H3 2006

Cylinder Head

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Removal & Installation



3.5L & 3.7L Engines
  1. Bleed the fuel pressure.
  2.  
  3. Remove the air induction assembly from the vehicle.
  4.  
  5. Remove the battery from the vehicle.
  6.  
  7. Disconnect the fuel/EVAP lines from the intake manifold and move aside. Includes fuel line removal from fuel rail.
  8.  
  9. Remove the bolt holding the oil indicator tube to the intake manifold and move the oil indicator tube aside. Do not remove.
  10.  
  11. Lift the vehicle.
  12.  
  13. Remove the engine shield from the vehicle.
  14.  
  15. Remove the oil pan skid plate from the vehicle.
  16.  
  17. Remove the drive belt.
  18.  
  19. Drain the engine oil.
  20.  
  21. Drain the engine coolant.
  22.  
  23. Remove the left front wheelhouse panel.
  24.  
  25. Remove the fir tree wiring harness connectors from the engine wiring harness bracket from the left front wheelhouse opening.
  26.  
  27. From the left front wheelhouse, remove the engine wiring harness bracket from the engine and set aside.
  28.  
  29. Remove the intake manifold bolts from the wheelhouse access. The bolts stay with intake manifold.
  30.  
  31. On 2WD models, the intake manifold bolts are removed from the top of the engine, not through the left front wheelhouse panel.
  32.  
  33. Lower the vehicle.
  34.  
  35. Remove the Positive Crankcase Ventilation (PCV) pipes from the cam cover and remove the intake manifold from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the Positive Crankcase Ventilation (PCV) pipes (2, 6) from the cam cover

  36.  
  37. Remove the alternator output BAT terminal nut.
  38.  
  39. Remove the alternator lead from the alternator.
  40.  
  41. Disconnect the alternator electrical connector.
    NOTE
    The alternator does not have to be removed from the vehicle. On a two-wheel drive vehicle, the alternator must be removed from the vehicle.

  42.  
  43. Remove the alternator bolts and set the alternator aside.
  44.  
  45. Disconnect the A/C pipe clamp from the engine lift hook bracket.
  46.  
  47. Remove the engine lift hook bracket bolts and bracket from the vehicle.
  48.  
  49. Remove the bolts holding the windshield washer solvent container and coolant recovery reservoir to the right inner fender. Move aside to gain access to the engine wiring harness to the Powertrain Control Module (PCM).
  50.  
  51. Disconnect the following cross-vehicle engine wiring harness connectors:

    PCM
     
    Engine coolant temperature sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Ignition coils
     
    Harness clamps at power steering pump
     
    Wiring harness fastener at right front inner fender
     
    Throttle body
     
    Camshaft sensors
     
    Exhaust camshaft actuator
     
    Fuel injectors
     
    HO2S 1
     

  52.  
  53. Set aside the cross-vehicle engine wiring harness on the left side of the vehicle.
  54.  
  55. If equipped, remove the secondary Air Injection (AIR) injection pipe block-off plate bolts from the cylinder head.
  56.  
  57. If equipped, remove the AIR injection pipe block-off plate.
  58.  
  59. Remove the bolts from the exhaust manifold heat shield.
  60.  
  61. Remove the exhaust manifold heat shield.
  62.  
  63. Remove the exhaust manifold bolts.
  64.  
  65. Move the exhaust manifold back and away from the cylinder head.
  66.  
  67. Remove the bolts to all ignition coil assemblies and remove all ignition coil assemblies from the cam cover.
  68.  
  69. Remove all the spark plugs from the cylinder head.
  70.  
  71. Remove the cam cover from the cylinder head.
  72.  
  73. Remove the inlet radiator hose and clamp from the cylinder head.
  74.  
  75. Before performing one of the top dead center (TDC) procedures, break loose both the exhaust and intake camshaft sprocket bolts. Use a 1 inches (25 mm) open end wrench on the camshaft hexes to hold the camshaft from turning. DO NOT remove the bolts.

