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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 557 (Engine Mechanical - 3.8L (On-Vehicle)) >> Repair Instructions >> Cylinder Head Replacement - Right >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable.
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) 
  3. Remove the right and the left engine mount struts. Refer to Engine Mount Strut Replacement - Right  or Engine Mount Strut Replacement - Left 
  4. Raise and support the vehicle.
  5. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in ENGINE COOLING .
  6. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement 
  7. Remove the three-way catalytic converter pipe from the right exhaust manifold. Refer to or CATALYTIC CONVERTER REPLACEMENT (3.8L) in ENGINE EXHAUST .
  8. Lower the vehicle.
  9. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36)  or Drive Belt Tensioner Replacement (L67) 
  10. Remove the power steering pump bolts and reposition power steering pump.
    Fig 1: Power Steering Pump And Bolts
    G01764269Courtesy of GENERAL MOTORS CORP.
  11. Rotate the engine to access 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 .
  13. Disconnect the heated oxygen (HO2) sensor electrical connector (4).
  14. Remove the lower intake manifold. Refer to Intake Manifold Replacement - Lower (L36)  or Intake Manifold Replacement - Lower (L67) 
    Fig 2: Heated Oxygen (HO2) Sensor Electrical Connector
    G01764270Courtesy of GENERAL MOTORS CORP.
  15. Remove the exhaust gas recirculation (EGR) valve from the EGR adapter.
    Fig 3: EGR Valve
    G01764271Courtesy of GENERAL MOTORS CORP.
  16. Remove the EGR valve adapter bolt from the right exhaust manifold.
    Fig 4: EGR Valve Adapter Bolt
    G01764272Courtesy 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: EGR Valve Adapter Bolts From The Right Cylinder Head
    G01764273Courtesy of GENERAL MOTORS CORP.
  19. Remove the right engine lift bracket.
  20. Remove the right exhaust manifold. Refer to or EXHAUST MANIFOLD REPLACEMENT - RIGHT (3.8L) in ENGINE EXHAUST .
  21. Remove the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right 
  22. Remove the right rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement 
    Fig 6: Right Rocker Arm Cover
    G01764274Courtesy of GENERAL MOTORS CORP.
  23. Remove the right cylinder head bolts. Discard the bolts.
  24. Remove the right cylinder head.
    Fig 7: Right Cylinder Head Bolts
    G01764275Courtesy of GENERAL MOTORS CORP.
  25. Remove the right cylinder head gasket.
  26. Remove the caps, the springs, the valves and the seals from the cylinder head. Refer to CYLINDER HEAD DISASSEMBLE
  27. Clean the gasket mating surfaces on the cylinder head, cylinder block and the intake manifold.
    28. Fig 8: Right Cylinder Head Gasket
    G01764276Courtesy of GENERAL MOTORS CORP.
  28. Clean the cylinder block bolt hole threads.
  29. Inspect the engine block. Refer to ENGINE BLOCK CLEANING AND INSPECTION
  30. Inspect the cylinder head. Refer to CYLINDER HEAD CLEANING AND INSPECTION
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