GM Century/Lumina/Grand Prix/Intrigue 1997-2000

Cylinder Head

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REMOVAL & INSTALLATION



3.1L and 3.4L (VIN E) Engines

Before removing a cylinder head, perform a compression test and/or leakdown test to verify is head removal is required.


NOTE
With some minor variations, this procedure can be used on both the left and right cylinder heads.

  1. Raise and safely support the vehicle.
  2.  
  3. Drain the engine coolant and the engine oil. Lower the vehicle.
  4.  
  5. Remove the upper and lower intake manifold using the procedures found in this section.
  6.  
  7. Remove the rocker arm and pushrods using the procedures found in this section.
  8.  
  9. Remove the exhaust crossover pipe.
  10.  
  11. Remove the engine mount strut bracket.
  12.  
  13. If removing the left side (front) head, remove the dipstick tube.
  14.  
  15. Tag for identification, then remove the spark plug wires. Remove the spark plugs. Please see for more information.
  16.  
  17. Remove the exhaust manifold using the procedures found in this section.
  18.  
  19. Remove the eight cylinder head bolts, then remove the cylinder head. There are locator pins that align the head to the block. Pull upwards on the head to disengage the pins, then remove the cylinder head to a suitable work area.
  20.  
  21. If the head is be overhauled, remove any remaining components such as the engine lift hook, the fuel line bracket bolts, the engine coolant temperature sensor, etc., as required.
  22.  



Click image to see an enlarged view

Fig. Unfasten the cylinder head bolts, then remove the head



Click image to see an enlarged view

Fig. Remove and discard the cylinder head gasket



Click image to see an enlarged view

Fig. Use a suitable scraper to thoroughly clean the gasket mating surfaces



Click image to see an enlarged view

Fig. Position a new gasket, install the head, then tighten the bolts in the sequence shown-3.1L engine shown, 3.4L (VIN E) similar

To install:


NOTE
The cylinder head should be cleaned and inspected before installation. Please see the Engine reconditioning information.

  1. If the head gasket failed, determine the cause. Gasket failure is caused by the following conditions: improper installation; overheating due to a failure in the electric cooling fan system or a leak in the cooling system; loose or warped cylinder head; missing, off location or not fully seated locator dowel pins; low torque on the cylinder head bolts; warped block surface; scratched or gouged gasket surfaces; excessive intake manifold torque and even cracked engine block tapped holes.
  2.  
  3. Clean all parts well. Remove all foreign material to the bare metal. Do not use a motorized wire brush on any gasket sealing surface. It is good practice to use the proper size thread-cutting tap to clean the threaded bolt holes in the block. This helps assure an accurate torque reading.
  4.  
  5. Place a new head gasket on the clean engine block deck surface. Many gaskets will have some sort of marking denoting TOP or THIS SIDE UP. Make sure the gasket sits flat and is not hung up on the locator dowel pins. Use no sealer on the head gasket.
  6.  
  7. Carefully set the cylinder head in place, using care not to damage the gasket. Make certain that the head engages the locator dowel pins that properly position the head.
  8.  
  9. The bolts should be very clean since dirt built-up on the bolt threads makes it difficult to get an accurate torque reading. These are 'torque to yield' bolts which stretch a small amount when tightened; new bolts are always recommended. On a used vehicle, especially a high-mileage vehicle, it may be difficult to determine if the heads have been removed before and how many cycles the bolts have been removed and tightened. New bolts should be part of any cylinder head service. Use GM Sealer #1052080, or equivalent, on the threads of the head bolts and install all eight bolts, finger-tight.
  10.  
  11. With an accurate torque wrench, tighten the bolts gradually, in sequence, working from the center outwards. Final torque should be 33 ft. lbs. (45 Nm), plus an additional 90 degrees (1/4-turn). A torque angle meter is recommended.
  12.  
  13. Install the remaining components in the reverse order of the removal process.
  14.  

3.4L (VIN X) Engine

WARNING
As with many procedures on the 3.4L VIN X DOHC engine, cylinder head removal is a long and complicated task. Be very sure of your diagnosis before attempting to remove the heads on this engine, especially with the engine still in the vehicle. A compression test and/or leakdown test should be performed. A pair of special tools, GM #J 38613-A Camshaft Timing Clamps, is required to hold the camshafts in place once the timing belt is removed and the head bolts loosened. Remember, the valve timing must be reset if the camshaft drive sprockets are removed from their camshafts. Once lost, there are no pins or keys to help you re-establish valve timing. In addition, use care when working with light alloy parts.

LEFT SIDE (FRONT)


Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.4L (VIN X) engine

  1. Remove the upper and lower intake manifolds, following the procedures given in this section.
  2.  
  3. Remove the left camshaft carrier using the following procedure.
    1. Remove the camshaft timing belt following the procedures given in this section.
    2.  
    3. Disconnect the exhaust crossover pipe and reposition out of the way.
    4.  
    5. Remove the engine mount strut.
    6.  
    7. Remove the front engine lift bracket.
    8.  
    9. The camshaft carrier covers should have been removed as part of the timing belt removal procedure. From shop stock, cut and install six pieces of rubber hose under the camshaft and between the lifters to hold the lifters in the carrier. The exhaust side uses six pieces of tubing 3/16 x 6 inches long. The intake side uses six pieces of tubing 5/32 x 6 inches long.
    10.  
    11. Remove the camshaft carrier mounting bolts and remove the camshaft carrier. Set aside in a safe place. Discard the gasket.
    12.  

  4.  
  5. Remove the left side exhaust manifold following the procedures given in this section.
  6.  
  7. Remove the dipstick tube.
  8.  
  9. Detach the electrical connector from the temperature sending unit.
  10.  
  11. Remove the cylinder head bolts and carefully lift the head from the vehicle.
  12.  

To install:


NOTE
The cylinder head should be cleaned and inspected before installation. Please see the Engine reconditioning information.

  1. Clean all parts well. Use care when working with light alloy parts not to gouge or scratch the gasket sealing surfaces. Clean the head bolts well. New replacement bolts are recommended. Clean the cylinder block bolt threads. Make sure all of the oil is removed from the bolt holes.
  2.  
  3. Carefully lay a new gasket on the engine block deck. Some brands of gaskets may say TOP or have some other marking indicating the surface that should face the cylinder head. Make sure the gasket sits flat on the block deck.
  4.  
  5. Carefully install the cylinder head to the block. Align any dowel pins or other locators. Install the head bolts and finger-tighten. Tighten gradually and in sequence, working up to 44 ft. lbs. (60 Nm). After achieving final torque, use a torque angle meter to turn the bolts an additional 90 degrees ( 1 / 4 turn).
  6.  
  7. Connect the temperature sensor wire and install the dipstick tube.
  8.  
  9. Install the left exhaust manifold following the procedures given in this section.
  10.  
  11. Install the left camshaft carrier using the following procedure:
    1. Remove the oil from the camshaft carrier to cylinder head bolts, the holes closest to the exhaust manifold.
    2.  
    3. Install a new camshaft carrier gasket.
    4.  

  12.  


WARNING
Remove the oil from the camshaft hold-down tool hole in the carrier before installing and tightening the bolt.

  1. Install J 38613-A or equivalent camshaft hold-down tool. Tighten the bolt to 22 ft. lbs. (30 Nm).
  2.  


NOTE
The use of petroleum jelly (never chassis grease) in the lifter bores, along with the use of the lifter hold-down hoses mentioned above, will help keep the lifters in place.

  1. Install the camshaft carrier to the cylinder head and position the hold-down bolts.
  2.  
  3. Tighten the camshaft carrier bolts to 20 ft. lbs. (27 Nm).
  4.  
  5. Remove the lifter hold-down hoses. Install the front engine lift bracket.
  6.  

  1. Install the lower and upper intake manifold following the procedures given in this section.
  2.  
  3. Install the remaining components in the reverse order of the removal process. Since coolant will run down into the engine oil system when the head is removed, it is most important to drain the engine oil and refill with clean engine oil. A filter change is also recommended.
  4.  

