- 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.
- Position the head gasket with the arrow
pointing to the front of the engine.
- 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.
- Install the new cylinder head bolts (1-8).
Tighten
- Tighten the cylinder head bolts in the following sequence (1-8)
to 50 N·m (37 lb ft).
- Use theJ 45059
to rotate
the cylinder head bolts in the following sequence (1-8) an additional
120 degrees.
- Install the right push rods and rocker arms. Refer to
Valve Rocker Arm and Push Rod Replacement
.
- Install the right valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement - Right Side
.
- Install the right exhaust manifold. Refer to
Exhaust Manifold Replacement - Right Side
in Engine Exhaust.
- Install the exhaust crossover pipe. Refer to
Exhaust Crossover Pipe Replacement
in Engine Exhaust.
- Install the right engine lift bracket.
- Install the right lift bracket bolt and the nut.
Tighten
Tighten the bolt and the nut to 30 N·m (22 lb ft).
- Install the EGR valve adapter to the right
cylinder head.
- Install the EGR valve adapter bolts to the right cylinder head.
Tighten
Tighten the bolts to 50 N·m (37 lb ft).
- Install the EGR valve.
- Install the EGR valve nuts.
Tighten
Tighten the nuts to 29 N·m (21 lb ft).
- Install the lower intake manifold. Refer to
Lower Intake Manifold Replacement
.
- Connect the heated oxygen sensor (HO2S) electrical connector (4).
- Install the right spark plugs to the right cylinder head. Refer to
Spark Plug Replacement
in Engine Controls - 3.8L.
- Carefully release the J 41131
and return the engine to the original position.
- Install the power steering pump.
- Install the power steering pump bolts.
Tighten
Tighten the bolts to 34 N·m (25 lb ft).
- Install the drive belt tensioner. Refer to
Drive Belt Tensioner Replacement
.
- Install the left and the right engine mount struts. Refer to
Engine Mount Strut Replacement - Left Side
, and
Engine Mount Strut Replacement - Right Side
.
- Raise the vehicle.
- Install the EGR valve pipe bolt to the right
exhaust manifold.
Tighten
Tighten the bolt to 29 N·m (21 lb ft).
- Install the catalytic converter to the right exhaust manifold. Refer to
Catalytic Converter Replacement
in Engine Exhaust.
- Lower the vehicle.
- Install the fuel injector sight shield. Refer to
Fuel Injector Sight Shield Replacement
.
- Fill the crankcase with engine oil. Refer to
Engine Oil and Oil Filter Replacement
.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Inspect for leaks.