    Click image to see an enlarged view

    Fig. Break loose the exhaust and intake camshaft sprocket bolts

  76.  
  77. Perform one of the following methods for the service timing procedure:
    1. First Method: Rotate the engine clockwise by hand to TDC on the compression stroke by using a piston TDC indicator tool and/or dial indicator in the number 1 cylinder. The TDC indicator tool graduation marks on the shaft should note top of the piston stroke. When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats.

      Click image to see an enlarged view

      Fig. First Method

    2.  
    3. Second Method: Rotate the crankshaft in the engine rotational direction clockwise until the number 1 piston is at TDC on the compression stroke. The word Delphi on the exhaust camshaft position actuator will be parallel with the cylinder head to cam cover mating surface. When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats. A 0.005 inch feeler gage should not slide under the straight edge.

      Click image to see an enlarged view

      Fig. Second Method

    4.  

  78.  
  79. Once TDC is located for the number 1 cylinder using above methods, raise the vehicle and lock the flywheel with the EN 46547.

    Click image to see an enlarged view

    Fig. Lock the flywheel with the EN 46547

  80.  
  81. Use a white paint pen or equivalent to place a reference mark on the harmonic balancer to the front cover for alignment purposes.

    Click image to see an enlarged view

    Fig. Place a reference mark on the harmonic balancer to the front cover for alignment purposes

  82.  
  83. Lower the vehicle.
    CAUTION
    The camshaft holding tools must be installed on the camshafts to prevent camshaft rotation. When performing service to the valve train and/or timing components, valve spring pressure can cause the camshafts to rotate unexpectedly and can cause personal injury.


    NOTE
    If the timing is correct, TDC compression stroke number 1 cylinder, the camshaft flats will be in the up position.

  84.  
  85. Install J 44221 to the back of the camshafts.

    Click image to see an enlarged view

    Fig. Install J 44221 (1) to the back of the camshafts

  86.  
  87. Remove the upper timing chain guide to the cylinder head.
  88.  
  89. Clean the timing chain and gears with brake cleaner or suitable solvent. Use a white paint pen or equivalent to place a reference mark on both timing gear sprockets and the timing chain to mark location prior to disassembly. It is recommended that the paint marks be in the 12 o'clock position.
    WARNING
    DO NOT use excessive force to seat the wedge tool. If excessive force is used, you may damage the timing chain tensioner or break the front cover bolt requiring complete disassembly of the front engine.



    Click image to see an enlarged view

    Fig. Place a reference mark on both timing gear sprockets and the timing chain to mark location prior to disassembly

  90.  
  91. Install EN-48464. It is important to install the tool with the proper orientation and to ensure that it is seated square against the timing chain and against the timing cover center bolt.

    Click image to see an enlarged view

    Fig. Install EN-48464 with the proper orientation and seated square against the timing chain and the timing cover center bolt

  92.  
  93. The narrow ramp of the wedge tool needs to be placed so that it faces the timing chain.

    Click image to see an enlarged view

    Fig. Place the narrow ramp of the wedge tool so that it faces the timing chain

  94.  
  95. The wedge tool should be lightly seated using a couple of very light taps with a small plastic or brass hammer.
  96.  
  97. Once the tool is correctly installed, unscrew the handle and remove the handle.
    WARNING
    Use a 25 mm open end wrench on the camshaft hexes to hold the camshaft from turning. It is critical that the crankshaft does not move and is held at TDC when the intake and exhaust camshaft sprocket bolts are removed.


    WARNING
    If the crankshaft is not held in place, the wedge tool could be dislodged. If the crankshaft moves, or if the tool is not seated properly allowing the timing chain tensioner to extend, the repair will have to be completed by removing the front cover to release the timing chain tensioner.

  98.  
  99. Remove both upper cylinder head access hole plugs from the front of the cylinder head.
  100.  
  101. Remove the 1 long and 2 short cylinder head bolts next to the exhaust and intake timing chain tensioner shoes and discard the bolts.
  102.  
  103. Remove upper timing chain tensioner shoe bolt.
  104.  
  105. Remove upper timing chain tensioner guide bolt.
  106.  
  107. Remove the exhaust and the intake camshaft sprocket bolts. Discard the bolts.
  108.  
  109. Carefully remove the exhaust and intake camshaft sprockets with the timing chain from the exhaust and intake camshafts.