RIGHT SIDE (REAR)
  1. Remove the upper and lower intake manifolds following the procedures given in this section.
  2.  
  3. Remove the right camshaft carrier using the following procedure.
    1. Remove the camshaft timing belt following the procedures given in this section.
    2.  
    3. The camshaft carrier covers should have been removed as part of the timing belt removal procedure. From shop stock, cut and install six pieces of rubber hose under the camshaft and between the lifters to hold the lifters in the carrier. The exhaust side uses six pieces of tubing 3/16 x 6 inches long. The intake side uses six pieces of tubing 5/32 x 6 inches long.
    4.  
    5. Remove the camshaft carrier mounting bolts and remove the camshaft carrier. Set aside in a safe place. Discard the gasket.
    6.  

  4.  
  5. Remove the exhaust crossover pipe.
  6.  
  7. Raise and suitably support the vehicle.
  8.  
  9. Disconnect the front exhaust pipe at the manifold.
  10.  
  11. Lower the vehicle.
  12.  
  13. Detach the electrical connector from the oxygen sensor.
  14.  
  15. Remove the rear timing belt tensioner actuator using the following procedure
    1. Remove the timing belt tensioner actuator pulley.
    2.  
    3. Remove the timing belt tensioner mounting bracket bolts. Do this by aligning the tool to the socket in the bolt head.
    4.  
    5. Remove the timing belt tensioner mounting bracket. Use care as there is a mounting base gasket. Reattach the gasket to the mounting bracket is the gasket is loose.
    6.  

  16.  
  17. Remove the cylinder head bolts and carefully lift the head along with the exhaust manifold from the vehicle. Discard the gasket.
  18.  

To install:


NOTE
The cylinder head should be cleaned and inspected before installation. Please see the Engine reconditioning information.

  1. Clean all parts well. Use care when working with light alloy parts not to gouge or scratch the gasket sealing surfaces. Clean the head bolts well. New replacement bolts are recommended. Clean the cylinder block bolt threads. Make sure all of the oil is removed from the bolt holes.
  2.  
  3. Carefully lay a new gasket on the engine block deck. Some brands of gaskets may say TOP or have some other marking indicating the surface that should face the cylinder head. Make sure the gasket sits flat on the block deck.
  4.  
  5. Carefully install the cylinder head to the block. Align any dowel pins or other locators. Install the head bolts and finger-tighten. Tighten gradually and in sequence, working up to 44 ft. lbs. (60 Nm). After achieving final torque, use a torque angle meter to turn the bolts an additional 90 degrees ( 1 / 4 turn).
  6.  
  7. Install the timing belt tensioner making sure the gasket is in place. Tighten the bolts to 37 ft. lbs. (50 Nm). Install the timing belt tensioner pulley.
  8.  
  9. Connect the oxygen sensor wire.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Install the front exhaust pipe to the rear manifold. Lower the vehicle.
  14.  
  15. Install the exhaust crossover pipe.
  16.  
  17. Install the right camshaft carrier using the following procedure.
    1. Make sure that the pieces of rubber tubing are in place under the camshaft and in between the lifter to hold the lifters in carrier.
    2.  
    3. Remove the oil from the camshaft carrier-to-cylinder head bolts.
    4.  
    5. Install a new camshaft carrier gasket.
    6.  

  18.  


WARNING
Remove the oil from the camshaft hold-down tool hole in the carrier before installing and tightening the bolt.

  1. Install J 38613-A or equivalent camshaft hold-down tool. Tighten the bolt to 22 ft. lbs. (30 Nm).
  2.  


NOTE
The use of petroleum jelly (never chassis grease) in the lifter bores, along with the use of the lifter hold-down hoses mentioned above, will help keep the lifters in place.

  1. Install the camshaft carrier to the cylinder head and position the hold-down bolts.
  2.  
  3. Tighten the camshaft carrier bolts to 20 ft. lbs. (27 Nm).
  4.  
  5. Remove the lifter hold-down hoses.
  6.  

  1. Install the lower and upper intake manifold following the procedures given in this section.
  2.  
  3. Install the remaining components in the reverse order of the removal process. Since coolant will run down into the engine oil system when the head is removed, it is most important to drain the engine oil and refill with clean engine oil. A filter change is also recommended.
  4.  

