Relieve the fuel system pressure.
Disconnect the negative battery cable.
Drain and recover the coolant into a suitable container.
Disconnect the heater inlet and throttle body heater hoses from water outlet.
Remove the exhaust manifold.
Remove the intake camshaft housing and lifters, then remove the exhaust camshaft housing and lifters.
Remove the oil fill tube.
Remove the throttle body-to-air cleaner duct.
Disconnect the power brake vacuum hose from throttle body.
Remove the throttle cable bracket.
Remove the throttle body from intake manifold, with electrical harness and throttle cable attached. Position it aside.
Disconnect the MAP sensor vacuum hose from intake manifold.
Remove the intake manifold brace.
Disconnect electrical connectione from the following sensors: MAP sensor, intake air temperature sensor and EVAP canister purge solenoid.
Disconnect the upper radiator hose from water outlet.
Detach the coolant temperature sensors connectors.
Unfasten the cylinder head bolt, then remove cylinder head and gasket.
This is an aluminum cylinder head and must be treated with care. Do not use abrasive pads to clean the cylinder head or block surfaces. An abrasive pad may damage the cylinder head and block.
Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. Use a new razor blade for each cylinder head. Hold the scraper so the razor blade is as parallel to the gasket surface as possible. Do not use any other method or technique to clean these gasket surfaces. In addition, GM warn not to use a tap to clean cylinder head bolt holes.
When working on an aluminum head, do not remove spark plug from an aluminum cylinder head until the cylinder head has cooled. Always clean all dirt and debris from the spark plug recess area. If the spark plug opening threads are damaged and NOT restorable with a Thread Chaser, replace the cylinder head. GM DOES NOT approve of the installation of thread inserts into the spark plug openings on this engine. If threads are installed into the spark plug openings, severe engine damage will occur.
Clean all the gasket surfacee completely. Clean the threads on cylinder head bolts and be sure all bolt holes are clean and free of debris. New bolts are recommended.
Inspect the cylinder head and block surface for cracks, nicks, heavy scratches and flatness.
Place a new cylinder head gasket on the block. Do not use any sealing material.
Carefully place the cylinder head on dowel pins, being careful not to disturb the gasket.
Apply a small amount of clean engine oil to the threads of the cylinder head bolts, and install finger-tight.
Tighten head bolts in sequence. Tighten bolts 1 through 8 to 40 ft. Lbs. (65 Nm), then, tighten bolts 9 and 10 to 30 ft. Lbs. (40 Nm). Turn all 10 bolts an additional 90 degreee ( 1 / 4 turn) in sequence.
Attach the coolant temperature sensor connections.
Connect upper radiator hose to coolant outlet.
Install manifold brace and tighten to 19 ft. Lbs. (26 Nm).
Attach all sensor connections.
Connect the MAP sensor vacuum hose to intake manifold.
Install throttle body to intake manifold, using a new gasket.
Install accelerator control cable bracket to the throttle body, and tighten the bolte to 106 inch lbs. (13 Nm). Tighten the nut to 19 ft. Lbs. (26 Nm).
Install the throttle body-to-air cleaner duct.
Install oil fill tube, tighten attaching bolt to 71 inch lbs. (8 Nm).
Install the liftere and camshaft housing.
Install the exhaust manifold, then tighten the exhaust nuts to 26 ft. Lbs. (35 Nm).
Connect negative battery.
Fill coolant system and bleed off air from system. An oil and filter change is recommended.
Check and verify that vehicle has no coolant or vacuum leaks.
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Monday, April 6th, 2009 AT 12:38 PM