Engine Mechanical - 3.8l (On-Vehicle) Buick LeSabre VIII

Fastener Tightening Specifications

TORQUE SPECIFICATIONS

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Engine Mechanical Specifications

Engine Mechanical Specifications

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Diagnostic Starting Point - Engine Mechanical

Begin the system diagnosis by reviewing the description and operation information. This will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Strategy Based Diagnostics

1. Perform A Diagnostic System Check in Engine Controls before using the symptom tables, if applicable.
2. Review the system operations in order to familiarize yourself with the system functions.

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system problem. The diagnostic flow is the place to start when repairs are necessary.

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the engine.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Check for the correct oil level, proper oil viscosity, and correct filter application.
4. Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
5. Compare the engine sounds, if applicable to a known good engine and make sure you are not trying to correct a normal condition.

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. See «Base Engine Misfire Without Internal Engine Noises»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. See «Base Engine Misfire With Abnormal Internal Lower Engine Noises»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
3. See «Base Engine Misfire With Abnormal Valve Train Noise»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
4. See «Base Engine Misfire With Coolant Consumption»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
5. See «Base Engine Misfire With Excessive Oil Consumption»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
6. See «Engine Compression Test»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-compression-test) .
7. See «Engine Noise On Start-Up, But Only Lasting A Few Seconds»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
8. See «Upper Engine Noise, Regardless Of Engine Speed»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
9. See «Lower Engine Noise, Regardless Of Engine Speed»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
10. See «Engine Noise Under Load»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
11. See «Engine Will Not Crank - Crankshaft Will Not Rotate»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
12. See «Oil Consumption Diagnosis»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__oil-consumption-diagnosis) .
13. See «Oil Pressure Diagnosis & Testing»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
14. See «Oil Leak Diagnosis»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
15. See «Drive Belt Chirping Diagnosis»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
16. See «Drive Belt Squeal Diagnosis»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
17. See «Drive Belt Whine Diagnosis»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
18. See «Drive Belt Rumbling Diagnosis»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
19. See «Drive Belt Vibration Diagnosis»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
20. See «Drive Belt Falls Off Diagnosis»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
21. See «Drive Belt Excessive Wear Diagnosis»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
22. See «Drive Belt Tensioner Diagnosis»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .

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Engine Compression Test

Tools Required: J 38722 Compression Tester

A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket.

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1. Run the engine until it reaches normal operating temperature. The battery must be at or near full charge.
2. Turn the engine OFF.
3. Disable the ignition.
4. Disable the fuel systems.
5. Remove the spark plugs from all the cylinders.
6. Remove the air duct from the throttle body.
7. Block the throttle plate in the open position.
8. Measure the engine compression, using the following procedure: 8.1. - Firmly install J 38722 to the spark plug hole. 8.2. - Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 8.3. - Check and record the readings on J 38722 at each stroke. 8.4. - Disconnect J 38722 . 8.5. - Repeat the compression test for each cylinder.
9. Record the compression readings from all of the cylinders. The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading should be less than 689 kPa (100 psi).
10. The following are examples of the possible measurements: When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause.
11. Remove the block from the throttle plate.
12. Install the air duct to the throttle body.
13. Install the spark plugs.
14. Install the Powertrain Control Module (PCM) fuse.
15. Install the ignition fuse to the Underhood fuse block.

Cylinder Leakage Test

Tool Required: J 35667-A Cylinder Head Leakdown Tester

With the use of air pressure, a cylinder leakage test will aid in the diagnosis. The cylinder leakage test may be used in conjunction with the engine compression test, to isolate the cause of leaking cylinders.

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1. Remove the battery ground - negative cable.
2. Remove the spark plugs.
3. Install the J 35667-A .
4. Measure each cylinder on the compression stroke, with both valves closed. Important: It may be necessary to hold the crankshaft balancer bolt, to prevent piston movement.
5. Apply air pressure, using the J 35667-A . Refer to the manufacturer's instructions.
6. Record the cylinder leakage readings for each cylinder. Important: Normal cylinder leakage is from 12-18 percent. Make a note of any cylinder with more leakage than the other cylinders. Any cylinder with 30 percent leakage or more requires service.
7. Inspect the four primary areas, to properly diagnose a leaking cylinder.
8. If air is heard from the intake or exhaust system, perform the following procedure: Remove the valve rocker arm cover of the suspect cylinder head. Ensure that both valves are closed. Inspect the cylinder head for a broken valve spring. Remove the suspect cylinder head and inspect. Refer to Cylinder Head Cleaning and Inspection in engine mechanical - unit repair.
9. If air is heard from the crankcase system at the crankcase, oil filler tube, perform the following procedure: Remove the piston from the suspect cylinder. Inspect the piston and connecting rod assembly. Refer to Piston, Connecting Rod, and Bearings Cleaning and Inspection in engine mechanical - unit repair. Inspect the engine block. Refer to Engine Block Cleaning and Inspection in engine mechanical - unit repair.
10. If bubbles are found in the radiator, perform the following procedure: Remove both cylinder heads and inspect. Refer to Cylinder Head Cleaning and Inspection Cylinder Head Cleaning and Inspection in engine mechanical - unit repair. Inspect the engine block. Refer to Engine Block Cleaning and Inspection in engine mechanical - unit repair.
11. Remove the J 35667-A .
12. Install the spark plugs.
13. Install the battery ground/negative cable.

Oil Consumption Diagnosis

An engine that has excessive oil consumption uses 0.9 L (1 qt) of oil, or more, within 3 200 km (2,000 mi). The following list indicates the conditions and corrections of excessive oil consumption

1. An improperly read oil level indicator dipstick. Inspect the oil level while the vehicle is parked on a level surface. Allow adequate drain-down time.
2. Improper oil viscosity. Use the recommended SAE viscosity for prevailing temperatures. Check for proper oil viscosity specifications.
3. Continuous high-speed driving
4. Severe hauling, such as a trailer. This causes decreased oil mileage.
5. A malfunctioning crankcase ventilation system
6. External oil leaks. Tighten the bolts, as needed. Replace the gaskets and seals, as needed.
7. Worn or omitted valve guides and/or valve stem seals Ream the guides. Install oversized service valves and/or new valve stem seals.
8. Broken or worn piston rings
9. Improperly installed or unseated piston rings
10. Improperly installed or improperly fitted piston
11. Plugged cylinder head gasket oil drain holes
12. Damaged intake gaskets

Low Or No Oil Pressure

The following can cause low or no oil pressure

1. Low oil level - fill to the full mark on the oil level indicator.
2. Slow idle speed.
3. Incorrect or malfunctioning oil pressure switch - replace the oil pressure switch.
4. Incorrect or malfunctioning oil pressure gage - replace the oil pressure gage.
5. Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. Install new oil if it is diluted.
6. The oil pump is worn or dirty - clean or replace the oil pump.
7. The oil filter is plugged - replace the oil filter.
8. The oil pickup screen is loose or plugged - replace the oil pickup screen.
9. A hole in the oil pickup tube - replace the oil pickup tube.
10. Excessive bearing clearance - replace the bearings.
11. Cracked, porous, or plugged oil galleries - repair or replace the engine block.
12. The gallery plugs are missing or improperly installed - install or repair as necessary.
13. The pressure regulator valve is stuck. Check the pressure regulator valve for sticking in the bore. Check the bore for scoring and burrs.
14. The camshaft is worn or poorly machined - replace the camshaft.
15. Worn valve guides - repair as needed.

Oil Pressure Testing

Tools Required: J 25087-C Oil Pressure Tester

If the vehicle has low oil pressure perform the following tests.