3.5L Engine
LEFT SIDE (FRONT)

WARNING
As with many procedures on the 3.5L (VIN H) DOHC engine, cylinder head removal is a long and complicated task. Be very sure of your diagnosis before attempting to remove the heads on this engine, especially with the engine still in the vehicle. A compression test and/or leakdown test should be performed. A pair of special tools, GM #J 42042 Camshaft Timing Clamps, is required to hold the camshafts in place once the timing chain is removed and the head bolts loosened. This tool, when properly installed, will be fully seated on the camshaft ends with the camshaft flats parallel to the cam cover sealing surfaces. This tool prevents unexpected camshaft rotation caused by valve spring pressure. This tool must be installed immediately after cam cover removal. Remember, the valve timing must be reset if the camshaft drive sprockets are removed from their camshafts. Once lost, there are no pins or keys to help you re-establish valve timing. In addition, GM specifies that new service replacement head bolts must be used. Do not reuse the head bolts. Procure the necessary parts before beginning this procedure.


NOTE
This engine is constructed primarily of aluminum. Use care when working with light alloy parts.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant and the engine oil into suitable containers.
  4.  
  5. Remove the upper and lower intake manifolds using the procedures found in this section.
  6.  
  7. Remove the water outlet housing (thermostat housing). Adjust the water crossover pipe for access.
  8.  
  9. Remove the engine mount strut bracket.
  10.  
  11. Remove the left side (front) exhaust manifold using the procedures found in this section.
  12.  
  13. Remove both camshaft covers using the procedures found in this section.
  14.  
  15. Install special tool J 42038, or equivalent on the camshafts. There should be two flat portions on the camshafts. The tool fits down on these flats to keep valve spring pressure from rotating the camshafts. Proceed no further if you do not have this tool or its functional equivalent.
  16.  
  17. Remove the primary camshaft drive chain using the procedures found in this section.
  18.  
  19. Remove the left side (front) cylinder head camshafts using the procedures found in this section.
  20.  


NOTE
Place the valve train parts in a rack in the order in which they are being removed so that they can be installed in the same location from which they were removed.

  1. Remove the valve rocker arms and lifters.
  2.  


NOTE
The head bolts are different sizes. While the head bolts must not be reused, it is good practice to note the location of each removed bolt so its correct replacement can be installed. Some technicians will place a replacement head gasket on a clean piece of cardboard and trace out the head bolt holes. The head bolts are punched through the cardboard in their corresponding locations as they are removed. In this way, the replacement bolts can be compared to the originals and the new replacement bolts eventually installed in their correct locations.

  1. Remove the head bolts observing the following:
    1. Remove the M6 external drive bolts from the front portion of the cylinder head. Note the location of the longer M6 bolt.
    2.  
    3. Remove and discard the M11 internal drive head bolts. DO NOT reuse the cylinder head bolts.
    4.  

  2.  
  3. Remove the cylinder head. Make sure the locating dowel guide pins are not pulled from the engine block and stuck in the head. Place the head on a flat, clean surface with the combustion chambers face-up to prevent damage to the deck face. Discard the gasket.
  4.  



Click image to see an enlarged view

Fig. Left side (front) cylinder head, gasket and bolt torque sequence-3.5L (VIN H) engine

To install:


NOTE
The cylinder head should be cleaned and inspected before installation. Please see the Engine reconditioning information.

  1. Clean all parts well. The heads are aluminum. Use care not to gouge or scratch the gasket sealing surfaces. It is good practice to clean the head bolt threaded holes in the engine block. This cleans out old sealer, rust and other debris which could interfere with getting an accurate torque reading. Use the correct size thread cutting tap, but use care since the engine block is also aluminum. Make sure all of the oil is removed from the bolt holes.
  2.  


WARNING
This engine uses special torque to yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage. The head bolts used on this engine are designed to permanently stretch when tightened. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt which is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The components may be damaged. In addition, the factory specifies new service replacement head bolts of the correct part number be used.

  1. Carefully lay a new head gasket on the engine block deck. Verify that the arrow or whatever marking is used on the gasket indicating which side is up and/or forward, is correctly aligned. Make sure the gasket sits flat on the block deck, not hung up on the alignment dowels. The alignment dowels (locating pins) should hold the gasket in place. Check that all the bolt holes and water passages line up correctly. Use no sealer on head gaskets.
  2.  


WARNING
A torque angle meter must be used to tighten these head bolts.

