GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Optra 🢒 Engine 🢒 Engine Mechanical - 1.6L (L91) 🢒 Cylinder Head Assemble

Tools Required

    • J 8062 (KM-348) Valve Spring Compressor - Head Off
    • KM-653-A Adaptor

    Object Number: 1289671 Size: SH
  1. Install the valve stem seals.
  2. Lubricate the valve stems with engine oil.
  3. Carefully install the valves in their original positions. Do not damage the valve stem seals.
  4. Install the valve springs in their original positions.
  5. Install the valve spring caps.

    6. Object Number: 1289657 Size: SH
  6. Compress the valve springs with J 8062 and KM-653-A
  7. Install the valve keys.
  8. Remove J 8062 and KM-653-A .

    9. Object Number: 1289656 Size: SH
  9. Lubricate the valve tappet adjusters with engine oil.
  10. Install the valve tappet adjusters.

    11. Object Number: 1291253 Size: SH
  11. Install the intake camshaft.
  12. Install the intake camshaft caps in their original positions.
  13. Install the exhaust camshaft.
  14. Install the exhaust camshaft caps in their original positions.
  15. Install the camshaft cap bolts.

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

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

    17. Tighten
    Tighten the camshaft cap bolts to 16 N·m (12 lb ft).


    Object Number: 1291225 Size: SH
  17. Install the spark plugs

    18. Tighten
    Tighten the spark plugs to 25 N·m (18 lb ft).

  18. Install the EGR valve adapter gasket.
  19. Install the EGR valve adapter.
  20. Install the EGR valve adapter bolts.

    21. Tighten
    Tighten the exhaust gas recirculation valve adapter bolts to 25 N·m (18 lb ft).

  21. Install the DIS coil mounting bracket.
  22. Install the DIS coil mounting bracket bolts.

    23. Tighten
    Tighten the direct ignition system coil mounting bracket bolts to 10 N·m (89 lb in).

  23. Install the DIS coil with the ignition wires attached.
  24. Install the DIS coil mounting bolts.

    25. Tighten
    Tighten the direct ignition system coil mounting bolts to 10 N·m (89 lb in).


    Object Number: 1291157 Size: SH
  25. Install the intake manifold studs.
  26. Install the intake manifold.
  27. Install the intake manifold retaining nuts and retaining bolts in the sequence shown.

    28. Tighten
    Tighten the intake manifold retaining nits and retaining bolts to 25 N·m (18 lb ft).


    Object Number: 1289655 Size: SH
  28. Install the fuel rail assembly with the bolts.

    29. Tighten
    Tighten the fuel rail assembly retaining bolts to 25 N·m (18 lb ft).

  29. Install the thermostat housing assembly.
  30. Install the thermostat housing mounting bolts.

    31. Tighten
    Tighten the thermostat housing mounting bolts 20 N·m (15 lb ft).


    Object Number: 1291215 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 25 N·m (18 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 15 N·m (11 lb ft).


    Object Number: 1289672 Size: SH
  37. Install the coolant temperature sensor.

    38. Tighten
    Tighten the coolant temperature sensor to 20 N·m (15 lb ft).

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