GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2009 🢒 Viva 🢒 Engine 🢒 Engine Mechanical - 1.8L (L79) 🢒 Cylinder Head Assemble

Special Tools

    • J 8062 (KM 348) Valve Spring Compressor - Head Off
    • KM-653-A Adapter

    Object Number: 1289888 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. 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 spring caps.

    9. Object Number: 1289869 Size: SH

    Warning: Valve springs can be tightly compressed. Use care when removing the retainers and plugs. Personal injury could result.

  9. Compress the valve springs with J 8062  (1) and adapter KM-653-A  (2).
  10. Install the valve keys.
  11. Remove the J 8062  (1) and the KM-653-A  (2).

    12. Object Number: 1289868 Size: SH
  12. Lubricate the valve tappet adjusters with engine oil.
  13. Install the valve tappet adjusters.

    14. Object Number: 1289787 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. Caution: Refer to Fastener Caution 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: 1289863 Size: SH
  20. Install the spark plugs.

    21. Tighten
    Tighten the spark plugs to 20 N·m (15 lb ft).

  21. Install the direct ignition system (DIS) coil and exhaust gas recirculation (EGR) mounting bracket.
  22. Install the DIS coil and EGR mounting bracket bolts.

    23. Tighten
    Tighten the direct ignition system coil and exhaust gas recirculation mounting bracket bolts to 25 N·m (18 lb ft).


    Object Number: 1289838 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 bolt in the sequence shown.

    27. Tighten
    Tighten the intake manifold retaining nuts and retaining bolt to 22 N·m (16 lb ft).


    Object Number: 1289846 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 and mounting bolts.

    31. Tighten
    Tighten the coolant bypass housing bolts to 15 N·m (11 lb ft).


    Object Number: 1289843 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.

    35. Tighten
    Tighten the exhaust manifold retaining nuts to 22 N·m (16 lb ft).

  35. Install the exhaust manifold heat shield.
  36. Install the exhaust manifold heat shield bolts.

    37. Tighten
    Tighten the exhaust manifold heat shield bolts to 8 N·m (71 lb in).

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