LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1218 (Engine Mechanical - 3.8L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Cylinder Head Replacement - Right >> Removal Procedure

Removal 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. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  2. Remove the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36)  or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67)  .
  3. Raise and support the vehicle. Refer to JACKING AND LIFTING in General Information.
    Fig 1: Removing Exhaust Gas Recirculation (EGR) Valve Adapter Bolt (Right)
    G02083653Courtesy of GENERAL MOTORS CORP.
  4. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  5. Drain the engine oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT  .
  6. Remove the catalytic converter from the right exhaust manifold. Refer to CATALYTIC CONVERTER REPLACEMENT (3.8L) in Engine Exhaust.
  7. Remove the exhaust gas recirculation (EGR) valve adapter bolt from the right exhaust manifold.
  8. Lower the vehicle.
  9. Remove the drive belt tensioner. Refer to DRIVE BELT TENSIONER REPLACEMENT  .
  10. Remove the power steering pump bolts and reposition the power steering pump.
  11. Rotate the engine to access the right cylinder head. Refer to ROTATING THE ENGINE FOR SERVICE ACCESS  .
  12. Remove the right spark plugs from the right cylinder head. Refer to SPARK PLUGS in Engine Performance - Removal and Installation.
    Fig 2: Removing Power Steering Pump And Bolts
    G02083654Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the heated oxygen sensor (HO2S) electrical connector (4).
  14. Remove the lower intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - LOWER (L36)  or INTAKE MANIFOLD REPLACEMENT - LOWER (L67)  .
    Fig 3: Disconnecting Heated Oxygen Sensor (HO2S) Electrical Connector
    G02083655Courtesy of GENERAL MOTORS CORP.
  15. Remove the EGR valve nuts.
  16. Remove the EGR valve.
    Fig 4: Removing EGR Valve
    G02083656Courtesy of GENERAL MOTORS CORP.
  17. Remove the EGR valve adapter bolts from the right cylinder head.
  18. Remove the EGR valve adapter from the right cylinder head.
    Fig 5: Removing EGR Valve Adapter From Right Cylinder Head
    G02083657Courtesy of GENERAL MOTORS CORP.
  19. Remove the right engine lift bracket bolt and the nut.
  20. Remove the right engine lift bracket.
  21. Remove the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT (3.8L) in Engine Exhaust.
  22. Remove the right exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.8L) in Engine Exhaust.
  23. Remove the right valve rocker arm cover. Refer to VALVE ROCKER ARM COVER REPLACEMENT - RIGHT  .
  24. Remove the right rocker arms and push rods. Refer to VALVE ROCKER ARM AND PUSH ROD REPLACEMENT  .
    Fig 6: Removing Right Engine Lift Bracket
    G02083658Courtesy of GENERAL MOTORS CORP.
  25. Remove the right cylinder head bolts. Discard the cylinder head bolts.
  26. Remove the right cylinder head.
    Fig 7: Removing Right Cylinder Head
    G02083659Courtesy of GENERAL MOTORS CORP.
  27. Remove the cylinder head gasket.
  28. Remove the caps, the springs, the valves and the seals from the cylinder head. Refer to CYLINDER HEAD DISASSEMBLE  .
  29. Clean the gasket mating surfaces on the cylinder head, the engine block and the intake manifold.
  30. Clean the cylinder block bolt hole threads.
  31. Inspect the engine block. Refer to ENGINE BLOCK CLEANING AND INSPECTION  .
  32. Inspect the cylinder head. Refer to CYLINDER HEAD CLEANING AND INSPECTION  .
    Fig 8: Removing Cylinder Head Gasket
    G02083660Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals