GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Vivant 🢒 Engine 🢒 Engine Mechanical - 2.0L (L34 GMDAT) 🢒 Cylinder Head Replacement

Removal Procedure

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


    Object Number: 1263069 Size: SH
  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.

    3. Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.

  3. Drain the engine coolant. Refer to Cooling System Draining and Filling .

    4. Caution: Refer to Battery Disconnect Caution in the Preface section.

  4. Disconnect the negative battery cable.
  5. Remove the air filter housing bolts and the air filter housing assembly.
  6. Remove the air inlet duct bolts and the air inlet duct.

    7. Object Number: 1263802 Size: SH
  7. Disconnect the intake air temperature (IAT) sensor and connector.
  8. Disconnect the breather tube from the valve cover.
  9. Remove the air intake tube from the throttle body.

    10. Object Number: 1263803 Size: SH
  10. Disconnect the camshaft position (CMP) sensor connector.
  11. Disconnect the oxygen sensor connector.
  12. Disconnect the engine coolant temperature (ECT) sensor connector.
  13. Disconnect the coolant temperature gage connector.
  14. Disconnect the exhaust gas recirculation (EGR) valve connector.

    15. Object Number: 1263804 Size: SH
  15. Remove the electronic ignition (EI) system ignition coil. Refer to Ignition Coil Replacement .
  16. Disconnect the heater inlet hose at the cylinder head.
  17. Remove the coolant pipe bracket bolt.

    18. Object Number: 1263805 Size: SH
  18. Remove the fuel injector rail and fuel injectors as an assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  19. Remove the generator-to-intake manifold support bracket bolts upper bracket bolts and support bracket.
  20. Remove the intake manifold-to-generator strap bracket bolt and loosen the bolt on the generator.
  21. Move the strap clear of the intake manifold.

    22. Object Number: 1263806 Size: SH

    23. Loosen the generator lower bracket-to-generator bolt.

  23. Pull out the generator backward.
  24. Disconnect the coolant hose from the throttle body.
  25. Disconnect the coolant hose from the cylinder head.
  26. Disconnect the upper radiator hose at the thermostat housing.

    27. Object Number: 1263807 Size: SH
  27. Remove the forward engine mount. Refer to Engine Mount Replacement .
  28. Disconnect the clips at the upper front timing belt cover.
  29. Remove the torque roll axis cover bolt.
  30. Remove the torque roll axis cover.

    31. Object Number: 1263767 Size: SH
  31. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation .
  32. Remove the right front wheel well splash shield.

    33. Notice: Refer to Belt Dressing Notice in the Preface section.

  33. Remove the serpentine accessory drive belt. Refer to Power Steering Pump Belt Replacement .
  34. Remove the crankshaft pulley bolts.
  35. Remove the crankshaft pulley.

    36. Object Number: 1263808 Size: SH
  36. Remove the front timing belt cover bolts.
  37. Remove the front timing belt cover.

    38. Object Number: 1263809 Size: SH
  38. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.
  39. Remove the timing belt. Refer to Timing Belt Replacement .

    40. Object Number: 1263745 Size: SH
  40. Remove the exhaust manifold heat shield bolts and the exhaust manifold heat shield.
  41. Remove the exhaust manifold retaining nuts.
  42. Disconnect the exhaust manifold from the cylinder head.

    43. Object Number: 1263746 Size: SH
  43. Remove the intake manifold retaining nut/bolt in the sequence shown.
  44. Disconnect the intake manifold from the cylinder head.

    45. Object Number: 1263772 Size: SH
  45. Remove the valve cover. Refer to Valve Rocker Arm Cover Replacement .

    46. Notice: Use extreme care when removing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.

    Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings.

  46. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
  47. Remove the intake camshaft gear.
  48. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
  49. Remove the exhaust camshaft gear.

    50. Object Number: 1263748 Size: SH
  50. Remove the camshaft bearing cap bolts gradually for each camshaft bearing cap.
  51. Remove the intake/exhaust camshaft caps. Maintain the correct positions for installation.
  52. Remove the intake/exhaust camshaft.

    53. Object Number: 1263749 Size: SH
  53. Loosen all of the cylinder head bolts gradually and in the sequence shown.
  54. Remove the cylinder head bolts.

    55. Notice: Use extreme care when removing the cylinder head to prevent any engine oil , dirt, or coolant from entering the engine. Damage to the engine could result.

  55. Remove the cylinder head and cylinder head gasket.

Installation Procedure

    Object Number: 1263749 Size: SH
  1. Clean and Inspect the cylinder head and sealing surface of the engine block. Refer to Cylinder Head Cleaning and Inspection .

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

  2. Install the cylinder head and the cylinder head gasket.

    3. Tighten
    Tighten the cylinder head bolts in the sequence shown to 25 N·m (18 lb ft) + 90° +90°+ 90°.

  3. Install the cylinder head bolts

    4. Object Number: 1263748 Size: SH
  4. Install the intake/exhaust camshaft.
  5. Install the intake/exhaust camshaft caps. Maintain the correct positions for installation.
  6. Install the camshaft bearing cap bolts gradually and in the sequence shown for each camshaft bearing cap.

