Tools Required

Notice: Refer to Engine Emission Notice in the Preface section.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
5. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
6. Remove the three-way catalytic converter pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement 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 and reposition.
11. Install the J 41131 .
12. Rotate the engine to access the right cylinder head. Refer to Rotating the Engine for Service Access .
13. Remove the right spark plugs from the right cylinder head. Refer to Spark Plug Replacement in Engine Controls - 3.8L.



14. Disconnect the oxygen sensor electrical connector (4).
15. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement .



16. Remove the EGR valve nuts.
17. Remove the EGR valve.



18. Remove the EGR valve adapter bolts from the right cylinder head.
19. Remove the EGR valve adapter from the right cylinder head.



20. Remove the engine lift bracket.
21. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement in Engine Exhaust.
22. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side in Engine Exhaust.
23. Remove the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right Side .
24. Remove the right rocker arms and push rods. Refer to Valve Rocker Arm and Push Rod Replacement .



25. Remove the right cylinder head bolts. Discard the bolts.
26. Remove the right cylinder head.



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 in Engine Mechanical - 3.8L Unit Repair.
29. Clean the gasket mating surfaces on the cylinder head, the cylinder 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 in Engine Mechanical - 3.8L Unit Repair.
32. Inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection in Engine Mechanical - 3.8L Unit Repair.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the valves, the seals, the springs and the caps to the cylinder head. Refer to Cylinder Head Assemble in Engine Mechanical - 3.8L Unit Repair.

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: 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.





Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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 the J 36660-A to rotate the cylinder head bolts an additional (1-8) 120 degrees.
5. Install the right push rods and rocker arms. Refer to Valve Rocker Arm and Push Rod Replacement .
6. Install the right valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Right Side .
7. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side in Engine Exhaust.
8. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement in Engine Exhaust.



9. Install the engine lift hook.
10. Install the right lift bracket bolt and nut.

Tighten
Tighten the engine lift bracket bolt and nut to 30 N·m (22 lb ft).




11. Install the EGR valve adapter to the right cylinder head.
12. Install the EGR valve adapter bolts to the right cylinder head.

Tighten
Tighten the EGR valve adapter bolts to 50 N·m (37 lb ft).




13. Install the EGR valve.
14. Install the EGR valve nuts.

Tighten
Tighten the EGR valve nuts to 29 N·m (21 lb ft).

15. Install the lower intake manifold. Refer to Lower Intake Manifold Replacement .



16. Connect the oxygen sensor electrical connector (4).
17. Install the right spark plugs to the right cylinder head. Refer to Spark Plug Replacement in Engine Controls - 3.8L.
18. Carefully release the J 41131 . Return the engine to the proper position.



19. Install the power steering pump.
20. Install the power steering pump bolts.

Tighten
Tighten the power steering pump bolts to 34 N·m (25 lb ft).

21. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
22. Install the left and the right engine mount struts. Refer to Engine Mount Strut Replacement - Left Side , and Engine Mount Strut Replacement - Right Side .
23. Raise the vehicle.



24. Install the EGR valve pipe bolt to the right exhaust manifold.

Tighten
Tighten the EGR valve pipe bolt to 29 N·m (21 lb ft).

25. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
26. Lower the vehicle.
27. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
28. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
29. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
30. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
31. Inspect for leaks.