3.8l v6 - Vins [a,3,9] Buick Electra Estate Wagon

ENGINE IDENTIFICATION

The engine may be identified from the Vehicle Identification Number (VIN) stamped on the metal tab located on the top of the instrument panel at the lower left of the windshield. The VIN number code also appears as part of the production or unit number stamped on the left rear of the cylinder block on all models. The VIN number contains 17 characters. The 8th character identifies the engine and the 10th character establishes the model year.

ENGINE IDENTIFICATION CODES

ENGINE

See ENGINE REMOVAL article.

CYLINDER HEAD & MANIFOLDS

Note. Unless 3.8L engine is MFI or Turbo equipped, proceed to intake manifold removal procedure.

MULTI-PORT FUEL INJECTION

Removal

1. To reduce fuel system pressure, remove fuse marked "Fuel Pump" (fuse block in passenger compartment), start engine (engine will start and run until fuel in line is exhausted) and when engine stops, engage starter again for 3 seconds to ensure engine will not start.
2. Disconnect negative battery terminal. Drain cooling system and remove radiator and heater hoses. Remove and mark all electrical connectors attached to engine. Disconnect and remove mass air flow sensor and air inlet tubes. Disconnect T.V. and accelerator cables at throttle body.
3. Remove cruise control cable (if equipped). Remove crankcase ventilation pipe. Remove vacuum lines at throttle body. Unplug fuel injector electrical connectors. Disconnect fuel lines at fuel rail. Remove fuel rail bracket mounting screws and lift off fuel rail. Remove injectors and plug holes.
4. Remove alternator and bracket. Remove distributor cap and rotor to access torx head bolt. Remove torx head bolt (Tool J-24394). Remove intake manifold bolts and manifold.

Installation

To install, use new "O" rings on fuel injectors and reverse removal procedures.

TURBOCHARGER

Note. Before beginning removal procedures on a turbocharging system, clean area around turbocharger with non-caustic solution and use extreme care during removal to avoid damaging turbine blades.

1. Disconnect negative battery cable. Remove air inlet tube, vacuum harness and 2 electrical connectors from throttle body. Remove electrical cable, attaching nuts and assembly from throttle body. Disconnect oil feed and drain lines, plug openings.
2. Remove vacuum hoses at compressor and wastegate actuator. Raise vehicle. Remove exhaust crossover pipe at turbocharger and loosen at both manifolds. Lower vehicle.
3. Remove 2 mounting bracket bolts at manifold and support bracket bolt at cylinder head holding turbocharger exhaust outlet housing. Lift turbocharger from manifold adapter.

To install, use new gaskets and reverse removal procedures.

1. Disconnect negative battery terminal, remove air cleaner and drain cooling system. Disconnect upper radiator hose, heater hose, accelerator linkage and bracket. Disconnect cruise control chain and brake booster vacuum line.
2. Disconnect fuel line at carburetor. Disconnect vacuum modulator line (if equipped). Remove distributor lead, temperature sending unit and CCC harness. Disconnect idle stop solenoid lead (if equipped).
3. Disconnect vacuum hoses from distributor TVS and EFE valve pipe, from carburetor to vacuum manifold and load leveler (if equipped). Disconnect coolant by-pass hose at intake manifold. Remove distributor cap and rotor to access to intake manifold Torx head bolt. Remove Torx head bolt (Tool J-24394).
4. Remove accessory mounting brackets. Remove intake manifold bolts. Remove intake manifold and carburetor as an assembly.

Note. Clean all of gasket surfaces on intake mainfold and cylinder heads.

