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Installation Procedure

WARNING: This page is about a different car, the 2004 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View of Transaxle To Engine Mounting
    GM160965Courtesy of GENERAL MOTORS CORP.
  1. Remove the engine from the engine stand.
  2. Install the flywheel. Refer to Engine Flywheel Installation .
  3. With the aid of an assistant, install the engine to the vehicle.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the bolts (2,3,4,5) which secure the upper transaxle to the engine.

    Tighten:  Tighten the bolts to 75 N.m (55 lb ft).

  5. Remove the engine lifting device.
    6. Fig 2: View Of A/C Compressor
    GM277915Courtesy of GENERAL MOTORS CORP.
  6. Install the A/C compressor and the A/C compressor nuts to the A/C compressor bracket.

    Tighten:  Tighten the nuts to 30 N.m (22 lb ft).

  7. Install the heater hoses to the drive belt tensioner. Refer to Heater Hose Replacement - Inlet (3.1L) or Heater Hose Replacement - Inlet (3.8L) and Heater Hose Replacement - Outlet (3.1L) or Heater Hose Replacement - Outlet (3.8L) in Heating, Ventilation and Air Conditioning.
  8. Install the radiator outlet hose to the engine. Refer to Radiator Hose Replacement - Outlet (3.1L) or Radiator Hose Replacement - Outlet (3.8L) in Engine Cooling.
  9. Install the radiator inlet hose to the engine. Refer to Radiator Hose Replacement - Inlet (3.1L) or Radiator Hose Replacement - Inlet (3.8L) in Engine Cooling.
  10. Reposition the engine wiring to the engine.
  11. Connect the upper engine electrical connectors to the following components:
    • Manifold absolute pressure (MAP) sensor
    • Exhaust gas recirculation (EGR) valve
    • EVAP purge solenoid
    • Idle air control (IAC) valve
    • Throttle position (T/P) sensor
    • Fuel injectors
  12. Install the upper engine wiring harness to the retaining clips.
    13. Fig 3: View Of Power Steering Pump And Mounting Bolts
    GM282122Courtesy of GENERAL MOTORS CORP.
  13. Install the power steering pump to the engine.

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

  14. Connect the A/C vacuum hose to the engine.
  15. Install the vacuum booster hose to the engine. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement in Hydraulic Brakes.
  16. Install the engine cooling fans. Refer to Cooling Fan Replacement - Electric in Engine Cooling.
  17. Connect the positive battery cable.

    Tighten:  Tighten the cable terminal bolt to 15 N.m (11 lb ft).

  18. Install the engine mount brackets to the upper radiator support. Refer to Engine Mount Strut Bracket Replacement - Upper Radiator Support .
  19. Install the engine mount struts to the engine mount strut brackets. Refer to Engine Mount Strut Replacement - Right  and to Engine Mount Strut Replacement - Left .
    20. Fig 4: View Of Water Pump Pulley And Bolts
    GM46174Courtesy of GENERAL MOTORS CORP.
  20. Install the water pump pulley.
  21. Install the water pump pulley bolts.

    Tighten:  Tighten the pulley bolts to 13 N.m (116 lb in).

  22. Install the drive belt. Refer to Drive Belt Replacement (L36)  or Drive Belt Replacement (L67) .
  23. Install the accelerator cable, the cruise control cable, and the bracket to the throttle body. Refer to Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.8L.
  24. Connect the fuel vapor line. Refer to Quick Connect Fitting(s) Service (Plastic Collar) in Engine Controls - 3.8L.
  25. Connect the fuel lines to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) or Quick Connect Fitting(s) Service (Plastic Collar) in Engine Controls - 3.8L.
  26. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
  27. Raise the vehicle and remove the transaxle support.
    28. Fig 5: View of Transaxle To Engine Mounting
    GM160965Courtesy of GENERAL MOTORS CORP.
  28. Install the bolt (6) and the stud (1) which secure the lower transaxle to the engine.

    Tighten:  Tighten the bolt and the stud to 75 N.m (55 lb ft).

  29. Install the engine ground to the transaxle stud.

    Tighten:  Tighten the engine ground nut to 35 N.m (26 lb ft).

  30. Install the oil filter adapter housing. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
  31. Reposition and connect the electrical connectors to the following components:
    • Heated oxygen sensor (H02S)
    • Knock sensors
    • Oil level sensor
    • Oil pressure sensor
    • Vehicle speed sensor (VSS)
  32. Install the oil level sensor harness retainer to the engine.
  33. Install the oil level sensor harness retainer bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

  34. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to Catalytic Converter Replacement (3.1L) or Catalytic Converter Replacement (3.8L) in Engine Exhaust.
    35. Fig 6: Engine Mount Lower Nuts
    GM50411Courtesy of GENERAL MOTORS CORP.
  35. Install the engine mount lower nuts.

    Tighten:  Tighten the nuts to 47 N.m (35 lb ft).

  36. Install the transaxle brace. Refer to Automatic Transmission Brace Replacement in Automatic Transaxle - 4T65 - E.
  37. Install the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65 - E.
  38. Install the starter motor. Refer to Starter Motor Replacement (3.8L) or Starter Motor Replacement (3.1L) in Engine Electrical.
  39. Install the torque converter covers. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65 - E.
  40. Lower the vehicle.
  41. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36)  or Fuel Injector Sight Shield Replacement (L67) .
  42. Install the hood. Refer to Hood Replacement in Body Front End.
  43. Install the cross vehicle brace. Refer to Brace Replacement - Cross Vehicle in Body Front End.
  44. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  45. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  46. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  47. Inspect for leaks.
  48. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Engine Controls - 3.8L.
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