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Home >> Buick >> 2004 >> Century Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 134 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Cylinder Head Replacement - Right >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the valves, the seals, the springs and the caps to the cylinder head. Refer to Cylinder Head Assemble .
    2. NOTE: Head gaskets are not interchangeable. The head gasket must be installed with the arrow pointing to the front of the engine. Installing the head gasket in any other direction will cause gasket failure and possible engine failure.
  2. Position the head gasket with the arrow pointing to the front of the engine.
    3. Fig 1: Right Cylinder Head Gasket
    GM190560Courtesy of GENERAL MOTORS CORP.
  3. Install the cylinder head.
    4. Fig 2: Right Cylinder Head & Bolts
    GM153598Courtesy of GENERAL MOTORS CORP.
    NOTE: This bolt is 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 that is stronger in this application. If the correct bolt is not used, the parts will not be tightened correctly. The system or the components may be damaged.
    NOTE: 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.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the new cylinder head bolts (1-8).

    Tighten: 

    1. Tighten the cylinder head bolts in the following sequence (1-8) to 50 N.m (37 lb ft).
    2. Use the J 45059  to rotate the cylinder head bolts in the following sequence (1-8) an additional 120 degrees.

    5. Fig 3: Identifying Cylinder Head Bolt Tightening Sequence
    GM38826Courtesy of GENERAL MOTORS CORP.
  5. Install the right push rods and rocker arms. Refer to Valve Rocker Arm and Push Rod Replacement .
  6. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right .
  7. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right in Engine Exhaust.
  8. Install the EGR valve inlet adapter pipe to the right cylinder head. Refer to Exhaust Gas Recirculation (EGR) Inlet Pipe Replacement in Engine Controls - 3.8L.
  9. Install the lower intake manifold. Refer to Intake Manifold Replacement - Lower (L26)  or Intake Manifold Replacement - Lower (L32) .
  10. Install the right spark plugs to the right cylinder head. Refer to Spark Plug Replacement in Engine Controls - 3.8L.
  11. Carefully release the J 41131  and return the engine to the original position.
  12. Install the power steering pump.
  13. Install the power steering pump bolts.

    Tighten:  Tighten the bolts to 34 N.m (25 lb ft).

    14. Fig 4: View Of Power Steering Pump And Mounting Bolts
    GM282122Courtesy of GENERAL MOTORS CORP.
  14. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  15. Install the left and the right engine mount struts. Refer to Engine Mount Strut Replacement - Left  and Engine Mount Strut Replacement - Right .
  16. Raise the vehicle.
  17. Install the exhaust gas recirculation (EGR) valve adapter bolt (1) to the right exhaust manifold.

    Tighten:  Tighten the bolt to 29 N.m (21 lb ft).

    18. Fig 5: EGR Valve Adapter Bolt & Right Exhaust Manifold
    GM911025Courtesy of GENERAL MOTORS CORP.
  18. Install the right exhaust manifold heat shield (1).
  19. Install the right exhaust manifold heat shield bolts (2).

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    20. Fig 6: Right Exhaust Manifold Heat Shield & Bolts
    GM911016Courtesy of GENERAL MOTORS CORP.
  20. Install the catalytic converter to the right exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  21. Lower the vehicle.
  22. Install the HO2S to the right exhaust manifold.

    Tighten:  Tighten the HO2S to 42 N.m (31 lb ft).

    23. Fig 7: HO2S Electrical Connector & Right Exhaust Manifold
    GM911055Courtesy of GENERAL MOTORS CORP.
  23. Connect the HO2S electrical connector.
  24. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L26)  or Fuel Injector Sight Shield Replacement (L32) .
  25. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  26. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  27. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  28. Inspect for leaks.
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