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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 390 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Cylinder Head Replacement - Right >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the seals, the valves, the springs and the caps to the cylinder head. Refer to CYLINDER HEAD ASSEMBLE
    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.
    Fig 1: Head Gasket
    G01764277Courtesy of GENERAL MOTORS CORP.
  3. Install the right cylinder head.
    Fig 2: Right Cylinder Head
    G01764278Courtesy 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.
  4. Install the new cylinder head bolts (1-8).

    Tighten: 

    1. 4.1. Tighten the cylinder head bolts (1-8) in the following sequence to 50 N.m (37 lb ft).
    2. 4.2. Use the J 36660-A to rotate the cylinder head bolts an additional (1-8) 120 degrees.
      3. Fig 3: Cylinder Head Bolts Tightening Sequence
      G01764279Courtesy 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 or EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.8L) in ENGINE EXHAUST .
  8. Install the right side engine lift bracket, nut and bolt.

    Tighten: 

    Tighten the right side engine lift bracket nut and bolt to 30 N.m (22 lb ft) 

    Fig 4: Right Side Engine Lift Bracket
    G01764280Courtesy of GENERAL MOTORS CORP.
  9. Install the EGR valve adapter to the right cylinder head.
  10. Install the EGR valve adapter bolts to the right cylinder head.

    Tighten: 

    Tighten the EGR valve adapter bolts to 50 N.m (37 lb ft) 

    Fig 5: EGR Valve Adapter
    G01764281Courtesy of GENERAL MOTORS CORP.
  11. Install the EGR valve pipe and bolt to the right exhaust manifold.

    Tighten: 

    Tighten the EGR valve pipe bolt to 29 N.m (21 lb ft) 

    Fig 6: EGR Valve Pipe
    G01764282Courtesy of GENERAL MOTORS CORP.
  12. Install the EGR valve and nuts to the EGR adapter.

    Tighten: 

    Tighten the EGR valve nuts to 30 N.m (22 lb ft) 

  13. Install the lower intake manifold. Refer to Intake Manifold Replacement - Lower (L36)  or Intake Manifold Replacement - Lower (L67) 
    Fig 7: EGR Valve And Nuts To The EGR Adapter
    G01764283Courtesy of GENERAL MOTORS CORP.
  14. Connect the heated oxygen (HO2) sensor electrical connector (4).
  15. Install the right spark plugs to the right cylinder head. Refer to SPARK PLUGS .
    Fig 8: HO2 Sensor Electrical Connector
    G01764284Courtesy of GENERAL MOTORS CORP.
  16. Install the power steering pump and the power steering pump bolts.

    Tighten: 

    Tighten the power steering pump bolts to 34 N.m (25 lb ft) 

    Fig 9: Power Steering Pump
    G01764285Courtesy of GENERAL MOTORS CORP.
  17. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67) 
  18. Carefully release the J 41131 and return the engine to the proper position.
  19. Install the right and the left engine mount struts. Refer to Engine Mount Strut Replacement - Right  or Engine Mount Strut Replacement - Left 
  20. Raise the vehicle.
  21. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to or CATALYTIC CONVERTER REPLACEMENT (3.8L) in ENGINE EXHAUST .
  22. Lower the vehicle.
  23. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) 
  24. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement 
  25. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in ENGINE COOLING .
  26. Connect the negative battery cable.
  27. Inspect for leaks.
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