Tools Required

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 catalytic converter 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 bolts and reposition the power steering pump.
11. Rotate the engine to access the 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 Plug Replacement in Engine Controls - 3.8L.



13. Disconnect the heated oxygen sensor (HO2S) electrical connector (4).
14. Remove the lower intake manifold. Refer to Lower Intake Manifold Replacement .



15. Remove the EGR valve nuts.
16. Remove the EGR valve.



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



19. Remove the right engine lift bracket bolt and the nut.
20. Remove the right 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 cylinder head 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 .
29. Clean the gasket mating surfaces on the cylinder head, the engine 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 .
32. 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 in the following sequence (1-8) 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 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 right engine lift bracket.
10. Install the right lift bracket bolt and the nut.

Tighten
Tighten the bolt and the 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 bolts to 50 N·m (37 lb ft).




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

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

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



16. Connect the heated oxygen sensor (HO2S) 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 and return the engine to the original position.



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

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

25. Install the catalytic converter 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.