Cylinder Head Replacement - Front

This article has been updated with TSB 02-06-01-003B, 4/15/08
This bulletin is being revised to include a Notice advising that the cylinder head bolts are NOT TO BE RE-USED. Please discard Corporate Bulletin Number 02-06-01-003A.
Removal Procedure

Important: During disassembly, keep the valve train components together and identified in order to install the parts in the original locations.

Perform a compression test. Refer to Engine Compression Test. Record the results before you perform the following repairs:
^ Remove the cylinder heads.
^ Disassemble the valve mechanism.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Depressurize the fuel system. Refer to Throttle Body Assembly Replacement in Powertrain Management.
3. Drain the cooling system. Recover the coolant. Refer to Cooling System Service and Repair.
4. Remove the top half of the air cleaner assembly.
5. Remove the throttle body duct.
6. Remove the exhaust crossover.
7. Remove the exhaust crossover.
8. Remove the valve rocker arms and pushrods.
9. Remove the front exhaust manifold.





10. Remove the cylinder head bolts.
11. Remove the cylinder head.
12. Clean the mating surfaces of the following items:
^ The cylinder head
^ The cylinder block
^ The intake manifold
13. Clean the cylinder block bolt threads.
14. Clean the cylinder head bolts.

Installation Procedure

^ Tools Required
- J 36660 Torque Angle Meter





1. Place the cylinder head gasket into position over the dowel pins. Ensure that the THIS SIDE UP note is showing.
2. Install the cylinder head.
3. Coat the cylinder head bolt threads using GM P/N 1052080 sealer or an equivalent.

Notice: Refer to Fastener Notice in Service Precautions.

Notice: This component uses torque-to-yield bolts. When servicing this component, do not re-use the bolts. New torque-to-yield bolts must be installed. Re-using 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.





4. Install the NEW cylinder head bolts.
- Tighten the NEW cylinder head bolts to 60 Nm (44 lb ft) in the order shown. Use the J 36660-A torque angle meter in order to rotate the cylinder head bolts an additional 95 degrees.


5. Install the intake gasket.
6. Refer to Valve Rocker Arm and Push Rod Replacement when you perform the following steps in order to install the pushrods that are loosely retained by the rocker arms:
6.1. Install the pushrods in their original locations
6.2. Coat the pushrod ends with prelube. Use GM P/N 1052356 or an equivalent.
6.3. The intake pushrods are identified with yellow stripes. The intake pushrods are 14.6 cm (5.75 inch) long.
6.4. The exhaust pushrods are identified with green stripes. The exhaust pushrods are 15.24 cm (6 inch) long.
6.5. Ensure that the pushrods seat in the lifter.
7. Install the rocker arm bolts.
8. Install the upper and the lower intake manifolds.
9. Install the valve rocker cover.
10. Install the left exhaust manifold.





11. Install the crossover pipe.





12. Install the crossover heat shield.
13. Fill the cooling system. Refer to Cooling System Service and Repair.
14. Install the throttle body duct.
Install the top half of the air cleaner assembly.
15. Connect the negative battery cable.