GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Tools Required

    • J 36660-A Torque Angle Meter
    • J 28467-A Engine Support Fixture
    • J 8614-01 Pinion Flange Holder
  1. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls.
  2. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  3. Disconnect the negative battery cable.
  4. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  5. Drain the engine oil.
  6. Remove the washer fluid tank mounting bolt.
  7. Position the washer fluid tank aside.
  8. Disconnect the washer pump connector.
  9. Disconnect the washer pump fluid line.
  10. Plug the washer pump fluid line in order to prevent washer fluid from escaping.

  11. Object Number: 244267  Size: SH
  12. Remove the serpentine drive belt. Refer to Drive Belt Replacement in Engine Mechanical.

  13. Object Number: 244251  Size: SH
  14. Disconnect the generator connector.
  15. Disconnect the positive cable at the generator.

  16. Object Number: 244308  Size: SH
  17. Remove the two generator bolts.
  18. Remove the generator (1).

  19. Object Number: 234418  Size: SH
  20. Remove the accelerator cable from the throttle body (1).

  21. Object Number: 236882  Size: SH
  22. Disconnect the intake air temperature (IAT) sensor.
  23. Remove the air cleaner hose and cap assembly (1).
  24. Disconnect the throttle position (TP) sensor connector.

  25. Disconnect the idle air control (IAC) Valve connector.
  26. Disconnect the manifold absolute pressure (MAP) sensor connector.
  27. Remove the two coolant bypass hose clamps from the throttle body.
  28. Remove the coolant bypass hoses.

  29. Object Number: 233518  Size: SH
  30. Disconnect the temperature sensor connector (2).

  31. Object Number: 234436  Size: SH
  32. Disconnect the four fuel injector connectors.
  33. Remove the upper radiator hose.
  34. Remove the following items from the intake manifold:
  35. • The three bolts (3, 4)
    • The fuel injector harness
  36. Position the fuel injector harness above the intake manifold.
  37. Remove the intake manifold support bracket bolts and bracket.
  38. Disconnect all of the necessary vacuum hoses.
  39. Remove the fuel injector harness brackets.
  40. Disconnect the oxygen sensor connector.
  41. Remove the oxygen sensor nuts.
  42. Remove the following components:
  43. • The oxygen sensor
    • The oxygen sensor gasket
  44. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  45. Object Number: 236842  Size: SH
  46. Remove the following items from the exhaust pipe at the manifold.
  47. • The two bolts (1,2)
    • The springs
  48. Remove the exhaust pipe to manifold seal.

  49. Object Number: 234425  Size: SH
  50. Remove the one bolt (1) from the exhaust manifold to the support bracket.
  51. Lower the vehicle.

  52. Object Number: 428195  Size: SH
  53. Raise and properly support the engine. Refer to Engine Support Fixture in Engine Mechanical.
  54. Remove the following items from the right side engine mount:
  55. • The two nuts
    • The four bolts
  56. Loosen the air conditioning receiver pinch clamp.
  57. Lift the air conditioning receiver in order to gain access to the right side engine mount.
  58. Remove the right side engine mount.
  59. Disconnect the two ignition coil connectors.
  60. Disconnect the fuel line at the fuel rail.
  61. Remove the injector fuel rail hold down clamp.

  62. Object Number: 244201  Size: SH
  63. Remove the secondary spark plug wires from the cylinder head cover (1).
  64. Remove the four bolts from the ignition coil bracket.
  65. Remove the coils with the spark plug wires attached.
  66. Remove the following items from the cylinder head:
  67. • The three bolts
    • The fuel rail
  68. Remove the following items from the cylinder head:
  69. • The two ground wire bolts
    • The ground wires
  70. Position the injector harness aside.
  71. Remove the heater hose at the cylinder head.
  72. Remove the following items from the cylinder head:
  73. • The one bolt
    • The water bypass pipe
  74. Remove the following items:
  75. • The one bolt
    • The camshaft sensor
  76. Remove the engine coolant temperature sensor.
  77. Remove the following items from the cylinder head cover:
  78. • The two PCV hoses
    • The PCV valve

    Object Number: 234134  Size: SH
  79. Remove the cylinder head cover from the cylinder head. Refer to Cylinder Head Cover Replacement in Engine Mechanical.
  80. Set the number one piston to top dead center.
  81. Align the camshaft timing sprockets.
  82. Disconnect the power steering oil pressure switch connector.
  83. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  84. Remove the right side lower engine splash shield.

