Installation Procedure

WARNING: This page is about a different car, the 2003 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

If removed, install the ECT sensor.
Tighten

Tighten the ECT sensor to 25 N.m (18 lb ft).
If removed, install the thermostat, the gasket, and the water outlet housing.

Fig 1: Installing Thermostat, Gasket, & Water Outlet Housing
Courtesy of GENERAL MOTORS CORP.
Install the water outlet housing bolt and the stud.
Tighten

Tighten the bolt and the stud to 27 N.m (20 lb ft).
Install the intake manifold gaskets.
Apply sealer, GM P/N 12346286, (Canadian P/N 10953472) or equivalent, to the ends of the intake seals.
Install the lower intake manifold seals.

Fig 2: Installing Intake Manifold Gaskets And Seals
Courtesy of GENERAL MOTORS CORP.
Align the coolant bypass tube with the opening in the manifold. Install the lower intake manifold.
Install the lower intake manifold bolts.
Tighten

Tighten the lower intake manifold bolts from the center to the outside in sequence to 15 N.m (11 lb ft).

Fig 3: Installing Lower Intake Manifold & Bolts
Courtesy of GENERAL MOTORS CORP.
Connect the ECT sensor electrical connector.
Install the EGR outlet pipe to the lower intake manifold.

Fig 4: Installing EGR Outlet Pipe To Lower Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the EGR outlet pipe bolt.
Tighten

Tighten the bolt to 29 N.m (21 lb ft).
Install the radiator inlet hose to the water outlet housing. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.8L) in Engine Cooling.

Fig 5: Installing Radiator Inlet Hose To Water Outlet Housing
Courtesy of GENERAL MOTORS CORP.
Install the supercharger. Refer to SUPERCHARGER REPLACEMENT .
Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
Inspect for fluid or vacuum leaks.