    Click image to see an enlarged view

    Fig. Remove the exhaust and intake camshaft sprockets with the timing chain from the exhaust and intake camshafts

  110.  
  111. Remove the sprockets from the chain; tie a piece of mechanic's wire on the timing chain and let it drop.
  112.  
  113. Before removing the cylinder head bolts, use a drift punch and hammer to shock the bolts. This will ensure that the cylinder head bolts will not strip out the threads in the engine block or break. If a bolt breaks during engine disassembly, EN-47702 is available to assist in the removal of the remaining bolt segment.

    Click image to see an enlarged view

    Fig. Use a drift punch and hammer to shock the bolts

  114.  
  115. Remove the cylinder head bolts. Discard the bolts.

    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts

  116.  
  117. Remove the cylinder head.
  118.  
  119. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent damage to the deck face.
  120.  
  121. Remove the cylinder head gasket.
  122.  
  123. Discard the gasket.

    Click image to see an enlarged view

    Fig. Remove the cylinder head and gasket

  124.  
  125. Remove all remaining gasket material from the engine block.
  126.  

To install:

  1. Install the dowel pins, cylinder head locator, if necessary.
  2.  
  3. Position a NEW cylinder head gasket to the engine block.
    NOTE
    Ensure all wires, components, etc. are out of the way when installing the cylinder head.

  4.  
  5. Install the cylinder head.
    WARNING
    This component uses torque-to-yield bolts. When servicing this component do not reuse the bolts, New torque-to-yield bolts must be installed. Reusing used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage.

  6.  
  7. Install NEW cylinder head bolts.
  8.  
  9. Tighten the NEW cylinder head bolts in the following sequence:
    1. Tighten the cylinder head bolts in sequence to 22 ft. lbs. (30 Nm). Use the J 45059 to rotate the cylinder head bolts in sequence an additional 155 degrees.
    2.  
    3. Tighten the (2 short) end bolts to 62 inch lbs. (7 Nm). Use the J 45059 to rotate the short cylinder head end bolts an additional 60 degrees.
    4.  
    5. Tighten the (1 long) end bolt to 62 inch lbs. (7 Nm). Use the J 45059 to rotate the long cylinder head end bolt an additional 120 degrees.
      CAUTION
      The camshaft holding tools must be installed on the camshafts to prevent camshaft rotation. When performing service to the valve train and/or timing components, valve spring pressure can cause the camshafts to rotate unexpectedly and can cause personal injury.


      NOTE
      Before installing the camshafts, refer to Camshafts Cleaning and Inspection.



      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence

    6.  

  10.  
  11. Install the camshafts with the flats up using J 44221.
    WARNING
    Tension must be always kept on the intake side of the timing chain to properly keep the engine in time. If the chain is loose the timing will be off, which may cause internal engine damage or set DTC P0017.


    WARNING
    The exhaust camshaft actuator must be fully advanced during installation. Engine damage may occur if the camshaft actuator is not fully advanced.

  12.  
  13. Ensure that the camshaft position actuator is in the fully advanced position.
    NOTE
    To aid in aligning the actuator to the camshaft, use a 1 inches (25 mm) open end wrench on the hex of the camshaft to rotate. This will ensure the alignment pin is properly engaged with the camshaft and hand tighten the new exhaust camshaft sprocket bolt.

  14.  
  15. Install the exhaust camshaft actuator/sprocket and chain onto the exhaust camshaft. Use the paint marks as an alignment guide.
    NOTE
    To aid in aligning the intake sprocket to the camshaft, use a 1 inches (25 mm) open end wrench on the hex of the camshaft to rotate. This will ensure the alignment pin is properly engaged with the camshaft and hand tighten the new intake camshaft sprocket bolt.

