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Home › Buick › 2003 › Regal GS › Repair and Diagnosis › Engine Mechanical › Engine Mechanical - 3.8L › Repair Instructions › On-Vehicle Repair Instructions › Engine Replacement › Installation Procedure

Installation Procedure

  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.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install the bolts (2, 3, 4, 5) which secure the upper transaxle to the engine.

    Tighten 

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

    Fig 1: Locating Bolts Securing Upper Transaxle To Engine
    G01969288Courtesy of GENERAL MOTORS CORP.
  5. Remove the engine lifting device.
  6. Install the A/C compressor and the A/C compressor nuts to the A/C compressor bracket.

    Tighten 

    Tighten the nuts to 30 N.m (22 lb ft).

    Fig 2: Installing A/C Compressor & Mounting Bolts
    G01969289Courtesy of GENERAL MOTORS CORP.
  7. Install the heater hoses to the drive belt tensioner. Refer to HEATER HOSE REPLACEMENT - INLET (3.8L) and HEATER HOSE REPLACEMENT - OUTLET (3.8L) in Heating, Ventilation and Air Conditioning.
  8. Install the radiator outlet hose to the engine. Refer to RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) in Engine Cooling.
  9. Install the radiator inlet hose to the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.8L) in Engine Cooling.
  10. Reposition the engine wiring to the engine.
  11. Connect the upper engine electrical connectors to the following components:
    • Manifold absolute pressure (MAP) sensor
    • Exhaust gas recirculation (EGR) valve
    • EVAP purge solenoid
    • Idle air control (IAC) valve
    • Throttle position (T/P) sensor
    • Fuel injectors
  12. Install the upper engine wiring harness to the retaining clips.
  13. Install the power steering pump to the engine.

    Tighten 

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

    Fig 3: Installing Power Steering Pump & Mounting Bolts
    G01969290Courtesy of GENERAL MOTORS CORP.
  14. Connect the A/C vacuum hose to the engine.
  15. Install the vacuum booster hose to the engine. Refer to VACUUM BRAKE BOOSTER CHECK VALVE AND/OR HOSE in Disc & Drum.
  16. Install the engine cooling fans. Refer to COOLING FAN REPLACEMENT - ELECTRIC in Engine Cooling.
  17. Connect the positive battery cable.

    Tighten 

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

  18. Install the engine mount brackets to the upper radiator support. Refer to ENGINE MOUNT STRUT BRACKET REPLACEMENT - UPPER RADIATOR SUPPORT  .
  19. Install the engine mount struts to the engine mount strut brackets. Refer to ENGINE MOUNT STRUT REPLACEMENT - RIGHT  and to ENGINE MOUNT STRUT REPLACEMENT - LEFT  .
  20. Install the water pump pulley.
  21. Install the water pump pulley bolts.

    Tighten 

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

    Fig 4: Installing Water Pump Pulley & Bolts
    G01969291Courtesy of GENERAL MOTORS CORP.
  22. Install the drive belt. Refer to DRIVE BELT REPLACEMENT (L36)  or DRIVE BELT REPLACEMENT (L67)  .
  23. Install the accelerator cable, the cruise control cable, and the bracket to the throttle body.
  24. Connect the fuel vapor line. Refer to FUEL LINE DISCONNECT FITTINGS in Removal & Installation.
  25. Connect the fuel lines to the fuel rail. Refer to FUEL LINE DISCONNECT FITTINGS in Removal & Installation.
  26. Install the air cleaner assembly.
  27. Raise the vehicle and remove the transaxle support.
  28. Install the bolt (6) and the stud (1) which secure the lower transaxle to the engine.

    Tighten 

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

  29. Install the engine ground to the transaxle stud.

    Tighten 

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

  30. Install the oil filter adapter housing. Refer to OIL FILTER ADAPTER AND BYPASS VALVE ASSEMBLY REPLACEMENT  .
  31. Reposition and connect the electrical connectors to the following components:
    • Heated oxygen sensor (H02S)
    • Knock sensors
    • Oil level sensor
    • Oil pressure sensor
    • Vehicle speed sensor (VSS)
      Fig 5: Locating Bolts Securing Lower Transaxle To Engine
      G01969292Courtesy of GENERAL MOTORS CORP.
  32. Install the oil level sensor harness retainer to the engine.
  33. Install the oil level sensor harness retainer bolt.

    Tighten 

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

  34. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to CATALYTIC CONVERTER REPLACEMENT (3.8L) in Engine Exhaust.
  35. Install the engine mount lower nuts.

    Tighten 

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

    Fig 6: Installing Engine Mount Lower Nuts
    G01969293Courtesy of GENERAL MOTORS CORP.
  36. Install the transaxle brace. Refer to TRANSAXLE BRACE in Removal & Installation - A/T.
  37. Install the engine flywheel-to-torque converter bolts. Refer to TRANSAXLE (2003) in Removal & Installation - A/T.
  38. Install the starter motor. Refer to STARTER in Starters.
  39. Install the torque converter covers.
  40. Lower the vehicle.
  41. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36)  or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67)  .
  42. Install the hood. Refer to HOOD REPLACEMENT in Body Front End.
  43. Install the cross vehicle brace. Refer to BRACE REPLACEMENT -- CROSS VEHICLE in Body Front End.
  44. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  45. Fill the crankcase with engine oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT  .
  46. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  47. Inspect for leaks.
  48. Perform the CKP system variation learn procedure. Refer to CKP SYSTEM VARIATION LEARN PROCEDURE in Self-Diagnostics - 3.8L.
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