GM Service Manual Online
For 1990-2009 cars only

Removal Procedures


    Object Number: 175681  Size: SH
  1. Disconnect the negative battery cables.
  2. • For the front battery, refer to Battery Cable Replacement in Engine Electrical.
    • For the auxiliary battery, refer to Battery Cable Replacement in Engine Electrical.
  3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  4. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Body and Accessories.
  5. Remove the air cleaner from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
  6. Remove the air intake duct from the turbocharger.

  7. Object Number: 104973  Size: SH
  8. Remove the transmission oil level indicator and tube from the upper intake manifold.
  9. Remove the fan shroud from the radiator. Refer to Fan Shroud Replacement in Engine Cooling.
  10. Remove the drive belt from the pulleys. Refer to Drive Belt Replacement .
  11. Remove the engine cooling fan from the water pump pulley. Refer to Fan Clutch Replacement in Engine Cooling.
  12. Remove the left accessory bracket from the engine block. Refer to Accessory Brackets Replacement .
  13. Remove the vacuum pump from the right accessory bracket. Refer toVacuum Pump Replacement .
  14. Remove the right accessory bracket from the engine block. Refer to Accessory Brackets Replacement .
  15. Remove the heater hoses from the thermostat housing.
  16. Remove the oil level indicator tube from the engine assembly. Refer to Oil Level Indicator and Tube Replacement .
  17. Remove the thermostat housing crossover from the cylinder heads.
  18. Remove the upper intake manifold from the lower intake manifold. Refer to Intake Manifold Replacement .
  19. Remove the turbocharger from the engine block. Refer to Turbocharger Replacement .
  20. Remove the lower intake manifold from the cylinder heads. Refer to Intake Manifold Replacement .

  21. Object Number: 400331  Size: SH
  22. Remove the front lower cylinder head bolt (5) and drain the coolant from the engine block.
  23. 19.1. Insert a cooper tube (3/8 inch x 12 to 18 inch long) and a hose into bolt hole (5)
    19.2. Siphon coolant from the engine block
  24. Remove the valve rocker arm covers from the cylinder heads. Refer to Valve Rocker Arm Cover Replacement .
  25. Remove the valve rocker arms, shafts, and push rods from the cylinder heads. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement
  26. Remove the exhaust manifolds from the cylinder heads. Refer to Exhaust Manifold Replacement .
  27. Remove the cooper tube used as a siphon from the cylinder head.

  28. Object Number: 400331  Size: SH
  29. Remove the remaining cylinder head bolts from the cylinder heads in sequence.
  30. Remove the cylinder heads from the engine block.

  31. Object Number: 311338  Size: SH
  32. Remove the cylinder head gasket from the engine block.
  33. Disassemble the cylinder heads. Refer to Cylinder Head Disassemble .

Installation Procedures


    Object Number: 311338  Size: SH
  1. Assemble the cylinder heads. Refer to Cylinder Head Assemble .
  2. Install the cylinder head gasket to the engine block.

  3. Object Number: 362141  Size: SH
  4. Install the cylinder heads to the engine block.

  5. Object Number: 60278  Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6. Install the cylinder head bolts and tighten in sequence in four passes.
  7. Tighten

    1. Tighten the bolts to 25 N·m (20 lb ft).
    2. Tighten the bolts to 75 N·m(55 lb ft).
    3. Retighten the bolts to 75 N·m(55 lb ft).
    4. In sequence, tighten all bolts an additional 90 to 100 degrees (¼+ turn).
  8. Install the exhaust manifolds to the cylinder heads. Refer to Exhaust Manifold Replacement .
  9. Install the valve rocker arms, shafts, and push rods to the cylinder heads. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
  10. Install the valve rocker arm covers to the cylinder heads. Refer to Valve Rocker Arm Cover Replacement .
  11. Install the lower intake manifold to the cylinder heads. Refer to Intake Manifold Replacement .
  12. Install the turbocharger to the engine block. Refer to Turbocharger Replacement .
  13. Install the upper intake manifold to the lower intake manifold. Refer to Intake Manifold Replacement .
  14. Install the thermostat housing coolant crossover to the cylinder heads.

  15. Object Number: 104973  Size: SH
  16. Install the transmission indicator and tube to the engine block.
  17. Install the oil level indicator tube to the engine block. Refer to Oil Level Indicator and Tube Replacement .
  18. Install the heater hoses to the thermostat housing.
  19. Install the right accessory bracket to the engine block. Refer to Accessory Brackets Replacement .
  20. Install the vacuum pump to the right accessory bracket. Refer to Vacuum Pump Replacement .

  21. Object Number: 59794  Size: SH
  22. Install the left accessory bracket to the engine block. Refer to Accessory Brackets Replacement .
  23. Install the engine cooling fan on the water pump pulley. Refer to Fan Clutch Replacement in Engine Cooling.
  24. Install the drive belt on the pulleys. Refer to Drive Belt Replacement .
  25. Install the fan shroud on the radiator. Refer to Fan Shroud Replacement in Engine Cooling.

  26. Object Number: 175681  Size: SH
  27. Install the air intake duct to the turbocharger.
  28. Install the air cleaner assembly in the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
  29. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  30. Connect the battery negative cables to the batteries.
  31. • For the front battery, refer to Battery Cable Replacement in Engine Electrical.
    • For the auxiliary battery, refer to Battery Cable Replacement in Engine Electrical.
  32. Install the engine cover in the vehicle. Refer to Engine Cover Replacement in Body and Accessories.