  16.  
  17. Install the intake camshaft sprocket and chain onto the intake camshaft. Use paint marks as alignment guide.
  18.  
  19. Position the timing chain tensioner shoe to the engine.
  20.  
  21. Install the timing chain tensioner shoe bolt and tighten to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view

    Fig. Position the timing chain tensioner shoe to the engine

  22.  
  23. Position the lower timing chain guide to the engine.
  24.  
  25. Install the lower timing chain guide bolts and tighten to 107 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Install the lower timing chain guide

  26.  
  27. Install both upper timing chain tensioner shoe bolts and tighten to 18 ft. lbs. (25 Nm).
  28.  
  29. Install both upper cylinder head access hole plugs to the front of the cylinder head. Tighten the plugs to 44 inch lbs. (5 Nm).
  30.  
  31. Tighten the new intake camshaft sprocket bolt. Using J 45059, tighten the intake camshaft sprocket bolt to 15 ft. lbs. (20 Nm) plus 100 degrees.

    Click image to see an enlarged view

    Fig. Using J 45059, tighten the intake camshaft sprocket bolt

  32.  
  33. Tighten the new exhaust camshaft actuator sprocket bolt. Using J 45059, tighten the exhaust camshaft actuator sprocket bolt to 18 ft. lbs. (25 Nm) plus 135 degrees.

    Click image to see an enlarged view

    Fig. Using J 45059, tighten the exhaust camshaft actuator sprocket bolt

  34.  
  35. Lift the vehicle and remove the EN 46547.
  36.  
  37. Lower the vehicle.
  38.  
  39. Remove the J 44221 from the back of the camshafts.
    WARNING
    Ensure that the wedge tool is removed from engine prior to rotation. If the wedge tool is not removed, engine damage will result.

  40.  
  41. Install the handle of EN-48464 and remove the wedge portion of the tool from the engine.
    WARNING
    It is critical that the engine is at TDC and not a couple of degrees off. If in doubt, repeat this step.

  42.  
  43. Rotate the engine clockwise by hand 2 complete revolutions to TDC number 1 on the compression stroke. Refer to First Method or Second Method for TDC. If you go past TDC, rotate the engine back approximately 45 degrees before TDC and then rotate clockwise up to TDC to ensure that the timing chain is tight (no slack) between the crank sprocket and the timing gears.
    NOTE
    DO NOT use the J 44221, installed to the back of the camshafts, as a method to verify timing.

  44.  
  45. Both intake and exhaust camshaft flats should be facing up and flat and level with the cylinder head. If J 44221 is used to verify cam timing, you could be off approximately one tooth and cause DTC P0017 to set. If a worn or new J 44221 is used to verify timing, the timing will be off.

    Click image to see an enlarged view

    Fig. Install J 44221 (1) to the back of the camshafts

  46.  
  47. To verify timing, set a straight edge across the flats of the camshafts.
  48.  
  49. A 0.005 inch feeler gage should not be able to slip under the straight edge. If the feeler gage slips under one or both camshaft flats, then the timing is off. Repeat step 20 and recheck. If the camshaft flats are still not flat, the camshaft timing will have to be reset. This may require removal and reinstallation of one or both camshaft sprockets.
  50.  
  51. Install the 1 long and 2 short cylinder head bolts next to the exhaust and intake timing chain tensioner shoes and tighten the bolts.
  52.  
  53. Position the upper timing chain guide to the cylinder head. Apply thread locker GM P/N 89021297 (Canadian P/N 10953488) to the upper timing chain guide bolt threads.
  54.  
  55. Install the upper timing chain guide bolts and tighten to 89 inch lbs. (10 Nm).
  56.  
  57. Install the radiator inlet hose and clamp to the cylinder head.
  58.  
  59. Clean and inspect the camshaft cover.
  60.  
  61. Install a NEW camshaft cover seal and NEW ignition control module seals to the cam cover. Position the camshaft cover to the cylinder head.
  62.  
  63. Install the camshaft cover bolts and tighten to 89 inch lbs. (10 Nm).
  64.  
  65. Check the gap on all of the spark plugs. The gap should be 0.042 inches (1.08 mm). Tighten all of the spark plugs to 13 ft. lbs. (18 Nm).
  66.  
  67. Install the ignition coils into the camshaft cover.
  68.  
  69. Install the ignition coil bolts and tighten to 89 inch lbs. (10 Nm).
  70.  
  71. Reposition the exhaust manifold to cylinder head and install the exhaust manifold bolts to the cylinder head.
  72.  
  73. If equipped, install a NEW AIR injection gasket, then the cover and pipe studs to the cylinder head.
  74.  
  75. Tighten the pipe studs to 18 ft. lbs. (25 Nm).
  76.  
  77. Install the exhaust manifold heat shield to the exhaust manifold.
  78.  
  79. Apply anti-seize GM P/N 12371386 (Canadian P/N 89021945) to the exhaust manifold heat shield nuts.
  80.  
  81. Install the exhaust manifold heat shield nuts and tighten to 89 inch lbs. (10 Nm).
  82.  
  83. Install the intake manifold to the cylinder head.
  84.  
  85. Reposition the engine wiring harness bracket to the engine and harnesses. Install the engine wiring harness bracket bolts and tighten to 89 inch lbs. (10 Nm).
  86.  
  87. Install the left front wheelhouse panel and the left wheel and tire.
  88.  
  89. Drain the engine oil again.
  90.  
  91. If removed, install the radiator outlet hose.
  92.  
  93. Install the oil pan skid plate and the engine shield.
  94.  
  95. Install the engine shield.
  96.  
  97. Lower the vehicle.
  98.  
  99. Install the cross-vehicle wiring harness connectors to the following components:

