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Home >> Pontiac >> 2008 >> Grand Prix GXP >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Mechanical - 3.8L) >> Repair Instructions - On Vehicle >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    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 .
  4. Install the upper transaxle to the engine bolts (2, 3, 4, 5).

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

  5. Remove the engine lifting device.
  6. Install the A/C compressor to the engine. Refer to Compressor Replacement (L26) .
  7. Install the heater hoses to the drive belt tensioner. Refer to Heater Inlet Hose Replacement (L26) and Heater Outlet Hose Replacement (L26) .
  8. Install the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement (L26) .
  9. Install the radiator inlet hose to the engine. Refer to Radiator Inlet Hose Replacement (L26) .
  10. Reposition and install the engine wiring harness to the engine as noted during removal.
  11. Connect the upper engine electrical connectors to the following components:
    • BARO sensor, if equipped
    • Manifold absolute pressure (MAP) sensor
    • Exhaust gas recirculation (EGR) valve
    • EVAP purge solenoid
    • Fuel injectors
    • Electronic throttle control (ETC)
  12. Install the upper engine wiring harness to the retaining clips.
    13. Fig 2: View Of Power Steering Pump And Mounting Bolts
    GM282122Courtesy of GENERAL MOTORS CORP.
  13. Install the power steering pump to the engine.
  14. Install the power steering pump bolts.

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

  15. Connect the A/C vacuum hose to the engine.
  16. Install the vacuum booster hose to the engine. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement .
  17. Install the engine cooling fans. Refer to Fan Shroud Replacement (L26) .
  18. Connect the positive battery cable.

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

  19. Install the engine mount brackets to the upper radiator support. Refer to Engine Mount Strut Bracket Replacement - Upper Radiator Support .
  20. Install the engine mount struts to the engine mount strut brackets. Refer to Engine Mount Strut Replacement - Right Side  and to Engine Mount Strut Replacement - Left Side .
    21. Fig 3: View Of Water Pump Pulley And Bolts
    GM46174Courtesy of GENERAL MOTORS CORP.
  21. Install the water pump pulley.
  22. Install the water pump pulley bolts.

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

  23. Install the drive belt. Refer to Drive Belt Replacement .
  24. Connect the fuel vapor line. Refer to Plastic Collar Quick Connect Fitting Service .
  25. Connect the fuel line to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  26. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  27. Raise the vehicle and remove the transaxle support.
    28. Fig 4: View of Transaxle To Engine Mounting
    GM160965Courtesy of GENERAL MOTORS CORP.
  28. Install the lower transaxle to the engine bolt (6) and the stud (1).

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

  29. Install the oil filter adapter housing. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
    30. Fig 5: Right Exhaust Manifold & Catalytic Converter Pipe
    GM911163Courtesy of GENERAL MOTORS CORP.
  30. Install a new gasket (1) and the catalytic converter (3) to the right exhaust manifold.
  31. Install the exhaust manifold pipe stud nuts (2).

    Tighten:  Tighten the nuts to 35 N.m (26 lb ft).

  32. Install the engine mount lower nuts.

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

  33. Install the transaxle brace. Refer to Automatic Transmission Brace Replacement .
  34. Install the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement .
  35. Install the starter motor. Refer to Starter Motor Replacement (L26) .
    36. Fig 6: View Of Engine Electrical Connectors (Left Side)
    GM911140Courtesy of GENERAL MOTORS CORP.
  36. Reposition and connect the electrical connectors to the following components:
    • Heated oxygen sensor (H02S)
    • Knock sensors
    • Oil level sensor (10)
    • Oil pressure sensor
    • Vehicle speed sensor (VSS)
  37. Install the oil level sensor harness retainer to the engine.
  38. Install the oil level sensor harness retainer bolt.

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

  39. Install the engine ground wire (6) and the engine ground wire nut (5) to the transaxle stud.

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

  40. Install the torque converter covers. Refer to Torque Converter Cover Replacement .
  41. Lower the vehicle.
  42. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  43. Install the hood. Refer to Hood Replacement .
  44. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (L26) .
  45. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  46. Fill the cooling system. Refer to Cooling System Draining and Filling (L26 GE 47716 Fill) or Cooling System Draining and Filling (L26 Static Fill) .
  47. Inspect for leaks.
  48. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .
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