GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Epica 🢒 Engine 🢒 Engine Mechanical - 2.0L (L34 GMDAT) 🢒 Cylinder Head Assemble
    • J 8062 Valve Spring Compressor - Head OFF
    • KM-653-A Adapter

Assembly Procedure

    Caution: Refer to Safety Glasses Caution in the Preface section.


    Object Number: 1241260 Size: SH
  1. Coat the valve stems with engine oil.
  2. Insert the valves in the cylinder head in their original positions.
  3. Insert the valve spring seats.

    4. Caution: Refer to Compressed Valve Spring Caution in the Preface section.

  4. Push the accompanying assembly sleeve onto the valve stem.
  5. Insert the new valve stem seat.
  6. Carefully drive the valve stem seal onto the stop with light taps.
  7. Install the valve springs in their original positions.
  8. Install the valve springs caps.

    9. Object Number: 1252182 Size: SH
  9. Compress the valve springs with the J 8062  (1) and KM-653-A  (2).
  10. Install the valve retainers.
  11. Remove the J 8062  (1) and KM-653-A  (2).

    12. Object Number: 1252180 Size: SH
  12. Lubricate the valve lash adjusters with engine oil.
  13. Install the valve lash adjusters.

    14. Object Number: 1252134 Size: SH
  14. Install the intake camshaft.
  15. Install the intake camshaft bearing caps in their original positions.
  16. Install the exhaust camshaft.
  17. Install the exhaust camshaft bearing caps in their original positions.
  18. Install the camshaft bearing cap bolts.

    19. Notice: Refer to Fastener Notice in the Preface section.

  19. Tighten the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft cap.

    20. Tighten
    Tighten the camshaft bearing cap bolts to 8 N·m (71 lb in).


    Object Number: 1241257 Size: SH
  20. Install the spark plugs.

    21. Tighten
    Tighten the spark plugs to 20 N·m (15 lb ft).

  21. Install the ignition coil and exhaust gas recirculation (EGR) mounting bracket and bolt.

    22. Tighten
    Tighten the ignition coil and EGR mounting bracket bolts to 25 N·m (18 lb ft).

  22. Install the ignition coil and EGR.

    23. Tighten
    Tighten the ignition coil and EGR to 10 N·m (89 lb ft).


    Object Number: 1252158 Size: SH
  23. Install the intake manifold studs.
  24. Install the intake manifold gasket.
  25. Install the intake manifold.
  26. Install the intake manifold retaining nuts and retaining bolts in the sequence shown.

    27. Tighten
    Tighten the intake manifold retaining nuts and retaining bolts to 22 N·m (16 lb ft).


    Object Number: 1241256 Size: SH
  27. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.0L.
  28. Install the thermostat housing assembly.
  29. Install the thermostat housing mounting bolts.

    30. Tighten
    Tighten the thermostat housing mounting bolts to 15 N·m (11 lb ft).

  30. Install the coolant bypass housing bolts.

    31. Tighten
    Tighten the coolant bypass housing bolts to 15 N·m (11 lb ft).


    Object Number: 1252166 Size: SH
  31. Install the exhaust manifold studs.
  32. Install the exhaust manifold gasket.
  33. Install the exhaust manifold.
  34. Install the exhaust manifold retaining nuts in the sequence shown.

    35. Tighten
    Tighten the exhaust manifold retaining nuts to 22 N·m (16 lb ft).

  35. Install the exhaust manifold heat shield.
  36. Install the exhaust manifold heat shield bolts.

    37. Tighten
    Tighten the exhaust manifold heat shield bolts to 8 N·m (71 lb in).

  37. Install the cylinder head with the intake manifold and the exhaust manifold attached. Refer to Cylinder Head Replacement .