Install new intake manifold gaskets and position new rubber seals on front and rear rails on cylinder block. Make sure pointed end of seal fits tightly against block and heads. Apply RTV sealer to seal ends. Install intake manifold and tighten bolts in sequence. To complete installation, reverse removal procedure. (Scheme 15)

Intake Manifold Tightening Sequence. Scheme 15

Removal (Front Wheel Drive)

1. Disconnect negative battery cable. Remove pinch bolt at intermediate shaft and separate intermediate shaft from stub shaft. Remove mass air flow sensor, air intake duct and crankcase ventilation pipe (if equipped). Remove spark plug wires at spark plugs. NOTE: If intermediate shaft is not disconnected from rack and pinion, damage may occur to steering gear and/or intermediate shaft.
2. Raise and support vehicle. Remove 2 exhaust manifold-to-exhaust pipe bolts. Lower vehicle. Remove upper engine support strut. Place a jack under front crossmember of cradle and raise vehicle to almost off floor. Remove 2 front body mount bolts and cushions.
3. Replace bolts and retainers a minimum of 3 turns into cage nuts. Lower jack slowly. Remove power steering pump and bracket. Disconnect crossover pipe from exhaust manifold. Remove 6 manifold-to-head attaching bolts and remove manifolds.

Note. Lowering cradle without restraint may cause damage to body and underhood components.

Removal (All Others)

1. Remove negative battery cable. On right side, remove oxygen sensor. On left side, remove EFE pipe. Raise vehicle and support it on jack stands.
2. Remove exhaust pipe at each exhaust manifold. Remove 6 bolts attaching each exhaust manifold to cylinder heads. Remove exhaust manifolds.

Note. If replacing an exhaust manifold, transfer oxygen sensor and/or exhaust pipe seal to new manifold.

Clean sealing surfaces of exhaust manifolds and cylinder heads. Install manifolds by reversing removal procedure. Tighten exhaust manifold bolts and check for exhaust leaks.

1. Remove negative battery cable and drive belts. On right side, remove PCV pipe to air cleaner, alternator and mounting bracket, necessary computer command control hoses and leads, and A/C compressor (if equipped) with hoses attached.
2. On left side, remove hot air tube, AIR pump (if equipped) with bracket, oil dipstick, power steering pump (if equipped) and bracket, and upper engine support strut (if equipped). Remove spark plug wires. NOTE: Before removing valve covers and intake manifold, clean them with compressed air and shop towels to keep dirt from getting into engine. CAUTION: When disassembling engine, all parts must be marked with locations for proper reassembly.
3. Remove valve cover bolts and valve covers. Remove rocker arm assemblies and push rods. Remove intake and exhaust manifold bolts and manifolds. Remove cylinder head bolts and cylinder heads.

Clean all mating surfaces and bolt holes. Position new head gasket on block (be careful not to damage gasket). Position head on block. Coat head bolts with sealer and install. Tighten head bolts in sequence using 4 steps. (Scheme 16) After a 15-minute wait, set final torque to 80 ft. lbs. (108 N.m). Reverse removal procedure to complete installation.

Cylinder Head Tightening Sequence. Tighten head bolts in 4 steps. Scheme 16

VALVE ARRANGEMENT

E-I-E-I-I-E (Left side, front-to-rear).

E-I-I-E-I-E (Right side, front-to-rear).

VALVE GUIDE SERVICING

If stem-to-guide clearance is excessive, replace valve. Some valves with oversize stems are used in production and can be identified by stamped number on back side of valve head. Oversize valve guides and valve guide reamers are available in .003", .006", and .010" oversize. When reconditioning, always use next oversize reamer and replacement valve.

VALVE STEM OIL SEALS

Valve stem oil seals are installed on intake valve guides. A new seal should be installed whenever a valve spring is removed. To install new seals, carefully slide seal over valve stem and push down until it contacts valve guide. Push seal onto guide until seal bottoms against guide.

Note. If "UMBRELLA" type oil seals are used, seat them on valve guides. Use oversize seals with oversize valves. If "O" ring type oil seals are used, make sure they are properly seated and not twisted.

With cylinder head removed, compress valve spring with spring compressor and remove valve keepers. Release spring compressor and remove spring retainer and spring. Remove valve stem oil seal from intake valves.