    PCM
     
    Map sensor
     
    Ignition coils
     
    Harness clamps at power steering pump
     
    Wiring harness fastener at right front inner fender
     
    Throttle body
     
    Camshaft sensors
     
    Exhaust camshaft actuator
     
    Fuel injectors
     
    HO2S 1
     

  100.  
  101. Install the windshield washer solvent container and coolant recovery reservoir bolts to the right inner fender. Tighten the bolts to 89 inch lbs. (10 Nm).
  102.  
  103. Install the PCV pipes to the intake manifold.
  104.  
  105. Reposition the oil indicator (dipstick) tube and tighten the bolt to the intake manifold.
  106.  
  107. Reposition the fuel/EVAP lines to the intake manifold retainer.
  108.  
  109. Install the following components:

    Alternator
     
    A/C compressor hose/pipe bracket clamp for the engine lift bracket
     

  110.  
  111. Drive belt
  112.  
  113. Install the battery.
  114.  
  115. Install the air induction assembly.
  116.  
  117. Install NEW engine oil.
  118.  
  119. Install NEW coolant.
  120.  
  121. Install a scan tool and start the engine.
  122.  
  123. Check for DTCs.
  124.  
  125. Road test the vehicle. DTC P0017 is a Type B diagnostic code. Three consecutive ignition key cycles must be performed during the road test with a minimum of a one minute run time between key cycles to verify that a DTC P0017 did not set. For further information on DTC P0017, refer to DTC P0017.
  126.  

5.3L Engine
Left Side

Specific to:

Hummer H3 2006-2010

  1. Remove the alternator bracket.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Remove the coolant air bleed pipe.
  6.  
  7. Remove the left exhaust manifold.
  8.  
  9. Remove the pushrods.
    NOTE
    The cylinder head bolts are of a torque-to-yield design and are NOT to be reused.

  10.  
  11. 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.

  12.  
  13. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts (220, 221) and cylinder head (218)

  14.  
  15. Remove and discard the cylinder head gasket.
  16.  
  17. If required, clean and inspect the cylinder head.
  18.  

To install:


CAUTION
Wear safety glasses in order to avoid eye damage.


CAUTION
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
If installing a new cylinder head it is necessary to install a new engine coolant air bleed plug into the rear coolant passage of the cylinder head.


NOTE
Do not reuse the cylinder head bolts. Install NEW cylinder head bolts during assembly.


NOTE
Do not use any type of sealant on the cylinder head gasket (unless specified).

  1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107, found in J 42385-200 may be used to clean the threads of old thread locking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981 (Canadian P/N 10953463), or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation 0.327 inches (8.3 mm).
    NOTE
    When properly installed, with FRONT on the left side, the tab on the cylinder head gasket should be located left of center.



