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Home >> Buick >> 2007 >> Lucerne CX >> Repair and Diagnosis >> External Pages >> Different car >> Section 237 (Engine Mechanical - 3.9L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2006 Pontiac Montana SV6, 2006 Chevrolet Uplander, and 2006 Buick Terraza. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install an engine hoist to the engine.
  2. Remove the engine from the engine stand.
    3. Fig 1: View Of Flywheel
    GM1526753Courtesy of GENERAL MOTORS CORP.
  3. Position the flywheel to the crankshaft.
  4. Install the flywheel bolts finger tight.
  5. Use the J 37096  in order to hold the flywheel.
  6. Tighten the flywheel bolts.

    Tighten:   Tighten the bolts to 70 Nm (52 lb ft).

    7. Fig 2: Installing Engine To Transaxle
    GM1679543Courtesy of GENERAL MOTORS CORP.
  7. Install the engine to the transaxle and the frame.
  8. Install the transaxle bolts and studs.

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

  9. Remove the support from the transaxle.
  10. Remove the engine hoist from the engine.
  11. Install the power steering pressure and return lines to the power steering pump. Refer to POWER STEERING PRESSURE PIPE/HOSE REPLACEMENT .
  12. Connect the power steering line retainer at the generator bracket.
    13. Fig 3: Installing Engine Harness & Clips
    GM1677212Courtesy of GENERAL MOTORS CORP.
  13. Place the engine wiring harness on top of the engine and position the harness branches.
  14. Install the engine harness clip to the oil pan.
    15. Fig 4: Identifying Engine Harness & Clips
    GM1677214Courtesy of GENERAL MOTORS CORP.
  15. Connect the engine harness electrical connector to the oil level sensor.
    16. Fig 5: Identifying Engine Harness, Clips & Transaxle Studs
    GM1679961Courtesy of GENERAL MOTORS CORP.
  16. Install the engine harness clips (1) to the transaxle studs.
    17. Fig 6: Identifying Engine Harness Clamp Bolts
    GM1679958Courtesy of GENERAL MOTORS CORP.
  17. Install the engine harness clamp bolt to the transaxle.

    Tighten:   Tighten the bolts to 20 Nm (15 lb ft).

    18. Fig 7: Identifying Engine Harness Clip Studs
    GM1679962Courtesy of GENERAL MOTORS CORP.
  18. Install the engine harness clip (1) to the stud on the transaxle.
    19. Fig 8: Identifying Engine Harness connector At Vehicle Speed Sensor (VSS)
    GM1679901Courtesy of GENERAL MOTORS CORP.
  19. Connect the engine harness electrical connector to the VSS.
    20. Fig 9: Identifying Engine Harness Connector At Transaxle
    GM1679878Courtesy of GENERAL MOTORS CORP.
  20. Connect the engine harness electrical connector to the transaxle.
    21. Fig 10: Identifying Oil Pressure Sensor & Knock Sensor Electrical Connectors
    GM1675553Courtesy of GENERAL MOTORS CORP.
  21. Connect the engine harness electrical connector (1) to the knock sensor.
  22. Connect the engine harness electrical connector (2) to the oil pressure sensor.
    23. Fig 11: Identifying Engine Harness connector At Crankshaft Position (CKP) Sensor
    GM1679872Courtesy of GENERAL MOTORS CORP.
  23. Connect the engine harness electrical connector (1) to the CKP sensor.
    24. Fig 12: Identifying Engine Harness Clip
    GM1675191Courtesy of GENERAL MOTORS CORP.
  24. Install the engine harness clip (1) to the strut bracket.
    25. Fig 13: View Of Rear Of Generator
    GM1679874Courtesy of GENERAL MOTORS CORP.
  25. Connect the engine harness electrical connector (4) to the HO2S.
  26. Connect the engine harness electrical connector (3) to the generator.
  27. Install the engine harness lead (2) to the generator.
  28. Install the generator terminal nut (1).

    Tighten:   Tighten the bolts to 30 Nm (22 lb ft).

