GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 Bonneville 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Cylinder Head Replacement - Left Side

Tools Required

J 45059 Electronic Torque Angle Meter

Removal Procedure
  1. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement .
  2. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 3.8L
  3. Remove the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side in Engine Exhaust.
  4. Remove the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side .
  5. Remove the electronic ignition module. Refer to Ignition Control Module Replacement in Engine Controls - 3.8L.
  6. Remove the valve rocker arm assemblies and the pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .

    7. Object Number: 35842 Size: SH
  7. Remove the cylinder head bolts. Discard the bolts.
  8. Remove the cylinder head.

    9. Object Number: 26157 Size: SH
  9. Remove the cylinder head gasket.
  10. Clean all of the gasket mating surfaces.
  11. Clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection .

Installation Procedure

    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.

  1. Clean the threads in the block using the appropriate tap.

    2. Object Number: 26157 Size: SH
  2. Install the head gasket with the arrow pointing to the front of the engine.

    3. Object Number: 35842 Size: SH
  3. Install the cylinder head.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 38826 Size: SH
  4. Install the new cylinder head bolts.

    5. Tighten

        • Tighten the cylinder head bolts in sequence (1-8) to 50 N·m (37 lb ft).
        • Rotate each bolt 120 degrees in sequence (1-8). Use the J 45059 .
  5. Install the valve rocker arm assemblies and the pushrods. Refer to Valve Rocker Arm and Push Rod Replacement .
  6. Install the electronic ignition module. Refer to Ignition Control Module Replacement in Engine Controls - 3.8L.
  7. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side .
  8. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side in Engine Exhaust.
  9. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 3.8L.
  10. Install the lower intake manifold. Refer to Lower Intake Manifold Replacement .