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

  7. Install the exhaust camshaft gear.
  8. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

    9. Tighten
    Tighten the camshaft gear bolt to 50 N·m (37 lb in) + 60° + 15°.

  9. Install the intake camshaft gear.

    10. Object Number: 1263772 Size: SH
  10. While holding the intake camshaft firmly in place, reinstall the intake camshaft gear bolt.

    11. Tighten
    Tighten the camshaft gear bolt to 50 N·m (37 lb ft) +60° +15°.

  11. Install the valve cover. Refer to Valve Rocker Arm Cover Replacement .

    12. Object Number: 1263746 Size: SH
  12. Connect the intake manifold to the cylinder head.
  13. Install the intake manifold retaining nuts/bolt.

    14. Tighten
    Tighten the intake manifold nuts/bolts to 18 N·m (13 lb ft).


    Object Number: 1263745 Size: SH
  14. Install the exhaust manifold to the cylinder head.

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

  15. Install the exhaust manifold retaining nuts. Tighten the exhaust manifold nuts in the following sequence: 9, 10, 6, 5, 8, 7, 2, 1, 3, 4.

    16. Tighten

        • Tighten the exhaust manifold nuts in the first stage to 13 N·m (10 lb ft).
        • Tighten the exhaust manifold nuts in the second stage to 13 N·m (10 lb ft).
        • Tighten the exhaust manifold nuts in the third stage to 15 N·m (11 lb ft).
        • Tighten the exhaust manifold nuts in the fourth stage to 15 N·m (11 lb ft).
  16. Install the exhaust manifold heat shield bolts and the exhaust manifold heat shield.

    17. Tighten
    Tighten the exhaust manifold heat shield bolts to 15 N·m (11 lb ft).


    Object Number: 1263809 Size: SH
  17. Install the timing belt. Refer to Timing Belt Replacement .
  18. Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.

    19. Object Number: 1263808 Size: SH
  19. Install the front timing belt cover.
  20. Install the front timing belt cover bolts.

    21. Tighten
    Tighten the front cover bolts to 6 N·m (53 lb ft).


    Object Number: 1263767 Size: SH
  21. Install the crankshaft pulley.
  22. Install the crankshaft pulley bolts.

    23. Tighten
    Tighten the crankshaft pulley bolts to 20 N·m (15 lb ft).

  23. Install the serpentine accessory drive belt. refer to Power Steering Pump Belt Replacement .
  24. Install the right front wheel well splash shield.
  25. Install the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

    26. Object Number: 1263807 Size: SH
  26. Install the torque roll axis cover.
  27. Install the torque roll axis cover bolt.

    28. Tighten
    Tighten the axis cover bolts to 6 N·m (53 lb in).

  28. Install the clips at the upper front timing belt cover.
  29. Install the forward engine mount. Refer to Engine Mount Replacement .

    30. Object Number: 1263806 Size: SH
  30. Install the upper radiator hose at the thermostat housing.
  31. Install the coolant hose from the cylinder head.
  32. Install the coolant hose from the throttle body.
  33. Push in the generator backward.
  34. Loosen the generator lower bracket-to-generator bolt.

    35. Object Number: 1263805 Size: SH
  35. Move the strap clear of the intake manifold.
  36. Install the intake manifold-to-generator strap bracket bolt and tighten the bolt on the generator.

    37. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).

  37. Install the generator-to-intake manifold support bracket bolts upper bracket bolts and support bracket.

    38. Tighten
    Tighten the bolts to 20 N·m (15 lb ft).

  38. Install the fuel injector rail and the fuel injectors as an assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .

    39. Object Number: 1263804 Size: SH
  39. Install the coolant pipe bracket bolt.
  40. Install the heater inlet hose at the cylinder head.
  41. Install the EI system ignition coil. Refer to Ignition Coil Replacement in Engine Controls - 2.0L.

    42. Object Number: 1263803 Size: SH
  42. Connect the EGR valve connector.
  43. Connect the coolant temperature gage connector.
  44. Connect the ECT sensor connector.
  45. Connect the oxygen sensor connector.
  46. Connect the CMP sensor connector.

    47. Object Number: 1263802 Size: SH
  47. Install the air intake tube from the throttle body.
  48. Install the breather hose to the valve cover.
  49. Connect the IAT sensor connector.

    50. Object Number: 1263069 Size: SH
  50. Install the air inlet duct bolts and the air inlet duct.

    51. Tighten
    Tighten the air duct bolts to 8 N·m (71 lb in).

  51. Install the air filter housing bolts and the air filter housing assembly.
  52. Connect the negative battery cable.
  53. Fill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  54. Install the fuel pump fuse.
  55. Start the engine and inspect for leaks.