  85. Object Number: 236875  Size: SH
  86. Remove the two power steering pump through bolts and nuts (1).
  87. Remove the power steering pump.
  88. Position the power steering pump aside.

  89. Object Number: 234153  Size: SH
  90. Remove the crankshaft pulley. Refer to Crankshaft Pulley Replacement in Engine Mechanical.

  91. Object Number: 234378  Size: SH
  92. Remove the following items:
  93. • The crankshaft position sensor bolt (5)
    • The crankshaft position sensor
  94. Lower the vehicle.
  95. Remove the drive belt tensioner nut.
  96. Remove the following items:
  97. • The drive belt tensioner bolt
    • The drive belt tensioner
  98. Remove the following items:
  99. • The three right side engine mounting bracket bolts
    • The engine mounting bracket

    Object Number: 234178  Size: SH
  100. Remove the timing chain tensioner bolts (1, 2).
  101. Remove the timing chain tensioner.

  102. Object Number: 234182  Size: SH
  103. Remove the timing chain cover bolts and nuts (1-15).
  104. Remove the timing chain cover.
  105. Remove the crank sensor reluctor.
  106. Remove the following items:
  107. • The timing chain slipper bolt
    • The slipper

    Object Number: 234188  Size: SH
  108. Remove the following items:
  109. • The crankshaft sprocket
    • The timing chain

    Object Number: 234284  Size: SH
  110. Remove the camshaft sprocket bolts.
  111. Remove the camshaft sprockets (1).

  112. Object Number: 234080  Size: SH
  113. Remove the following items in sequence:
  114. • The camshaft bearing cap bolts
    • The camshaft bearing caps
  115. Remove the camshafts.
  116. Remove the valve lifters. Keep the lifters in order so that the lifters can be reinstalled in the original location.
  117. Important: Use a wooden block in order to protect the oil pan when lifting the engine.

  118. Use a floor jack in order to raise the engine.
  119. Reposition the holding fixture.
  120. Remove the Intake Manifold. Refer to Intake Manifold Replacement in Engine Machanical.
  121. Remove the Exhaust Manifold.Refer to Exhaust Manifold Replacement in Engine Mechanical.

  122. Object Number: 234516  Size: SH
  123. Remove the following items in sequence:
  124. • The cylinder head bolts
    • The cylinder head washers

    Object Number: 234526  Size: SH
  125. Remove the cylinder head.

  126. Object Number: 235541  Size: SH
  127. Remove the cylinder head gasket (1).

  128. Object Number: 234571  Size: SH
  129. Clean the cylinder block mating surfaces.

  130. Object Number: 234792  Size: SH
  131. Clean the cylinder head mating surface.
  132. Clean the timing chain cover mating surface.

Installation Procedure

  1. Install the new cylinder head gasket on the cylinder block.
  2. Install the cylinder head on the cylinder block.
  3. Install the cylinder head bolts and washers into the cylinder head.

  4. Object Number: 235572  Size: SH
  5. Progressively torque the cylinder head bolts using three steps in the sequence shown.
  6. 1st Pass
    Tighten the cylinder head bolts to 25 N·m (18 lb ft).

    2nd Pass
    Tighten the cylinder head bolts to 49 N·m (36 lb ft).

    3rd Pass
    After reaching the torque of 49 N·m (36 lb ft). Use a J 36660-A and tighten the cylinder head bolts an additional 90 degrees.

    Important: Use a wooden block in order to protect the oil pan when lifting the engine.

  7. Use a floor jack in order to raise the engine.
  8. Reposition the holding fixture.
  9. Support the engine by the support hook.
  10. Lower the floor jack.
  11. Install the intake camshaft. Refer to Intake Camshaft and Valve Lifter Replacement in Engine Mechanical.
  12. Install the exhaust camshaft. Refer to Exhaust Camshaft and Valve Lifter Replacement in Engine Mechanical.
  13. Install the timing chain. Refer to Timing Chain and Sprocket Replacement in Engine Mechanical.
  14. Install the timing chain housing. Refer to Timing Chain Housing Replacement in Engine Mechanical.
  15. Install the crankshaft pulley. Refer to Crankshaft Pulley Replacement in Engine Mechanical.
  16. Install the cylinder head cover. Refer to Cylinder Head Cover Replacement in Engine Mechanical.
  17. Install the engine coolant temperature (ECT) sensor.
  18. Install the camshaft sensor.
  19. Use the one bolt in order to secure the camshaft sensor.
  20. Tighten
    Tighten the camshaft sensor bolt to 15 N·m (11 lb ft).