    29. Fig 14: Identifying Fuel Injector Harness Connector & Bracket
    GM1675736Courtesy of GENERAL MOTORS CORP.
  29. Connect the engine harness electrical connector (3) to the fuel injector harness electrical connector.
  30. Install the CPA retainer (2).
  31. Connect the engine harness electrical connector (1) to the intake manifold tuning valve.
    32. Fig 15: View Of Engine Harness Clip At Bracket
    GM1679954Courtesy of GENERAL MOTORS CORP.
  32. Install the engine harness clip (1) to the bracket.
  33. Install the engine harness bracket (2) to the stud.
  34. Install the engine harness bracket nut (1).
    35. Fig 16: Locating Engine Harness Electrical Connector
    GM1677450Courtesy of GENERAL MOTORS CORP.
  35. Connect the engine harness electrical connector to the camshaft actuator magnet.
  36. Install the engine harness bolt.

    Tighten:   Tighten the bolts to 20 Nm (15 lb ft).

    37. Fig 17: View Of Engine Harness To Engine
    GM1679945Courtesy of GENERAL MOTORS CORP.
  37. Install the engine harness clip to the engine.
    38. Fig 18: View Of Engine Harness At Ignition Coil Bracket
    GM1679943Courtesy of GENERAL MOTORS CORP.
  38. Install the engine harness clip (1) to the ignition coil bracket.
    39. Fig 19: View Of Engine Harness At Ignition Coil Bracket
    GM1679957Courtesy of GENERAL MOTORS CORP.
  39. Install the engine harness clip (1) to the ignition coil bracket.
    40. Fig 20: Locating Engine Harness Electrical Connectors
    GM1675732Courtesy of GENERAL MOTORS CORP.
  40. Connect the engine harness electrical connector (2) to the ignition coil.
  41. Connect the engine harness electrical connector (1) to the MAP sensor.
    42. Fig 21: Locating EVAP & ETC Electrical Connectors
    GM1675738Courtesy of GENERAL MOTORS CORP.
  42. Connect the engine harness electrical connector (2) to the throttle actuator.
  43. Connect the engine harness electrical connector (1) to the EVAP purge solenoid.
    44. Fig 22: Identifying Exhaust Crossover Pipe
    GM1679429Courtesy of GENERAL MOTORS CORP.
  44. Install the exhaust crossover pipe (2) and nuts (1).

    Tighten:   Tighten the bolts to 25 Nm (18 lb ft).

    45. Fig 23: Identifying Exhaust Manifold Heat Shield & Bolts - Left
    GM1679427Courtesy of GENERAL MOTORS CORP.
  45. Install the exhaust crossover pipe shield (2) and bolts (1).

    Tighten:   Tighten the bolts to 10 Nm (89 lb in).

  46. Install the transaxle brace and bolts.

    Tighten:   Tighten the bolts to 43 Nm (32 lb ft).

    47. Fig 24: Identifying Engine Harness Clips At Transaxle Brace
    GM1679949Courtesy of GENERAL MOTORS CORP.
  47. Install the engine harness clips (1) to the transaxle brace.
    48. Fig 25: Identifying Torque Converter Bolts
    GM1679947Courtesy of GENERAL MOTORS CORP.
  48. Install the engine harness clips (1) to the transaxle brace.
    49. Fig 26: Identifying Engine Mount-To-Support Frame Bolts
    GM1674892Courtesy of GENERAL MOTORS CORP.
  49. Install the engine mount to frame nuts.

    Tighten:   Tighten the bolts to 47 Nm (35 lb ft).

    50. Fig 27: Identifying Torque Converter Bolts
    GM1679504Courtesy of GENERAL MOTORS CORP.
  50. Install the torque converter bolts.
  51. Use the J 37096  in order to hold the flywheel.
  52. Tighten the torque converter bolts.

    Tighten:   Tighten the bolts to 63 N.m (`47 lb ft).

    53. Fig 28: Identifying Torque Converter Cover & Bolts
    GM1679424Courtesy of GENERAL MOTORS CORP.
  53. Install the torque converter covers (2, 4).
  54. Install the torque converter cover bolts (1, 3).