Check valve springs in a valve spring tester and replace as necessary. Install valve stem oil seals on intake valves only. Both intake and exhaust valve springs may be installed with either end up. Reverse removal procedure to complete installation.

1. Remove valve cover, rocker arm shaft retaining bolts and rocker arm shaft assembly. With rocker arm assembly removed, remove nylon rocker arm retainers and rocker arms from shaft. Inspect shaft and rocker arms for wear, scoring or damage. NOTE: Place rocker arm assembly on a clean surface and note component locations for reassembly purposes.
2. Replace components as necessary. If rocker arms are being replaced, note that rocker arms are marked left and right.

1. Reverse removal procedure to assemble rocker arms. The rocker arms must be installed in correct order on shafts. Nylon rocker arm retainers are NOT reusable and must be replaced upon reassembly.
2. Center each arm on hole in shaft. Install new nylon retainers in holes, using a drift punch with at least a .50" (12.7 mm) diameter shaft.

Rocker Arm Positioning. Scheme 17

HYDRAULIC VALVE LIFTER ASSEMBLY

If hydraulic valve lifters are being removed, mark or identify lifters to ensure that they are installed in original position. The lifters are serviced as complete assemblies ONLY. If lifter is damaged or worn, complete lifter must be replaced. If lifters are disassembled for cleaning and inspection, after reassembly they should be tested using a leak-down rate tester.

Exploded View of Hydraulic Lifter Assembly. Replace as a complete assembly. Scheme 18

OIL PAN

See OIL PAN REMOVAL article.

1. With cylinder heads removed, check top of cylinder bore for ridge. With piston at bottom of stroke and covered with a cloth, remove ridge using a ridge reamer. Mark piston/rod assemblies to ensure that they are installed in original position.
2. With oil pan removed, rotate engine until No. 1 piston is down. Remove connecting rod nuts and cap. Install thread protectors on rod bolts and push piston/rod assembly out through top of cylinder bore. Remove remaining piston/rod assemblies and install connecting rod caps on rods from which they were removed.

Scheme 19

1. Position rings on piston. (Scheme 19) Make sure that cylinder bores, pistons and bearing journals are clean. Coat bearing surfaces, pistons and cylinder bores with engine oil. Rotate crankshaft until connecting rod journal of piston/rod assembly being installed is down. (Scheme 19): Piston Ring Gap Positioning
2. Place bearing insert in connecting rod and install thread protectors on rod bolts. Using a ring compressor, compress piston rings. Position piston in bore so that notch in top of piston is facing toward front of engine.
3. Push piston into bore, carefully guiding connecting rod over crankshaft until bearing is seated against journal. Remove thread protectors and install connecting rod cap and bearing. Tighten connecting rod cap nuts. (Scheme 20)

Piston & Rod Assembly. Scheme 20

FITTING PISTONS

1. With piston/rod assembly removed, thoroughly clean cylinder bore. Inspect bore for taper or out-of-round.
2. If cylinder tapers more than .005" (.13 mm) or is out-of-round more than .003" (.076 mm), cylinder must be bored and an oversize piston and rings installed.
3. Measure piston diameter at 90° angle to piston pin and .25" (6.35 mm) below oil ring groove. If clearance between piston and cylinder is excessive, cylinder must be bored and oversize pistons and rings installed.

FITTING RINGS

1. Position a ring in cylinder bore where it will be used. Push ring down to a point in bore to where ring wear is not encountered. Use head of piston to position ring squarely in bore.
2. Measure gap between ends of ring using a feeler gauge; if it is not to specification, file ends of rings carefully using a smooth file to obtain proper ring gap.

Note. Use care to avoid damage to ring and/or cylinder bore.