    Object Number: 235545  Size: SH
  21. Install the water bypass pipe (1) to the cylinder head.
  22. Use the one bolt in order to secure the coolant bypass pipe to the cylinder head.
  23. Tighten
    Tighten the coolant bypass pipe to 15 N·m (11 lb ft).

  24. Install the heater hose to the cylinder head.
  25. Install the engine ground wires to the cylinder head.
  26. Use the two bolts in order to secure the engine ground wires.
  27. Tighten
    Tighten the ground wire bolts to 15 N·m (11 lb ft).

  28. Install the fuel rail to the cylinder head.
  29. Use the three bolts in order to secure the fuel rail.
  30. Tighten
    Tighten the fuel rail bolts to 14 N·m (10 lb ft).

  31. Connect the fuel line to the fuel rail.
  32. Install the two ignition coils.
  33. Use the four bolts in order to secure the two ignition coils.
  34. Tighten
    Tighten the ignition coil bracket bolts to 14 N·m (10 lb ft).


    Object Number: 244201  Size: SH
  35. Install the secondary spark plug wires (1).
  36. Connect the two ignition coil connectors.

  37. Object Number: 234412  Size: SH
  38. Install the right side engine mount.
  39. Use the two nuts (3) and the four bolts (1,2,4,5) in order to secure the right side engine mount:
  40. Tighten
    Tighten the right side engine mount bolts and nuts to 54 N·m (40 lb ft).

  41. Tighten the air conditioning receiver pinch clamp.
  42. Remove the engine support fixture.
  43. Raise and support the vehicle.

  44. Object Number: 234425  Size: SH
  45. Install the one bolt (1) from the manifold to the support bracket.
  46. Tighten
    Tighten the support bracket bolt to 35 N·m (26 lb ft).


    Object Number: 236842  Size: SH
  47. Use a new seal in order to install the exhaust pipe to the exhaust manifold.
  48. Use the two bolts and two springs (1, 2) in order to secure the exhaust pipe.
  49. Tighten
    Tighten the exhaust pipe bolts to 62 N·m (46 lb ft).

  50. Lower the vehicle.
  51. Install the oxygen sensor and the oxygen sensor gasket.
  52. Install the two oxygen sensor nuts.
  53. Tighten
    Tighten the oxygen sensor nuts to 41 N·m (30 lb ft).

  54. Connect the oxygen sensor connector.
  55. Install the injector harness brackets.
  56. Connect all of the necessary vacuum hoses.
  57. Install the intake manifold support bracket.
  58. Use the support bracket bolts in order to secure the intake manifold support bracket.
  59. Tighten
    Tighten the support bracket bolts to 50 N·m (37 lb ft).

  60. Install the fuel injector harness to the intake manifold.
  61. Use the three bolts in order to secure the fuel injector harness.
  62. Tighten
    Tighten the fuel injector harness bolts to 12 N·m (106 lb in).

  63. Install the upper radiator hose.
  64. Connect the four fuel injector connectors.
  65. Connect the temperature sensor connector.
  66. Install the two coolant bypass hoses to the throttle body.
  67. Use the two hose clamps in order to secure the two coolant bypass hoses.
  68. Connect the MAP sensor connector.
  69. Connect the IAC valve connector.
  70. Connect the TP sensor connector.
  71. Install the air cleaner hose and cap assembly.
  72. Connect the IAT sensor connector.
  73. Install the accelerator cable to the throttle body.

  74. Object Number: 244308  Size: SH
  75. Install the generator (1). Refer to Generator Replacement in Engine Electrical.
  76. Connect the positive cable to the generator.

  77. Object Number: 244251  Size: SH
  78. Connect the generator connector.

  79. Object Number: 244267  Size: SH
  80. Install the serpentine drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
  81. Remove the washer pump outlet plug.
  82. Connect the washer pump fluid line.
  83. Connect the washer pump connector.
  84. Install the washer fluid tank.
  85. Use the one bolt in order to secure the washer fluid tank.
  86. Tighten
    Tighten the washer fluid tank bolt to 10 N·m (89 lb in).

  87. Refill the engine oil.
  88. Refill the engine coolant.