Montana, Silhouette, Venture 2000-2005

Cylinder Head

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Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove the lower intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
  8.  
  9. Remove the valve rocker arms and the pushrods. For additional information, refer to the following section, -Rocker Arms, Removal & Installation.-
  10.  
  11. Remove the exhaust crossover pipe. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  12.  
  13. For the left cylinder head, remove the oil level indicator tube.
  14.  
  15. Remove the spark plug wires from the spark plugs.
  16.  
  17. Remove the spark plugs.
  18.  
  19. For the right side cylinder head, remove the alternator. For additional information, refer to the following section, -Alternator, Removal & Installation.-
  20.  
  21. Remove the appropriate side exhaust manifold. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  22.  
  23. Remove the cylinder head bolts and discard.
  24.  
  25. Remove the cylinder head.
  26.  
  27. Remove the cylinder head gasket.
  28.  
  29. Clean and inspect the cylinder head and the gasket mating surfaces.
  30.  

To install:

  1. Install a new cylinder head gasket over the alignment pins.
  2.  
  3. Install the cylinder head over the locator pins and the gasket.
  4.  
  5. Install the new cylinder head bolts. Tighten the bolts, in the sequence shown, to 44 ft. lbs. (60 Nm).
  6.  
  7. Use the angle tool, J 45059, or suitable angle measuring device, to rotate the bolts in sequence an additional 95 degrees.
  8.  
  9. Install the exhaust manifold. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  10.  
  11. Install the spark plugs. Torque the spark plugs to 15 ft. lbs. (20 Nm), if using a new cylinder head, or to 11 ft. lbs. (15 Nm), if using an existing head.
  12.  
  13. For the right side cylinder head, install the alternator. For additional information, refer to the following section, -Alternator, Removal & Installation.-
  14.  
  15. Install the spark plug wires to the spark plugs.
  16.  
  17. For the left side cylinder head, install the oil level indicator tube.
  18.  
  19. Install the exhaust crossover pipe. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  20.  
  21. Install the valve rocker arms and pushrods. For additional information, refer to the following section, -Rocker Arms, Removal & Installation.-
  22.  
  23. Install the lower intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
  24.  
  25. Fill the crankcase with engine oil.
  26.  
  27. Fill the cooling system.
  28.  
  29. Start the engine and inspect for leaks.

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-3.5L and 3.9L engines



    Click image to see an enlarged view

    Fig. Cylinder head gasket installation

  30.  

3.9L Engine
  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 the lower intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
  8.  
  9. Remove the exhaust crossover pipe. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  10.  
  11. If removing the left side cylinder head, remove the oil dipstick tube.
  12.  
  13. Remove the spark plugs.
  14.  
  15. Remove the and discard the cylinder head bolts.
  16.  
  17. Remove the cylinder head.
  18.  

To install:

  1. Clean and inspect the cylinder head and the gasket mating surfaces.
  2.  
  3. Install the spark plugs to the cylinder head.

    Click image to see an enlarged view

    Fig. Head gaskets are specific for right hand and left hand applications, and also must be installed with the correct side facing up. Note the markings (1) on the head gaskets for proper installation.

  4.  
  5. Install a new cylinder head gasket.
  6.  
  7. Install the cylinder head on to the locator pins on the engine block. Install the cylinder head bolts finger tight.
  8.  
  9. Tighten the bolts, in the sequence shown, to 44 ft. lbs. (60 Nm).
  10.  
  11. Use the angle tool, J 45059, or suitable angle measuring device, to rotate the bolts in sequence an additional 95 degrees.
  12.  
  13. Install the oil dipstick tube, if removed.
  14.  
  15. Install the exhaust crossover pipe. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
  16.  
  17. Install the lower intake manifold. For additional information, refer to the following section, -Intake Manifold, Removal & Installation.-
  18.  
  19. Refill the engine with oil to the correct level.
  20.  
  21. Refill the cooling system to the correct level.
  22.  
  23. Start the engine and check for leaks.
  24.  

Left Side (Front)

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

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

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

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

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

  10.  

To install:

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

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-3.4L engine

  6.  
  7. Install or connect the following:

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

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

Right Side (Rear)

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

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

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

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

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

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-3.4L engine

     

  10.  

To install:

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

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

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

 
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