PISTON PINS

1. Piston pin is a press fit in connecting rod. Using a Piston Pin Remover/Installer (J-24086) and a press, remove piston pin and separate piston and rod. (Scheme 21)
2. Inspect pin for wear and/or scoring. Check clearance of pin in piston. If clearance is excessive, piston/pin assembly must be replaced.
3. Place connecting rod in correct position for bank in which piston and rod is being installed. (Scheme 20) Lubricate piston pin and press it into piston and rod, using Piston Pin Remover/Installer (J-24086) and press used during removal process. (Scheme 21)

Piston Pin Removal & Installation. Scheme 21

CONNECTING ROD BEARINGS

Note. Ends of bearings must never be filed flush with parting surfaces of rod cap or cylinder block and cap.

1. With connecting rod cap removed, inspect bearings for flaking or wear. Check connecting rod journal for scoring or grooves. Measure rod journal with a micrometer and check journal for out-of-round conditions. Journal out-of-round condition should not exceed .0015" (.038 mm).
2. Check bearing-to-journal clearance using Plastigage method. If clearance exceeds .003" (.08 mm), select fit undersize bearings may be installed to obtain correct clearance.
3. If clearance is excessive, crankshaft must be reconditioned or replaced. Measure rod side clearance using a feeler gauge. Clearance should be .005-.026" (.13-.66 mm).

MAIN BEARINGS

Note. Ends of bearings must never be filed flush with parting surfaces of rod cap or cylinder block and cap.

1. Upper bearing halves are grooved to supply oil to connecting rod bearings. Lower cap bearing halves are not grooved. With main bearing cap removed, inspect bearing for flaking or scoring.
2. Inspect main bearing journal for wear or grooves. Check journal for out-of-round conditions with a micrometer. If journal is out-of-round more than .0015" (.038 mm), crankshaft must be replaced. NOTE: To remove upper bearing, place a cotter pin in crankshaft oil hole and rotate crankshaft. When installing bearing caps, arrows must point to front of engine.
3. To check bearing-to-journal clearance using Plastigage method. If clearance exceeds .003" (.08 mm), select fit undersized bearings may be installed to obtain correct clearance. If clearance is excessive, crankshaft must be reconditioned or replaced.

REAR MAIN BEARING OIL

Note. Upper half of seal can only be replaced if crankshaft is removed. A leaking seal can be repaired without being replaced.

Oil Seal Replacement

1. With crankshaft removed, pry old seals out of cylinder block and main bearing cap. Apply RTV sealer to seal groove. Within 1 minute, install a new rope seal and insert Seal Installer (J-28693/BT-2318) against one end of seal in block.
2. Pack seal until it is tight, by driving against seal with installer. The seal should be packed approximately .25" to .75" (6.35 to 19 mm) above edge of cylinder block. Repeat same procedure on bearing cap. Measure amount that is packed into groove and add .062" (1.6 mm).
3. Measure total distance on seal that was removed from main bearing cap and cut off same amount. Cut off same amount for opposite side. Replace crankshaft. Apply RTV sealer to mating surface of rear bearing cap and install bearing caps.

Main Bearing Cap Side Seals

1. Neoprene seals are placed on sides of bearing cap. The seals are slightly undersize when newly installed (and may leak) since neoprene composition swells in presence of heat and oil. The seals are slightly longer than grooves in cap, but should not be cut off.
2. Soak seals in light oil or kerosene for 5 minutes before installation. After seals are installed, force them into cap with end of a hammer handle. Apply RTV sealer to mating surface of main bearing cap before installation.

THRUST BEARING ALIGNMENT

With thrust bearing cap bolts finger tight, move crankshaft forward and backward, with last movement being forward. Tighten all of main bearing cap bolts and rotate crankshaft. Be sure there is no excessive drag. Using a dial indicator, check crankshaft end play. It should be .003-.009" (.08-.23 mm).

