LEMON Manuals: Even more car manuals for everyone
Home >> Buick >> 2004 >> Century Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 87 (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 Buick Regal. 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.
    Fig 1: Right Cylinder Head Gasket
    GM190560Courtesy of GENERAL MOTORS CORP.
  2. Position the head gasket with the arrow pointing to the front of the engine.
    3. Fig 2: Right Cylinder Head & Bolts
    GM153598Courtesy of GENERAL MOTORS CORP.
  3. Install the cylinder head.
    4. 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.
    Fig 3: Identifying Cylinder Head Bolt Tightening Sequence
    GM38826Courtesy of GENERAL MOTORS CORP.
    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 theJ 45059  to rotate the cylinder head bolts in the following sequence (1-8) an additional 120 degrees.

  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 (3.1L) or Exhaust Manifold Replacement - Right (3.8L) in Engine Exhaust.
  8. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement (3.1L) or Exhaust Crossover Pipe Replacement (3.8L) in Engine Exhaust.
    9. Fig 4: Right Engine Lift Bracket (3.8L)
    GM153580Courtesy of GENERAL MOTORS CORP.
  9. Install the right engine lift bracket.
  10. Install the right lift bracket bolt and the nut.

    Tighten:  Tighten the bolt and the nut to 30 N.m (22 lb ft).

    11. Fig 5: EGR Valve Adapter & Bolts
    GM190558Courtesy of GENERAL MOTORS CORP.
  11. Install the EGR valve adapter to the right cylinder head.
  12. Install the EGR valve adapter bolts to the right cylinder head.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    13. Fig 6: EGR Valve & Nuts
    GM190555Courtesy of GENERAL MOTORS CORP.
  13. Install the EGR valve.
  14. Install the EGR valve nuts.

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

  15. Install the lower intake manifold. Refer to Intake Manifold Replacement - Lower (L36)  or Intake Manifold Replacement - Lower (L67) .
    16. Fig 7: HO2S Sensor Electrical Connector (3.8L)
    GM371512Courtesy of GENERAL MOTORS CORP.
  16. Connect the heated oxygen sensor (HO2S) electrical connector (4).
  17. Install the right spark plugs to the right cylinder head. Refer to Spark Plug Replacement in Engine Controls - 3.8L.
  18. Carefully release the J 41131  and return the engine to the original position.
    19. Fig 8: View Of Power Steering Pump And Mounting Bolts
    GM282122Courtesy of GENERAL MOTORS CORP.
  19. Install the power steering pump.
  20. Install the power steering pump bolts.

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

  21. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  22. Install the left and the right engine mount struts. Refer to Engine Mount Strut Replacement - Left , and Engine Mount Strut Replacement - Right .
  23. Raise the vehicle.
    24. Fig 9: EGR Valve Adapter Bolt
    GM190557Courtesy of GENERAL MOTORS CORP.
  24. Install the EGR valve pipe bolt to the right exhaust manifold.

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

  25. Install the catalytic converter to the right exhaust manifold. Refer to Catalytic Converter Replacement (3.1L) or Catalytic Converter Replacement (3.8L) in Engine Exhaust.
  26. Lower the vehicle.
  27. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) .
  28. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  29. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  30. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  31. Inspect for leaks.
scientia non olet · About LEMON Manuals