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

    55. Fig 29: Identifying Starter Motor & Bolts
    GM1679421Courtesy of GENERAL MOTORS CORP.
  55. Install the starter motor and bolts.

    Tighten:   Tighten the bolts to 40 N.m (30 lb ft).

    56. Fig 30: Identifying Engine Transaxle Brace
    GM1677238Courtesy of GENERAL MOTORS CORP.
  56. Install the transaxle brace and bolts.

    Tighten:   Tighten the bolts to 43 N.m (32 lb ft).

    57. Fig 31: Identifying Engine Harness Ground Nuts
    GM1679875Courtesy of GENERAL MOTORS CORP.
  57. Install the negative battery cable to the transaxle stud.
  58. Install the engine harness grounds to the studs.
  59. Install the engine harness ground nuts (1, 2) to the transaxle studs.

    Tighten:   Tighten the bolts to 25 N.m (`18 lb ft).

    60. Fig 32: Identifying Engine Harness Ground Wire Nut
    GM1679831Courtesy of GENERAL MOTORS CORP.
  60. If necessary perform the following steps, connect the engine harness electrical connector (3) to the starter.
  61. Install the engine battery positive wire terminal (2) to the stud.
  62. Install the engine battery positive wire nut (1).

    Tighten:   Tighten the bolts to 20 N.m (15 lb ft).

    63. Fig 33: Identifying Frame Bolts
    GM1679266Courtesy of GENERAL MOTORS CORP.
  63. Lower the vehicle over the powertrain/frame assembly.
  64. Position the frame rear straps (1, 4).
  65. Install the frame rear strap bolts (2, 3).

    Tighten:   Tighten the bolts to 50 N.m (37 lb ft).

    66. Fig 34: Identifying Frame Bolts
    GM1677195Courtesy of GENERAL MOTORS CORP.
  66. Install the front and rear frame bolts (1, 2).

    Tighten:   Tighten the bolts to 240 N.m (177 lb ft).

    67. Fig 35: Identifying Utility Stand
    GM333118Courtesy of GENERAL MOTORS CORP.
  67. Raise the vehicle off of the J 39580  .
  68. Remove the J 39580  from under the frame.
    69. Fig 36: Identifying Wheel Intermediate Steering Shaft & Pinch Bolt
    GM1679186Courtesy of GENERAL MOTORS CORP.
  69. Connect the intermediate steering shaft to the power steering gear.
  70. Install the intermediate steering shaft pinch bolt.

    Tighten:   Tighten the bolts to 48 N.m (35 lb ft).

  71. Position the intermediate steering shaft seal onto the steering gear.
    72. Fig 37: Identifying Wheel Drive Shafts
    GM1679243Courtesy of GENERAL MOTORS CORP.
  72. Unsecure the wheel drive shafts from the steering knuckle/struts.
  73. Install the wheel drive shafts to the transaxle.
  74. Verify that the wheel drive shaft is properly engaged to the transaxle by grasping the inner tripot housing and pulling outward. Do not pull on the wheel drive shaft bar. The wheel drive shaft will remain firmly in place when properly engaged.
    75. Fig 38: Identifying Ball Joint Castle Nut
    GM384426Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Align the ball joint cotter pin hole parallel to the knuckle in order to ease the cotter pin installation.
  75. Install the ball joints to the knuckles.
  76. Install the ball joint castle nuts.
    77. IMPORTANT: DO NOT loosen the castle nut in order to align the nut to the cotter pin hole.
  77. If necessary, tighten the castle nut in order to align the nut slot (1) to the cotter pin hole (2) as shown.
    78. Fig 39: View Of Outer Tie Rod Ends & Steering Knuckles
    GM1677211Courtesy of GENERAL MOTORS CORP.
  78. Tighten the lower ball joint castle nuts (1).

    Tighten:   Tighten the bolts to 55 N.m (40 lb ft).

  79. Install NEW lower ball joint cotter pins (2) to the ball joints.
    80. Fig 40: Securing Cotter Pin In Ball Joint Castle Nut
    GM384428Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the cotter pin ends do NOT contact the ABS wheel speed sensor, the ABS sensor connector or the drive axle.
  80. Install the tie rod end nuts (1) at the steering knuckles. (FWD shown, AWD similar).
    81. Fig 41: Identifying Outer Tie Rod End & Steering Knuckle
    GM297628Courtesy of GENERAL MOTORS CORP.
  81. Install the outer tie rod (2) to the steering knuckle (1).
    82. Fig 42: Identifying Tie Rod End Nuts
    GM1678394Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: This is a prevailing torque type fastener. You may reuse this fastener ONLY under the following conditions:
    • The fastener and its counterpart are clean and free from rust.
    • The fastener develops 2 Nm (18 lb in) of torque/drag against its counterpart prior to fastener seating.

      If the fastener does not meet these criteria, REPLACE the fastener.

  82. Install the tie rod end nuts (1) at the steering knuckles. (FWD shown, AWD similar).

    Tighten:   Tighten the nuts to 30 Nm (22 lb ft) plus an additional 120 degrees using the J 45059  .

  83. If equipped with FWD, install the stabilizer shaft links (2) to the stabilizer shaft. (left side shown, right side similar).
  84. Install the stabilizer shaft link lower nuts (3).

    Tighten:   Tighten the nuts to 23 Nm (17 lb ft).

    85. Fig 43: Identifying Engine Harness Clips At Heat Shield
    GM1679941Courtesy of GENERAL MOTORS CORP.
  85. Install the engine harness clips (1, 2) to the heat shield, if equipped with FWD.
  86. Connect the battery cable retainers at the core support.
    87. Fig 44: Identifying Engine Harness Clips At Catalytic Converter Heat Shield
    GM1679937Courtesy of GENERAL MOTORS CORP.
  87. Install the engine harness clips (1, 2) to the catalytic converter heat shield, if equipped with AWD.
  88. Install the engine splash shield. Refer to Splash Shield Replacement - Engine .
  89. Install the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT .
    90. Fig 45: Identifying A/C Compressor Front Bolt & Nut
    GM1675217Courtesy of GENERAL MOTORS CORP.
  90. Position and install the A/C compressor onto the stud.
  91. Install the A/C compressor front bolt and nut.

    Tighten:   Tighten the nuts to 50 Nm (37 lb ft).

    92. Fig 46: Identifying A/C Compressor Rear Bolt & Nut
    GM1675218Courtesy of GENERAL MOTORS CORP.
  92. Install the A/C compressor rear bolt.

    Tighten:   Tighten the nuts to 50 Nm (37 lb ft).

  93. Connect the engine harness electrical connectors to the A/C compressor.
  94. Install the drive belt. Refer to Drive Belt Replacement .
    95. Fig 47: Identifying Engine Harness Electrical Connectors Located At Left & Right Wheel Speed Sensors
    GM1679800Courtesy of GENERAL MOTORS CORP.
  95. Connect the engine harness electrical connectors (1) to the left and right wheel speed sensors. (right side shown, left side similar).
  96. Install rear propeller shaft, if equipped with AWD. Refer to PROPELLER SHAFT REPLACEMENT .
  97. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation .
  98. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Left  and Engine Mount Strut Replacement - Right .
    99. Fig 48: Identifying Fuel Feed & Evaporative Emission (EVAP) Line Quick Connect Fittings
    GM1677966Courtesy of GENERAL MOTORS CORP.
  99. Connect the fuel feed (1) and EVAP (2) line quick connect fittings. Refer to METAL COLLAR QUICK CONNECT FITTING SERVICE and PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
    100. Fig 49: View Of Booster Vacuum Hose
    GM1677963Courtesy of GENERAL MOTORS CORP.
  100. Install the brake booster vacuum hose to the upper intake manifold fitting.
  101. Connect the heater inlet (2) and outlet (1) hose quick connect fittings to the inlet and outlet pipes.
    102. Fig 50: View Of Radiator Outlet Hose
    GM1677957Courtesy of GENERAL MOTORS CORP.
  102. Install the radiator outlet hose to the thermostat housing.
  103. Using the J 38185  , release the radiator outlet hose clamp.
    104. Fig 51: View Of Radiator, Inlet Hose & Coolant Recovery Reservoir Inlet Hose
    GM1677950Courtesy of GENERAL MOTORS CORP.
  104. Install the radiator inlet hose to the coolant crossover
  105. Using the J 38185  , release the radiator inlet hose clamp.
    106. Fig 52: Identifying Engine Harness connector At Mass Air Flow (MAF)/intake Air Temperature (IAT) Sensor
    GM1677915Courtesy of GENERAL MOTORS CORP.
  106. Remove the engine harness wiring branch from on top of the engine.
  107. Install the air cleaner outlet duct to the throttle body and MAF/IAT sensor.
  108. Tighten the air cleaner outlet duct clamps at the throttle body and the MAF/IAT sensor.

