GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Vivant 🢒 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: 1263749 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 25 N·m (18 lb ft).

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

    22. Tighten

        • Tighten the left lower side to 25 N·m (18 lb ft).
        • Tighten all others to 30 N·m (22 lb ft).
  22. Install the ignition coil and EGR.

    23. Tighten

        • Tighten the ignition coil and EGR to 10 N·m (89 lb ft).
        • Tighten the EGR valve bolts to 20 N·m (15 lb ft).

    Object Number: 1263746 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 18 N·m (13 lb ft).


    Object Number: 1241256 Size: SH
  27. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  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. Tighten the exhaust manifold nuts in the following sequence: 9, 10, 6, 5, 8, 7, 2, 1, 3, 4.

    35. Tighten

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

    36. Object Number: 1263745 Size: SH
  36. Install the exhaust manifold heat shield bolts.

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

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