Scheme 22

1. Remove negative battery terminal, electrical connector at ignition module, spark plug wires at coil assembly and 4 nuts and washers holding ignition module assembly to bracket. Remove electrical connector at camshaft position sensor and 2 screws securing sensor.
2. Remove camshaft position sensor. With camshaft position sensor removed, record position of slot in rotating vane. Remove retaining bolt and camshaft sensor drive assembly.
3. Disconnect crankshaft sensor electrical connector. Raise vehicle and position harmonic balancer so that slot in disc is lined up with sensor. Loosen sensor retaining bolt and slide sensor out through notch in sensor housing. (Scheme 22): Computer Controlled Coil Ignition Components Used on 3.8L turbocharged engines.
4. Drain cooling system. Disconnect radiator hoses and heater hose at water pump. Remove drive belts, fan and pulleys. If equipped, loosen the AIR pump and position it out of way. Disconnect fuel lines and remove fuel pump. Remove alternator and brackets.
5. Remove distributor. If timing chain and sprocket are not being removed, note position for reinstallation. Loosen front clamp on thermostat by-pass hose. Remove harmonic balancer. Remove front engine cover bolts and 2 oil pan-to-front cover attaching bolts. Remove front cover.

Note. Oil pump cover should be removed. Always pack petroleum jelly around oil pump gears whenever front cover is removed. Oil pump may lose its prime when front engine cover is removed.

Installation (3.8L Turbo Only)

To install, reverse removal procedures. Position crackshaft sensor with .030" (.76 mm) between disc and rotor.

Scheme 23

1. Remove No. 1 spark plug and place piston on TDC. Mark harmonic balancer and rotate engine to 25° after TDC. Remove spark plug wires and coil assembly. Using Weather Remover (J-28742-A), remove terminal "B" of electrical connector on module side. (Scheme 23): Camshaft Position Sensor Adjustment
2. Install jumper wire to "B" terminal and reconnect wire which was removed. Connect a voltmeter between jumper wire and ground. Turn ignition "ON" (engine stopped).
3. Rotate camshaft sensor counterclockwise until sensor switch just closes (when reading drops to 0-2 volts). Tighten retaining bolt. Reinstall spark plug and wires. Remove jumper wire and reinstall wire into "B" terminal.

1. Drain cooling system. Disconnect radiator hoses and heater hose at water pump. Remove drive belts, fan and pulleys. If equipped, loosen the AIR pump and position it out of way. Disconnect fuel lines and remove fuel pump. Remove alternator and brackets.
2. Remove distributor. If timing chain and sprocket are not being removed, note position for reinstallation. Loosen front clamp on thermostat by-pass hose. Remove harmonic balancer. Remove front engine cover bolts and 2 oil pan-to-front cover attaching bolts. Remove front cover.

Note. Oil pump cover should be removed. Always pack petroleum jelly around oil pump gears whenever front cover is removed. Oil pump may lose its prime when front engine cover is removed.

Installation (All Others)

Make sure that gasket surfaces are clean and use a new gasket. Use sealer on bolt threads. Reverse removal procedure to install front engine cover.

Front Cover Assembly. Pack oil pump gears with petroleum jelly. Scheme 24

With front engine cover removed, drive seal and shedder out to rear of cover, using a drift punch.

Coil new packing around the opening so that ends are at top. Using a punch, drive in shedder and stake it in place at three points. Size packing by rotating it around with a hammer handle until balancer hub can be inserted through opening.

TIMING CHAIN

Note. Timing chain should be replaced if in-out movement exceeds 1" (25 mm) on slack side of chain.

Scheme 25

1. With front cover removed, temporarily install harmonic balancer, washer and bolt. Rotate engine until timing marks on sprockets are aligned. (Scheme 25) Remove harmonic balancer bolt without distrubing position of sprockets. Remove front oil slinger. (Scheme 25): Timing Chain Sprocket Alignment. Rotate engine to align timing marks on sprocket.
2. Remove camshaft sprocket bolts and alternately pry sprockets of camshaft and crankshaft to enable removal of timing chain and sprockets. Clean all parts thoroughly and replace any part showing wear and/or damage.