    Click image to see an enlarged view

    Fig. Check the cylinder head locating pins for proper installation (a) 0.327 inches (8.3 mm)

  8.  
  9. Install the NEW cylinder head gasket onto the locating pins.
  10.  
  11. Install the cylinder head onto the locating pins.
  12.  
  13. Install the NEW cylinder head bolts.
  14.  
  15. Tighten the cylinder head bolts:
    1. Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees using J 45059.
    4.  
    5. Tighten the M11 cylinder head bolts (1-10) a final pass to 70 degrees using J 45059.
    6.  
    7. Tighten the M8 cylinder head bolts (11-15) to 22 ft. lbs. (30 Nm). Begin with the center bolt and alternating side-to-side, work outward tightening all of the bolts.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence

    8.  

  16.  
  17. Install the pushrods.
  18.  
  19. Install the left exhaust manifold.
  20.  
  21. Install the coolant air bleed pipe.
  22.  
  23. Install the intake manifold.
  24.  
  25. Install the alternator bracket.
  26.  

Right Side

Specific to:

Hummer H3 2006-2010

  1. Remove the oil level indicator.
  2.  
  3. Remove the intake manifold.
  4.  
  5. Remove the coolant air bleed pipe.
  6.  
  7. Remove the right exhaust manifold.
  8.  
  9. Remove the pushrods.
  10.  
  11. Remove the heater hose bracket bolt from the front of the right cylinder head.
    NOTE
    The cylinder head bolts are of a torque-to-yield design and are NOT to be reused.

  12.  
  13. 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.

  14.  
  15. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. Remove and discard the cylinder head (218) and bolts (220, 221)

  16.  
  17. Remove and discard the cylinder head gasket.

    Click image to see an enlarged view

    Fig. Remove and discard the cylinder head gasket (217)

  18.  
  19. If required, clean and inspect the cylinder head.
  20.  

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
If installing a new cylinder head it is necessary to install a new engine coolant air bleed plug into the rear coolant passage of the cylinder head.


NOTE
Do not reuse the cylinder head bolts. Install NEW cylinder head bolts during assembly.


NOTE
Do not use any type of sealant on the cylinder head gasket (unless specified).

  1. Clean the engine block cylinder head bolt holes, if required. Thread repair tool J 42385-107, found in J 42385-200 may be used to clean the threads of old thread locking material.
  2.  
  3. Spray cleaner GM P/N 12346139, P/N 12377981 (Canadian P/N 10953463), or equivalent into the hole.
  4.  
  5. Clean the cylinder head bolt holes with compressed air.
  6.  
  7. Check the cylinder head locating pins for proper installation 0.327 inches (8.3 mm).
    NOTE
    When properly installed, with FRONT on the right side, the tab on the cylinder head gasket should be located right of center.



    Click image to see an enlarged view

    Fig. Check the cylinder head locating pins for proper installation (a) 0.327 inches (8.3 mm)

  8.  
  9. Install the NEW cylinder head gasket onto the locating pins.
  10.  
  11. Install the cylinder head onto the locating pins.
  12.  
  13. Install the NEW cylinder head bolts.
  14.  
  15. Tighten the cylinder head bolts:
    1. Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 22 ft. lbs. (30 Nm).
    2.  
    3. Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees using J 45059.
    4.  
    5. Tighten the M11 cylinder head bolts (1-10 ) a final pass to 70 degrees in sequence using J 45059.
    6.  
    7. Tighten the M8 cylinder head bolts (11-15) to 22 ft. lbs. (30 Nm). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.

      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence

    8.  

  16.  
  17. Install the heater hose bracket bolt to the front of the right cylinder head and tighten to 18 ft. lbs. (25 Nm).
  18.  
  19. Install the pushrods.
  20.  
  21. Install the right exhaust manifold.
  22.  
  23. Install the coolant air bleed pipe.
  24.  
  25. Install the intake manifold.
  26.  
  27. Install the oil level indicator.
  28.  

 
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