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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 709 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Cylinder Head Replacement - Left >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 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  .
    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: Installing Cylinder Head Gasket
    G02083650Courtesy of GENERAL MOTORS CORP.
  3. Install the cylinder head.
    Fig 2: Installing Cylinder Head
    G02083651Courtesy 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. 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 in the following sequence (1-8) an additional 120 degrees.
  5. Install the left push rods and rocker arms. Refer to VALVE ROCKER ARM AND PUSH ROD REPLACEMENT  .
  6. Install the left valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - LEFT  .
    Fig 3: Tightening Cylinder Head Bolts In Sequence
    G02083652Courtesy of GENERAL MOTORS CORP.
  7. Install the left exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - LEFT (3.8L) in Engine Exhaust.
  8. Install the left spark plugs to the left cylinder head. Refer to SPARK PLUGS in Engine Performance - Removal and Installation.
  9. Install the lower intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - LOWER (L36)  or INTAKE MANIFOLD REPLACEMENT - LOWER (L67)  .
  10. Install the left engine mount strut bracket. Refer to ENGINE MOUNT STRUT BRACKET REPLACEMENT - LEFT  .
  11. Install the right engine mount strut bracket. Refer to ENGINE MOUNT STRUT BRACKET REPLACEMENT - RIGHT UPPER (L36)  or ENGINE MOUNT STRUT BRACKET REPLACEMENT - RIGHT UPPER (L67)  .
  12. Install the ignition control module bracket and the ignition control module to the left cylinder head. Refer to IGNITION CONTROL MODULE in Engine Performance - Removal and Installation.
  13. Install the air cleaner intake duct.
  14. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36)  or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67)  .
  15. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  16. Fill the crankcase with engine oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT  .
  17. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  18. Inspect for leaks.
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