GM Service Manual Online
For 1990-2009 cars only

Special Tools

KM-470-B Angular Torque Gage

Removal Procedure

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


    Object Number: 1863838  Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the engine cover. Refer to Engine Cover Replacement.
  3. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
  4. Remove the accessory belt. Refer to Drive Belt Replacement.

  5. Object Number: 1820436  Size: SH
  6. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement.
  7. Remove the timing belt. Refer to Timing Belt Replacement.

  8. Object Number: 1864052  Size: SH
  9. Remove the fuel pipe-to-common rail between common rail and fuel injection pump. Refer to Fuel Injector Fuel Feed Pipe Replacement.
  10. Remove the power steering pump fastener and pull it left side.
  11. Remove the oil level indicator tube.
  12. Remove the radiator upper hose from the thermostat housing.
  13. Remove the engine wiring connectors.

  14. Object Number: 1822555  Size: SH
  15. Remove the turbocharger wheel bearing oil inlet pipe.
  16. Remove the turbocharger wheel bearing oil outlet hose.
  17. Remove the pre-catalyst tightening clamp from the turbocharger.

  18. Object Number: 1822557  Size: SH
  19. Remove the cylinder head bolts.
  20. Remove the cylinder head assembly with the gasket.
  21. Remove the intake manifold and exhaust manifold from cylinder head assembly.

Cleaning Procedure

  1. Clean the cylinder head surface.
  2. Clean the engine block surface.
  3. Clean the cylinder head bolts.
  4. Clean the engine block bolt holes.

Selective Cylinder Head Gasket Procedure

  1. Clean the cylinder block sealing surface and piston.
  2. Align the TDC of the piston.
  3. Measure the piston projection thickness by using dial gage.
  4. Repeat the measuring process on the other cylinders and average the measured piston projection values.
  5. Choose the correct cylinder head gasket from the following:
  6. Specifications

        • Piston Projection 0.194-0.337 mm
            Gasket Thickness 1.1 mm
        • Piston Projection 0.337-0.440 mm
            Gasket Thickness 1.2 mm
        • Piston Projection 0.440-0.542 mm
            Gasket Thickness 1.3 mm

Installation Procedure


    Object Number: 1822557  Size: SH
  1. Install the cylinder head assembly with a new gasket.
  2. Caution: Refer to Fastener Caution in the Preface section.

  3. Install the cylinder head tightening bolts.
  4. Tighten
    Tighten the cylinder head bolts to 65 N·m (47.9 lb ft). Using KM-470-B , tighten the cylinder head bolts another 120 degrees plus 120 degrees.


    Object Number: 1822555  Size: SH
  5. Install the pre-catalyst tightening clamp to the turbocharger.
  6. Install the turbocharger wheel bearing oil inlet pipe.
  7. Tighten
    Tighten the turbocharger wheel bearing oil inlet pipe bolts to 23 N·m (17 lb ft).


    Object Number: 1864052  Size: SH
  8. Install the power steering pump fastener.
  9. Install the fuel pipe-to-common rail between common rail and fuel injection pump.
  10. Install the oil level indicator tube.
  11. Tighten

        • Tighten the engine wiring splice pack tightening bolt to 15 N·m (11.1 lb ft).
        • Tighten the power steering pump bolts to 25 N·m (18.4 lb ft).
        • Tighten the fuel pipe-to-common rail retaining to 20 N·m (14.8 lb in).
        • Tighten the fuel pipe-to-common rail retaining bolt to 10 N·m (88.5 lb in).
        • Tighten the oil level indicator tube bolts to 11 N·m (97.4 lb in).