Tools Required

J 45059 Angle Meter

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
4. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
5. Lower the vehicle.
6. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
7. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Control - 3.8L.
8. Remove the ignition control module and the bracket from the left cylinder head. Refer to Ignition Control Module Replacement in Engine Controls - 3.8L.
9. Remove the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Right Upper .
10. Remove the left engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Left Side .
11. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement .
12. Remove the left spark plugs from the left cylinder head. Refer to Spark Plug Replacement in Engine Controls - 3.8L.
13. Remove the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side in Engine Exhaust.
14. Remove the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side .
15. Remove the left rocker arms and the push rods. Refer to Valve Rocker Arm and Push Rod Replacement .



16. Remove the left cylinder head bolts. Discard the cylinder head bolts.
17. Remove the left cylinder head.



18. Remove the cylinder head gasket.
19. Remove the caps, the springs, the valves and the seals from the cylinder head. Refer to Cylinder Head Disassemble .
20. Clean the gasket mating surfaces on the cylinder head, the cylinder block and the intake manifold.
21. Clean the cylinder block bolt hole threads.
22. Inspect the engine block. Refer to Engine Block Cleaning and Inspection .
23. Inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection .

1. Install the valves, the seals, the springs and the caps to the cylinder head. Refer to Cylinder Head Assemble .

Notice: 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.



3. Install the cylinder head.

Notice: Refer to Fastener Notice in the Preface section.

Notice: This bolt is designed to permanently stretch when tightened, and therefore MUST be replaced anytime it is removed. 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.

Notice: 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.




4. Install the new cylinder head bolts (1-8).

Tighten

1. Tighten the cylinder head bolts (1-8) in the following sequence to 50 N·m (37 lb ft).
2. Use theJ 45059 to rotate the cylinder head bolts in the following sequence (1-8) an additional 120 degrees.
5. Install the left push rods and rocker arms. Refer to Valve Rocker Arm and Push Rod Replacement .
6. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side .
7. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side in Engine Exhaust.
8. Install the left spark plugs to the left cylinder head. Refer to Spark Plug Replacement in Engine Controls - 3.8L.
9. Install the lower intake manifold. Refer to Lower Intake Manifold Replacement .
10. Install the left engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Left Side .
11. Install the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Right Upper .
12. Install the ignition control module bracket and the ignition control module to the left cylinder head. Refer to Ignition Control Module Replacement in Engine Controls - 3.8L.
13. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
14. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
15. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
16. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
18. Inspect for leaks.