Cylinder Head Assembly
Cylinder Head Replacement - Right Side/Left SideCylinder Head Bolt
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 the cylinder head bolts (1-8) in the following sequence
First Pass 50 N.m (37 lb ft)
Use the J 45059 to rotate the cylinder head bolts in the following sequence (1-8).
Final Pass 120 degrees
Upper Intake Manifold bolts
Install the upper intake manifold bolts and the studs (1-10).
Tighten the bolts in sequence to 10 N.m (89 lb in).
Lower intake manifold. (3.8L)
Install the lower intake manifold bolts (1-12).
Tighten the lower intake manifold bolts in sequence to 15 N.m (11 lb ft).
Lower Intake Manifold bolts (3.8LSC)
Install the lower intake manifold bolts.
Tighten the lower intake manifold bolts from the center to the outside in sequence to 15 N.m (11 lb ft).
Exhaust Manifold Replacement - Left Side
Install the exhaust manifold bolts and the nuts.
Tighten the bolts and the nuts to 30 N.m (22 lb ft).
Exhaust Manifold - Right Side (RPOs L26/L32)
Install the right exhaust manifold studs (4) and the nuts (3).
Tighten the studs and the nuts to 30 N.m (22 lb ft).
Camshaft Position Sensor Bolt 10 N.m (89 lb in)
Camshaft Sprocket Bolt
First Pass 100 N.m (74 lb ft)
Final Pass 90 degrees
Camshaft Thrust Plate Bolt 15 N.m (11 lb ft)
Drive Belt Tensioner Bolt/Nut 50 N.m (37 lb ft)
Drive Belt Tensioner Bracket Stud 17 N.m (12 lb ft)
EGR Valve Adapter to Cylinder Head Bolt/Stud 50 N.m (37 lb ft)
EGR Valve Inlet Pipe to Exhaust Manifold Bolt 29 N.m (21 lb ft)
EGR Valve Nut 29 N.m (21 lb ft)
EGR Valve Outlet Pipe Bolt/Nut 29 N.m (21 lb ft)
EGR Valve Wiring Harness Heat Shield Bolt/Nut 10 N.m (89 lb in)
Camshaft
Camshaft Bearing Inside Diameter - 1 and 4 46.970-46.934 mm (1.8478-1.8492 in)
Camshaft Bearing Inside Diameter 2 and 3 46.977-46.942 mm (1.8481-1.8495 in)
Camshaft Journal Diameter 47.655-46.858 mm (1.8462-1.8448 in)
Camshaft Journal Out-of-Round 0.00635 mm (0.00025 in)
Camshaft Journal to Bearing Clearance 0.041-0.119 mm (0.0016-0.0047 in)
Camshaft Lobe Duration - Exhaust 330 Crankshaft degrees
Camshaft Lobe Duration - Intake 320 Crankshaft degrees
Camshaft Lobe Lift - Exhaust 6.56 mm (0.258 in)
Camshaft Lobe Lift - Intake 6.56 mm (0.258 in)
Camshaft Lobe Overlap 96 Crankshaft degrees
Cylinder Head
Combustion Chamber Depth - at Measurement Point 3.9166-5.4356 mm (0.154-0.214 in)
Cylinder Head Height/Thickness 103.492-104.178 mm (4.0745-4.1015 in)
Surface Finish 0.0032 mm (0.000125 in)
Surface Flatness - Block Deck 0.1016 mm (0.004 in)
Surface Flatness - Exhaust Manifold Deck 0.1016 mm (0.004 in)
Surface Flatness - Intake Manifold Deck 0.1016 mm (0.004 in)
Valve Guide Bore - Exhaust 8.001-8.0213 mm (0.3150-0.3158 in)
Valve Guide Bore - Intake 8.001-8.0213 mm (0.3150-0.3158 in)
Exhaust Manifold
Surface Flatness - Maximum 0.5 mm (0.02 in)