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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
    G02083661Courtesy of GENERAL MOTORS CORP.
  3. Install the cylinder head.
    Fig 2: Installing Cylinder Head
    G02083662Courtesy 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 Cylinder Head Bolts In Sequence
    G02083663Courtesy 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.
  10. Install the right lift bracket bolt and the nut.

    Tighten 

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

    Fig 4: Installing Right Engine Lift Bracket
    G02083664Courtesy 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).

    Fig 5: Installing EGR Valve Adapter To Right Cylinder Head
    G02083665Courtesy 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)  .
    Fig 6: Installing EGR Valve
    G02083666Courtesy 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 PLUGS in Engine Performance - Removal and Installation.
  18. Carefully release the J 41131  and return the engine to the original position.
    Fig 7: Connecting Electrical Connector
    G02083667Courtesy 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.
    Fig 8: Installing Power Steering Pump
    G02083668Courtesy 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 (3.8L) 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.
    Fig 9: Installing EGR Valve Pipe Bolt
    G02083669Courtesy of GENERAL MOTORS CORP.
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