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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1676 (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 2003 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  .
    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 Right Cylinder Head Gasket
    G01969235Courtesy of GENERAL MOTORS CORP.
  3. Install the cylinder head.
    Fig 2: Installing Right Cylinder Head
    G01969236Courtesy 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 in the following sequence (1-8) 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.
    Fig 3: Tightening Sequence Of Right Cylinder Head Bolts
    G01969237Courtesy 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 (3.8L) in Engine Exhaust.
  8. Install the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT (3.8L) in Engine Exhaust.
  9. Install the right engine lift bracket.
    Fig 4: Installing Right Engine Lift Bracket, Nut & Bolt
    G01969238Courtesy of GENERAL MOTORS CORP.
  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. Install the EGR valve adapter to the right cylinder head.
    Fig 5: Installing EGR Valve Adapter & Bolts To Right Cylinder Head
    G01969239Courtesy of GENERAL MOTORS CORP.
  12. Install the EGR valve adapter bolts to the right cylinder head.

    Tighten 

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

  13. Install the EGR valve.
    Fig 6: Installing EGR Valve & Nuts
    G01969240Courtesy of GENERAL MOTORS CORP.
  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. Connect the heated oxygen sensor (HO2S) electrical connector (4).
    Fig 7: Connecting Heated Oxygen Sensor Electrical Connector
    G01969241Courtesy of GENERAL MOTORS CORP.
  17. Install the right spark plugs to the right cylinder head. Refer to SPARK PLUGS in Self-Diagnostics - 3.8L.
  18. Carefully release the J 41131 and return the engine to the original position.
  19. Install the power steering pump.
    Fig 8: Installing Power Steering Pump & Bolts
    G01969242Courtesy of GENERAL MOTORS CORP.
  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. Install the EGR valve pipe bolt to the right exhaust manifold.

    Tighten 

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

    Fig 9: Installing EGR Valve Pipe Bolt To Right Exhaust Manifold
    G01969243Courtesy of GENERAL MOTORS CORP.
  25. Install the catalytic converter to the right exhaust manifold. Refer to 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 Battery.
  31. Inspect for leaks.
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