1. Make sure that No. 1 piston is at TDC and align camshaft timing marks. Carefully install timing chain and sprockets without distrubing alignment of marks. Place oil slinger (with concave side toward front of engine) on crankshaft.
2. Install camshaft sprocket bolts and tighten. Install camshaft thrust spring, button and timing chain dampers. Install front cover and tighten. (Scheme 26)

Exploded View of Timing Chain Assembly. Scheme 26

Remove intake manifold, rocker arm assemblies, push rods and lifters. Mark or identify push rods and lifters to ensure that are installed in original position. Remove front engine cover and timing chain with sprockets. Carefully slide camshaft out to avoid damaging camshaft bearings or lobes.

Thoroughly clean and inspect camshaft. Lubricate journals and camshaft lobes. Carefully insert camshaft taking care not to damage bearings or camshaft lobes. Reverse removal procedures to complete installation.

Remove camshaft and rear cover. Using Camshaft Bearing Remover/Installer (J6098-01), remove inner bearings first. The front bearings may be removed by using a spacer between engine block and puller plate and remove from rear.

Note. DO NOT reuse camshaft bearings once they have been removed.

Install by reversing removal procedures. Carefully pull bearings into place by using Camshaft Bearing Remover/Installer (J6098-01). Be sure oil holes in bearings and journal are aligned. Apply RTV sealer to camshaft rear cover before installation.

1. Disconnect negative battery cable, and remove drive belts. Drain cooling system and remove hoses from water pump. Remove water pump attaching bolts and engine support strut. Using a floor jack under cradle, raise vehicle until it starts to rise.
2. Remove 2 front (right) body mount bolts with cushions and retainers. Remove cushions from bolts. Thread bolts and retainers back into place. Release floor jack slowly until crossmember contacts body mount retainers. Remove water pump from engine.

If installing a new water pump, transfer pulley from old pump. Clean all of sealing surfaces to ensure a proper seal. Apply a 1/8" bead of sealant to water pump sealing surface. While sealer is wet, install water pump and tighten attaching bolts. To complete installation, reverse removal procedure.

Note. For information on cooling system capacities and other cooling system components, see ENGINE COOLING SYSTEMS article.

CRANKCASE CAPACITY

The 3.8L turbocharged engine uses 6 quarts (5.8L) with filter change; 5 quarts (4.7L) without. All others use 5 quarts (4.7L) with filter change; 4 quarts (3.8L) without.

NORMAL OIL PRESSURE

Normal oil pressure should be 37 psi (2.60 kg/cm 2 ) at 2400 RPM.

PRESSURE REGULATOR VALVE

Pressure regulator valve is located in oil pump and is non-adjustable.

ENGINE OILING SYSTEM

The lubrication is a force-feed type. The oil is supplied under full pressure to crankshaft, connecting rods, camshaft bearings, and valve lifters. A controlled volume of oil is supplied to rocker arms and push rods. All other moving parts are lubricated by splash or gravity flow.

Engine Oiling System. Scheme 27

OIL PUMP

Note. The oil filter by-pass valve and spring are staked in place. Do not attempt to remove them.

Remove oil filter. Remove bolts securing oil pump cover assembly to front engine cover. Remove cover assembly and slide pump gears out of pocket. Remove pressure regulator plug, spring and valve from cover assembly.

Inspection

1. Thoroughly clean all of components and inspect for wear or damage. Check fit of valve in bore. If clearance is excessive, replace valve and/or cover.
2. Place a straightedge across gears and measure clearance between straightedge and gasket surface with a feeler gauge. The clearance is .002-.006" (.05-.15 mm). If clearance is less than .002" (.05 mm), check gear pocket for wear.

Pack gear pocket with petroleum jelly and insert gears into pocket, making sure that jelly is packed into all pockets. Lubricate and install regulator valve in cover. Install spring, gasket and plug. Install a new gasket and position cover on oil pump. Tighten cover retaining bolts.

Oil Pump and Components. Pack petroleum jelly into gear pockets. Scheme 28

OIL PUMP SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARING SPECIFICATIONS

VALVE SPRING SPECIFICATIONS

VALVE SPRING SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS