Installation Procedure

WARNING: This page is about a different car, the 2002 Buick Regal. However, it is still accessible from the selected car via links, so may be relevant.

If removed, install the engine coolant temperature (ECT) sensor.
Tighten:

Tighten the engine coolant temperature (ECT) sensor to 25 N.m (18 lb ft)
If removed, install the thermostat, the gasket, the water outlet housing.
Install the water outlet housing bolt and stud.
Tighten:

Tighten the water outlet housing bolts and stud to 27 N.m (20 lb ft)

Fig 1: Thermostat
Courtesy of GENERAL MOTORS CORP.
Install the lower intake manifold gaskets.

Fig 2: Lower Intake Manifold Gaskets
Courtesy of GENERAL MOTORS CORP.
Apply sealer GM P/N 12346286 or equivalent to the ends of the intake manifold seals.
Install the lower intake manifold seals.

Fig 3: Lower Intake Manifold Seals
Courtesy of GENERAL MOTORS CORP.
Install the lower intake manifold.

Fig 4: Lower Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the lower intake manifold bolts (1-12). Apply thread lock compound GM P/N 12345382 or equivalent to the two hidden bolts and ensure they are installed.
Tighten:

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

Fig 5: Lower Intake Manifold Bolts Tightening Sequence
Courtesy of GENERAL MOTORS CORP.
Install the evaporative emissions canister purge solenoid valve.

Fig 6: Evaporative Emissions Canister Purge Solenoid Valve
Courtesy of GENERAL MOTORS CORP.
Install the generator brace bracket.
Install the generator brace bracket bolts.
Tighten:

Tighten the generator brace bracket bolts to 50 N.m (37 lb ft)

Fig 7: Generator Brace Bracket Bolts
Courtesy of GENERAL MOTORS CORP.
Connect the engine coolant (ECT) temperature sensor electrical connector.

Fig 8: ECT Temperature Sensor Electrical Connector
Courtesy of GENERAL MOTORS CORP.
Install the radiator inlet hose to the water outlet housing. Refer to or RADIATOR HOSE REPLACEMENT - INLET (3.8L) in ENGINE COOLING .

Fig 9: Radiator Inlet Hose To The Water Outlet Housing
Courtesy of GENERAL MOTORS CORP.
Install the EGR outlet pipe to the lower intake manifold.
Tighten:

Tighten the EGR outlet pipe bolt to 29 N.m (21 lb ft)

Fig 10: EGR Outlet Pipe To The Lower Intake Manifold
Courtesy of GENERAL MOTORS CORP.
Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (L36) or Drive Belt Tensioner Replacement (L67)
Install the generator brace. Refer to GENERATOR
Install the upper intake manifold. Refer to Intake Manifold Replacement - Upper