    Tighten:   Tighten the nuts to 2 Nm (18 lb in).

  109. Connect the PCV fresh air tube quick connect fitting to the air cleaner outlet duct. Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
  110. Connect the engine harness electrical connector to the MAF/IAT sensor.
    111. Fig 53: Identifying Engine Harness connector At junction block.
    GM1679798Courtesy of GENERAL MOTORS CORP.
  111. Install the engine harness connector to the junction block retainer.
  112. Install the underhood junction block. Refer to UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT .
    113. Fig 54: View Of Engine Harness Clip At A/C Line
    GM1679804Courtesy of GENERAL MOTORS CORP.
  113. Install the engine harness clip (1) to the A/C line.
    114. Fig 55: Identifying Engine Harness Clip At A/C Line
    GM1679803Courtesy of GENERAL MOTORS CORP.
  114. Install the engine harness clip (1) to the A/C line.
  115. Connect the engine harness electrical connector (6) to the ABS module.
  116. Connect the engine harness electrical connector (5) to the I/P harness electrical connector (4).
  117. Connect the engine harness electrical connector (3) to the I/P harness electrical connector (2).
  118. Connect the engine harness electrical connector (1) to the TCM.
    119. Fig 56: View Of Air Cleaner Cover
    GM1679799Courtesy of GENERAL MOTORS CORP.
  119. Install the ECM to the air cleaner cover.
  120. Install the air cleaner cover.
  121. Tighten the air cleaner cover bolts.

    Tighten:   Tighten the nuts to 4 Nm (35 lb in).

    122. Fig 57: View Of Junction Block Cover
    GM1679797Courtesy of GENERAL MOTORS CORP.
  122. Install the junction block cover.
  123. Install the left side diagonal brace. Refer to BRACE REPLACEMENT - SHEET METAL DIAGONAL .
  124. Install the coolant reservoir. Refer to COOLANT RECOVERY RESERVOIR REPLACEMENT .
    125. Fig 58: View Of Coolant Crossover Pipe
    GM1679795Courtesy of GENERAL MOTORS CORP.
  125. Install the coolant recovery reservoir hose (2) to the crossover.
  126. Position the coolant recovery reservoir hose clamp (1) at the coolant crossover.
    127. Fig 59: Identifying J 42640
    GM333146Courtesy of GENERAL MOTORS CORP.
  127. Remove the J 42640  from the underside of the steering column.
  128. Install the lower radiator air baffle. Refer to RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS .
  129. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  130. Connect the positive battery cable.
  131. Connect the positive battery cable at the junction box.
  132. Connect the auxiliary ground cable on the inner fender.
  133. Connect the electrical connector to the sensor on the negative battery cable.
  134. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM (STATIC FILL) .
  135. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
  136. Perform the CKP system variation learn procedure. Refer to CKP SYSTEM VARIATION LEARN PROCEDURE .
    137. Fig 60: Identifying Engine Manifold Cover
    GM1674775Courtesy of GENERAL MOTORS CORP.
  137. Align the cover to the studs on the engine, push down on the cover above the stud in order to engage the cover to the studs
  138. Install the engine oil fill cap.
  139. Start the engine listen for unusual noises.
  140. Inspect the engine for leaks.
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