  1. Carefully install the cylinder head to the block. Align the dowel pins. Install the new head bolts and finger-tighten. The M11 bolts MUST NOT be reused. Tighten gradually, in the proper sequence, in the following steps.
    1. Using a torque angle meter, tighten the M11 bolts in sequence to 22 ft. lbs. (30 Nm) plus 60 degrees.
    2.  
    3. Repeat the sequence turning each bolt an additional 60 degrees.
    4.  
    5. Repeat the sequence again, turning each bolt an additional 60 degrees (total 180 degrees).
    6.  
    7. Tighten the long M6 bolt to 22 ft. lbs. (30 Nm).
    8.  
    9. Tighten the two short M6 bolts to 106 inch lbs. (12 Nm).
    10.  

  2.  
  3. Install the lifters and the rocker arms.
  4.  
  5. Install the camshafts using the procedures found in this section.
  6.  
  7. Install the primary camshaft drive using the procedures found in this section.
  8.  
  9. Remove tool J 42038, or equivalent, from the camshafts.
  10.  
  11. Install the camshaft covers.
  12.  
  13. Install the remaining components in the reverse order of the removal process. Since coolant will run down into the engine oil system when the head is removed, it is most important to drain the engine oil and refill with clean engine oil. A filter change is also recommended.
  14.  

RIGHT SIDE (REAR)

WARNING
As with many procedures on the 3.5L (VIN H) DOHC engine, cylinder head removal is a long and complicated task. Be very sure of your diagnosis before attempting to remove the heads on this engine, especially with the engine still in the vehicle. A compression test and/or leakdown test should be performed. A pair of special tools, GM #J 42042 Camshaft Timing Clamps, is required to hold the camshafts in place once the timing chain is removed and the head bolts loosened. This tool, when properly installed, will be fully seated on the camshaft ends with the camshaft flats parallel to the cam cover sealing surfaces. This tool prevents unexpected camshaft rotation caused by valve spring pressure. This tool must be installed immediately after cam cover removal. Remember, the valve timing must be reset if the camshaft drive sprockets are removed from their camshafts. Once lost, there are no pins or keys to help you re-establish valve timing. In addition, GM specifies that new service replacement head bolts must be used. Do not reuse the head bolts. Procure the necessary parts before beginning this procedure.


NOTE
This engine is constructed primarily of aluminum. Use care when working with light alloy parts.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant and the engine oil.
  4.  
  5. Remove the upper and lower intake manifolds using the procedures found in this section.
  6.  


WARNING
DO NOT remove the right side (rear) exhaust manifold from the cylinder head.

  1. Remove the water outlet housing (thermostat housing). Adjust the water crossover pipe for access.
  2.  
  3. Remove both camshaft covers using the procedures found in this section.
  4.  
  5. Install tool J 42038 on the camshafts. There should be two flat portions on the camshafts. The tool fits down on these flats to keep valve spring pressure from rotating the camshafts. Proceed no further if you do not have this tool or its functional equivalent.
  6.  
  7. Remove the primary camshaft drive chain using the procedures found in this section.
  8.  
  9. Remove the right side (rear) cylinder head camshafts using the procedures found in this section.
  10.  


NOTE
Place the valve train parts in a rack in the order in which they are being removed that that they can be installed in the same location from which they were removed.

  1. Remove the valve rocker arms and lifters.
  2.  
  3. Remove the coolant temperature sensor from the right side (rear) cylinder head.
  4.  


NOTE
The head bolts are different sizes. While the head bolts must not be reused, it is good practice to note the location of each removed bolt so its correct replacement can be installed. Some technicians will place a replacement head gasket on a clean piece of cardboard and trace out the head bolt holes. The head bolts are punched through the cardboard in their corresponding locations as they are removed. In this way, the replacement bolts can be compared to the originals and the new replacement bolts eventually installed in their correct locations.

  1. Remove the head bolts observing the following.
    1. Remove the M6 external drive bolts from the front portion of the cylinder head. Note the location of the longer M6 bolt.
    2.  
    3. Remove and discard the M11 internal drive head bolts. DO NOT reuse the cylinder head bolts.
    4.  

  2.  
  3. Remove the cylinder head. Make sure the locating dowel guide pins are not pulled from the engine block and stuck in the head. Place the head on a flat, clean surface with the combustion chambers face-up to prevent damage to the deck face. Discard the gasket.
  4.  



