlarged view

Fig. Fig. 10: Use a gasket scraper to remove the bulk of the old head gasket from the mating surface



Click image to see an enlarged view

Fig. Fig. 11: An electric drill equipped with a wire wheel will expedite complete gasket removal


WARNING
DO NOT use a steel wire brush to clean an aluminum cylinder head. Special brushes are sold just for use on aluminum. Always wear eye protection when grinding chipping or wire brushing.

Be sure that the deposits are actually removed, rather than burnished. Have the cylinder head cleaned to remove grease, corrosion, and scale from the water passages. Clean the remaining cylinder head parts in an engine cleaning solvent. Do not remove the protective coating from the springs.

RESURFACING



See Figures 12 and 13

All machine work should be performed by a competent, professional machine shop.

Place a straightedge across the gasket surface of the cylinder head. Using feeler gauges, determine the clearance at the center of the straightedge. If warpage is between 0.002 in. (0.05mm) to 0.010 in. (0.25mm) in a 6 in. (152mm) span, or 0.004 in. (0.1mm) to 0.010 in. (0.25mm) over all, resurface the cylinder head. If warpage exceeds 0.010 in. (0.25mm) in a 6 in. (152mm) span, the cylinder head must be replaced.



Click image to see an enlarged view

Fig. Fig. 12: Check the cylinder head for warpage along the center using a straightedge and a feeler gauge



Click image to see an enlarged view

Fig. Fig. 13: Be sure to check for warpage across the cylinder head at both diagonals

If warpage exceeds the manufacturer's maximum tolerance for material removal, the cylinder head must be replaced. When milling the cylinder heads of V-type engines, the intake manifold mounting position is altered, and must be corrected by milling the manifold flange a proportionate amount.

 
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