GM Service Manual Online
For 1990-2009 cars only
Makes 馃 Holden 馃 2009 馃 Epica 馃 Preface 馃 Dangers, Warnings, and Cautions 馃 Cylinder Head Replacement

Removal Procedure

    Object Number: 1375807 Size: SH
  1. Remove the fuel pump fuse.
  2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.

    3. Warning: Refer to Battery Disconnect Warning in the Preface section.

  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. Refer to Cooling System Draining and Filling.
  5. Drain the engine oil.
  6. Drain the transaxle oil.

    7. Object Number: 1375964 Size: SH
  7. Drain the power steering oil.
  8. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
  9. Remove the engine assembly. Refer to Engine Replacement.
  10. Remove the timing chain. Refer to Camshaft Timing Chain and Sprocket Replacement.
  11. Remove the intake manifold support bracket.

    12. Object Number: 1375967 Size: SH
  12. Remove the power steering pump.

    13. Object Number: 1375970 Size: SH
  13. Remove the generator. Refer to Generator Replacement.
  14. Remove the upper pad bracket bolts and the upper pad bracket.

    15. Object Number: 1375973 Size: SH
  15. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement.
  16. Remove the EGR pipes. Refer to Exhaust Gas Recirculation Valve Pipe Replacement.
  17. Remove the EGR adapter.

    18. Object Number: 1375974 Size: SH
  18. Remove the heater pipe.
  19. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement.
  20. Remove the exhaust manifold gasket.
  21. Remove the camshaft position (CMP) sensor. Refer to Camshaft Position Sensor Replacement.
  22. Remove the engine coolant temperature (ECT) sensor. Refer to Engine Coolant Temperature Sensor Replacement.
  23. Remove the coolant outlet port.

    24. Object Number: 1375977 Size: SH

    Caution: 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.

  24. Remove the cylinder head bolts in sequence shown and the cylinder head.
  25. Remove the cylinder head gasket.
  26. Remove the liquid gasket.

Installation Procedure

    Object Number: 1375978 Size: SH
  1. Clean the contact surfaces between the cylinder head and the cylinder block.
  2. Install the dowel pins.

    3. Object Number: 1375980 Size: SH
  3. Apply the liquid gasket Loctite庐 5900-M8585 on the surface of the cylinder block (1) as shown in the illustration.
  4. Install the cylinder head gasket.
  5. Apply the liquid gasket Loctite庐 5900-M8585 on the upper surface of the cylinder head gasket (1) as shown in the illustration.

    6. Object Number: 1375981 Size: SH
  6. Install the cylinder head.

    7. Caution: Refer to Fastener Caution in the Preface section.

  7. Tighten the cylinder head bolts gradually and in the sequence shown.

    8. Tighten
    Tighten the cylinder head bolts to 20 N路m (15 lb ft). After finishing the initial tightening, tighten all the cylinder head bolts to 25 N路m (18 lb ft) and turn the bolts another 2 turns of 70 degrees.


    Object Number: 1375985 Size: SH
  8. Install the coolant outlet port.

    9. Tighten
    Tighten the coolant outlet port retaining bolts to 10 N路m (89 lb in).

  9. Install the ECT sensor. Refer to Engine Coolant Temperature Sensor Replacement.
  10. Instal the CMP sensor. Refer to Camshaft Position Sensor Replacement.
  11. Discard the used exhaust manifold gasket and replace with a new one.
  12. Install the exhaust manifold. Refer to Exhaust Manifold Replacement.
  13. Install the heater pipe.

    14. Object Number: 1375989 Size: SH
  14. Install the EGR adapter.

    15. Tighten
    Tighten the EGR adapter retaining bolts to 20 N路m (15 lb ft).

  15. Install the EGR pipes. Refer to Exhaust Gas Recirculation Valve Pipe Replacement.
  16. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement.

    17. Object Number: 1375970 Size: SH
  17. Install the upper pad bracket.

    18. Tighten
    Tighten the upper pad bracket bolts to 45 N路m (33 lb ft).

  18. Install the alternator. Refer to Generator Replacement.

    19. Object Number: 1375993 Size: SH
  19. Install the power steering pump.

    20. Tighten
    Tighten the power steering pump retaining bolts to 25 N路m (18 lb ft).


    Object Number: 1375994 Size: SH
  20. Install the intake manifold support bracket.

    21. Tighten
    Tighten the intake manifold support bracket bolt to 25 N路m (18 lb ft).


    Object Number: 1375905 Size: SH
  21. Install the timing chain and the timing chain cover. Refer to Camshaft Timing Chain and Sprocket Replacement.
  22. Install the engine assembly. Refer to Engine Replacement.
  23. Install the fuel pump fuse.
  24. Connect the negative battery cable.
  25. Refill the crankcase with engine oil.
  26. Refill the engine coolant system. Refer to Cooling System Draining and Filling.
  27. Fill and bleed the power steering system Refer to Power Steering System Bleeding.
  28. Refill the A/C System. Refer to Refrigerant Recovery and Recharging.