Click image to see an enlarged view

Fig. Right side (rear) cylinder head, gasket and bolt torque sequence-3.5L (VIN H) engine

To install:


NOTE
The cylinder head should be cleaned and inspected before installation. Please see the Engine reconditioning information.

  1. Clean all parts well. The heads are aluminum. Use care not to gouge or scratch the gasket sealing surfaces. It is good practice to clean the head bolt threaded holes in the engine block. This cleans out old sealer, rust and other debris which could interfere with getting an accurate torque reading. Use the correct size thread cutting tap, but use care since the engine block is also aluminum. Make sure all of the oil is removed from the bolt holes.
  2.  


WARNING
This engine uses special torque to yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage. The head bolts used on this engine are designed to permanently stretch when tightened. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt which is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The components may be damaged. In addition, the factory specifies new service replacement head bolts of the correct part number be used.

  1. Carefully lay a new head gasket on the engine block deck. Verify that the arrow or whatever marking is used on the gasket indicating which side is up and/or forward, is correctly aligned. Make sure the gasket sits flat on the block deck, not hung up on the alignment dowels. The alignment dowels (locating pins) should hold the gasket in place. Check that all the bolt holes and water passages line up correctly. Use no sealer on head gaskets.
  2.  


WARNING
A torque angle meter must be used to tighten these head bolts.

  1. Carefully install the cylinder head to the block. Align the dowel pins. Install the new head bolts and finger-tighten. The M11 bolts MUST NOT be reused. Tighten gradually and in the following sequence.
    1. Using a torque angle meter, tighten the M11 bolts in sequence to 22 ft. lbs. (30 Nm) plus 60 degrees.
    2.  
    3. Repeat the sequence turning each bolt an additional 60 degrees.
    4.  
    5. Repeat the sequence again, turning each bolt an additional 60 degrees (total 180 degrees).
    6.  
    7. Tighten the long M6 bolt to 22 ft. lbs. (30 Nm).
    8.  
    9. Tighten the two short M6 bolts to 106 inch lbs. (12 Nm).
    10.  

  2.  
  3. Install the coolant temperature sensor into the cylinder head.
  4.  
  5. Install the lifters and rocker arms using the procedures found in this section.
  6.  
  7. Install the right side (rear) camshaft using the procedures found in this section.
  8.  
  9. Install the primary camshaft drive using the procedures found in this section.
  10.  
  11. Remove tool J 42038, or equivalent, from the camshafts.
  12.  
  13. Install the camshaft covers.
  14.  
  15. Install the remaining components in the reverse order of the removal process. Since coolant will run down into the engine oil system when the head is removed, it is most important to drain the engine oil and refill with clean engine oil. A filter change is also recommended.
  16.  

3.8L Engines
LEFT SIDE (FRONT)
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant and the engine oil into suitable containers.
  4.  
  5. Remove the cosmetic/acoustic engine cover.
  6.  
  7. Remove the air cleaner duct.
  8.  
  9. Remove the right engine mount strut.
  10.  
  11. Remove the upper and lower intake manifolds, using the procedures found in this section.
  12.  
  13. Remove the left side (front) rocker arms and pushrods.
  14.  
  15. Remove the cylinder head bolts and lift the cylinder head from the engine. Discard the gasket.
  16.  



Click image to see an enlarged view

Fig. Cylinder head and gasket arrangement and bolt tightening sequence-3.8L engines

To install:


NOTE
The cylinder head should be cleaned and inspected before installation. Please see the Engine reconditioning information.

  1. Clean all parts well. Use care not to gouge or scratch the gasket sealing surfaces. It is good practice to clean the head bolt threaded holes in the engine block. This cleans out old sealer, rust and other debris which could interfere with getting an accurate torque reading. Use the correct size thread cutting tap. Most 3.8L engines will require a 7/16-14 tap. Make sure all of the oil is removed from the bolt holes.
  2.  


WARNING
This engine uses special torque to yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage. The head bolts used on this engine are designed to permanently stretch when tightened. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt which is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The components may be damaged. In addition, the factory recommends new service replacement head bolts of the correct part number be used.


NOTE
The head gaskets on the 3.8L engine are not interchangeable. The head gasket must be installed with the arrow (or noting any other mark, depending on the gasket manufacturer) pointing to the front of the engine. Installing the gasket in any other direction will cause gasket failure and possible engine failure.

  1. Carefully lay a new head gasket on the engine block deck. Verify that the arrow or whatever marking is used on the gasket indicating which side is up and/or forward, is correctly aligned. Make sure the gasket sits flat on the block deck, not hung up on the alignment dowels. Check that all the bolt holes and water passages line up correctly. Use no sealer on head gaskets.
  2.  
  3. Carefully install the cylinder head to the block. Align any dowel pins or other locators. Install the head bolts and finger-tighten. Tighten gradually in the following sequence:
    1. Tighten the bolts in sequence to 37 ft. lbs. (50 Nm).
    2.  
    3. Using a torque angle meter, rotate each bolt an additional 130 degrees, in sequence.
    4.  
    5. Rotate the center four bolts an additional 30 degrees, in sequence.
    6.  

  4.  
  5. Install the pushrods and rocker arms using the procedures found in this section.
  6.  
  7. Install the lower and upper intake manifold following the procedures given in this section.
  8.  
  9. Install the remaining components in the reverse order of the removal process. Since coolant will run down into the engine oil system when the head is removed, it is most important to drain the engine oil and refill with clean engine oil. A filter change is recommended.
  10.  

RIGHT SIDE (REAR)
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant and the engine oil into suitable containers.
  4.  
  5. Remove the cosmetic/acoustic engine cover.
  6.  
  7. Remove the air cleaner duct.
  8.  
  9. Remove the accessory drive belt tensioner.
  10.  
  11. Remove the EGR valve.
  12.  
  13. Remove the upper and lower intake manifold using the procedures found in this section.
  14.  
  15. Remove the right side (rear) exhaust manifold using the procedures found in this section.
  16.  
  17. Remove the right side (rear) rocker arms and pushrods.
  18.  
  19. Remove the cylinder head bolts and lift the cylinder head from the engine. Discard the gasket.
  20.  

To install:


NOTE
The cylinder head should be cleaned and inspected before installation. Please see the Engine reconditioning information.

  1. Clean all parts well. Use care not to gouge or scratch the gasket sealing surfaces. It is good practice to clean the head bolt threaded holes in the engine block. This cleans out old sealer, rust and other debris which could interfere with getting an accurate torque reading. Use the correct size thread cutting tap. Most 3.8L engines will require a 7/16-14 tap. Make sure all of the oil is removed from the bolt holes.
  2.  


WARNING
This engine uses special torque to yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage. The head bolts used on this engine are designed to permanently stretch when tightened. The correct part number fastener must be used to replace this type of fastener. Do not use a bolt which is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The components may be damaged. In addition, the factory recommends new service replacement head bolts of the correct part number be used.


NOTE
The head gaskets on the 3.8L engine are not interchangeable. The head gasket must be installed with the arrow (or noting any other mark, depending on the gasket manufacturer) pointing to the front of the engine. Installing the gasket in any other direction will cause gasket failure and possible engine failure.

  1. Carefully lay a new head gasket on the engine block deck. Verify that the arrow or whatever marking is used on the gasket indicating which side is up and/or forward, is correctly aligned. Make sure the gasket sits flat on the block deck, not hung up on the alignment dowels. Check that all the bolt holes and water passages line up correctly. Use no sealer on head gaskets.
  2.  
  3. Carefully install the cylinder head to the block. Align any dowel pins or other locators. Install the head bolts and finger-tighten. Tighten gradually and in the following sequence:
    1. Tighten the bolts in sequence to 37 ft. lbs. (50 Nm).
    2.  
    3. Using a torque angle meter, rotate each bolt an additional 130 degrees, in sequence.
    4.  
    5. Rotate the center four bolts an additional 30 degrees, in sequence.
    6.  

  4.  
  5. Install the pushrods and rocker arms using the procedures found in this section.
  6.  
  7. Install the lower and upper intake manifold using the procedures found in this section.
  8.  
  9. Install the remaining components in the reverse order of the removal process. Since coolant will run down into the engine oil system when the head is removed, it is most important to drain the engine oil and refill with clean engine oil. A filter change is also strongly recommended.
  10.  

 
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