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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1224 (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 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to FASTENER NOTICE .
  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: Right Cylinder Head Gasket
    G01703336Courtesy of GENERAL MOTORS CORP.
  3. Install the cylinder head.
    Fig 2: Right Cylinder Head
    G01703337Courtesy 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 .
  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.
      Fig 3: Installing Cylinder Head Bolts
      G01703338Courtesy 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 (3.1L) or EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.8L) .
  8. Install the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT (3.1L) or EXHAUST CROSSOVER PIPE REPLACEMENT (3.8L) .
  9. Install the engine lift hook.
  10. Install the right lift bracket bolt and nut.

    Tighten 

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

    Fig 4: Engine Lift Bracket
    G01703339Courtesy 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 EGR valve adapter bolts to 50 N.m (37 lb ft).

    Fig 5: EGR Valve Adapter
    G01703340Courtesy of GENERAL MOTORS CORP.
  13. Install the EGR valve.
  14. Install the EGR valve nuts.

    Tighten 

    Tighten the EGR valve 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) .
    Fig 6: EGR Valve
    G01703341Courtesy of GENERAL MOTORS CORP.
  16. Connect the oxygen sensor electrical connector (4).
  17. Install the right spark plugs to the right cylinder head. Refer to SPARK PLUGS .
  18. Carefully release the J 41131.  Return the engine to the proper position.
    Fig 7: Connecting Oxygen Sensor Electrical Connector
    G01703342Courtesy of GENERAL MOTORS CORP.
  19. Install the power steering pump.
  20. Install the power steering pump bolts.

    Tighten 

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

  21. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67) .
  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.
    Fig 8: Power Steering Pump
    G01703343Courtesy of GENERAL MOTORS CORP.
  24. Install the EGR valve pipe bolt to the right exhaust manifold.

    Tighten 

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

  25. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to CATALYTIC CONVERTER REPLACEMENT (3.1L) or CATALYTIC CONVERTER REPLACEMENT (3.8L) .
  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 .
  30. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  31. Inspect for leaks.
    Fig 9: EGR Valve Pipe Bolt
    G01703344Courtesy of GENERAL MOTORS CORP.
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