GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Grand Prix 🢒 Engine 🢒 Engine Mechanical - 5.3L 🢒 Cylinder Head Replacement - Right Side

Tools Required

    • J 42385-100 Head/Main Bolt Thread Repair Kit
    • J 42385-200 Common Threads Repair Kit
    • J 45059 Torque Angle Meter

Removal Procedure

    Object Number: 1411945 Size: SH
  1. Remove the intake manifold. Refer to Intake Manifold Replacement .
  2. Remove the coolant air bleed pipe. Refer to Coolant Air Bleed Pipe Assembly Replacement .
  3. Remove the generator bracket. Refer to Generator Bracket Replacement .
  4. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .
  5. Remove the pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .

    6. Important: The cylinder head bolts are of a torque to yield design and are NOT to be used again.

  6. Remove and discard the cylinder head bolts (220, 221).

    7. Notice: After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.

  7. Remove the cylinder head (218).

    8. Object Number: 1411947 Size: SH
  8. Remove and discard the cylinder head gasket (217).
  9. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection .

Installation Procedure

Caution: Wear safety glasses in order to avoid eye damage.

Notice: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.

Important: 

   • Do not reuse the cylinder head bolts. Install NEW cylinder head bolts during assembly.
   • Do not use any type of sealant on the cylinder head gasket (unless specified).
   • The cylinder head gaskets must be installed in the proper direction and position.

  1. Clean the cylinder head bolt holes, if required. J 42385-100 can be used to clean the threads of old threadlocking material.
  2. Clean the engine block bolt holes, if required. J 42385-200 can be used to clean the threads of old threadlocking material.
  3. Use spray cleaner to clean out the hole.
  4. Clean the cylinder head bolt holes with compressed air.
  5. Check the cylinder head locating pins for proper installation.

    6. Object Number: 1655022 Size: SH
  6. Inspect the displacement markings on the cylinder head gasket, for the proper usage.

    7. Object Number: 1411947 Size: SH
  7. Install the NEW cylinder head gasket (217) onto the locating pins.

    8. Object Number: 1411945 Size: SH
  8. Install the cylinder head (218) onto the locating pins.
  9. Install the NEW cylinder head bolts (220, 221).

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


    Object Number: 260150 Size: SH
  10. Tighten the cylinder head bolts.

    11. Tighten

    1. Tighten the M11 bolts (1-10) a first pass in sequence to 30 N·m (22 lb ft).
    2. Tighten the M11 bolts (1-10) a second pass in sequence to 90 degrees using J 45059 .
    3. Tighten the M11 bolts (1-10) a final pass in sequence to 70 degrees using J 45059 .
    4. Tighten the M8 bolts (11-15) to 30 N·m (22 lb ft). Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts.
  11. Install the pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
  12. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side .
  13. Install the generator bracket. Refer to Generator Bracket Replacement .
  14. Install the coolant air bleed pipe. Refer to Coolant Air Bleed Pipe Assembly Replacement .
  15. Install the intake manifold. Refer to Intake Manifold Replacement .