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, and 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.
Apply sealer GM P/N 12346286 or equivalent to the ends of the intake seals.
Install the lower intake manifold seals.

Fig 2: Lower 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)
Connect the engine coolant temperature (ECT) sensor electrical connector.
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 3: EGR Outlet Pipe To The Lower Intake Manifold
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 4: Radiator Inlet Hose To The 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 leaks.