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1. Check the oil level.
2. Raise the vehicle and remove the oil filter.
3. Assemble the plunger valve in the large hole of J 25087-C base and the hose in the small hole of J 25087-C base. Connect the gage to the end of the hose.
4. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve itself.
5. Install J 25087-C on the filter mounting pad.
6. Start the engine and check the overall oil pressure, the oil pressure switch, and for noisy lifters. The engine should be at operating temperature before checking the oil pressure. The oil pressure should be approximately 414 kPa (60 psi) at 1850 RPM using 10W30 engine oil.
7. If adequate oil pressure is indicated, check the oil pressure switch.
8. If a low reading is indicated, press the valve on the tester base to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the valve would indicate a faulty pump.

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Diagnostic Aids

The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution.

A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

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1. 2) - The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table.
2. 3) - The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed.
3. 4) - Inspect all drive belt pulleys for piling. Piling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust.
4. 6) - Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
5. 10) - Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed.
6. 12) - Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley.
7. 14) - Replacing the drive belt when it is not damaged or there is not excessive piling will only be a temporary repair.

A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise.

If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.

The numbers below refer to the step numbers on the diagnostic table.

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1. 2) - The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table.
2. 3) - The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed.
3. 4) - This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly.
4. 5) - This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise.
5. 6) - This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction.
6. 7) - Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
7. 8) - This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.

The drive belt will not cause the whine noise.

If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing.

The numbers below refer to the step numbers on the diagnostic table.

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1. 3) - This test is to verify that the noise is being caused by the drive belt or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed.
2. 4) - The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure.

Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise.

The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom.

If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise.

The numbers below refer to the step numbers on the diagnostic table.

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1. 2) - This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom.
2. 3) - This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed.
3. 4) - Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plies of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt.
4. 5) - Small amounts of piling is normal condition and acceptable. When the piling is severe the drive belt does not have a smooth surface for proper operation.

The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components.

The numbers below refer to the step numbers on the diagnostic table.

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1. 2) - This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain.
2. 3) - This test is to verify that the drive belt or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed.
3. 4) - The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the belt.
4. 6) - Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed.
5. 8) - This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump.
6. 9) - Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate.

If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.

An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly.

If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.

The numbers below refer to the step numbers on the diagnostic table.

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1. 2) - This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plies.
2. 4) - Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley.
3. 5) - Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley.
4. 6) - Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
5. 7) - Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.

Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application.

Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off.

Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off.

The numbers below refer to the step numbers on the diagnostic table.

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1. 2) - The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley.
2. 3) - The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys.
3. 4) - This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle.

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1. Remove oil filler neck.
2. Lift the front of the shield up and pull towards the front of the vehicle.
3. Remove fuel injector sight shield.

Installation Procedure

1. Align the extension on the rear edge of the shield to the bracket on the rear of the engine.
2. Push the shield rearward and push down to align it with the oil filler hole.
3. Install oil filler neck.

Removal Procedure

The drive belt drives all engine mounted accessories. All driven accessories are rigidly mounted to the engine. Drive belt tension is maintained by a spring loaded belt tensioner. A belt squeak when the engine is started or stopped is normal and has no effect on belt durability. The drive belt tensioner can control belt tension over a broad range of belt lengths.

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1. Rotate the tensioner (2) counterclockwise to remove the drive belt (1).
2. Remove the accessory drive belt (1) from the engine.

1. Position the accessory drive belt (1) to the pulleys.
2. Rotate the tensioner (2) counterclockwise to install the drive belt (1).

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1. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling .
2. Remove the generator.
3. Remove the heater hoses from the drive belt tensioner fittings.
4. Remove the drive belt tensioner bolts.
5. Remove the drive belt tensioner from the engine.

1. Install the drive belt tensioner to the engine.
2. Install the drive belt tensioner bolts. Tighten the drive belt tensioner bolts to 50 N.m (37 ft lbs).
3. Connect the heater hoses to the drive belt tensioner fittings.
4. Install the generator.
5. Fill the cooling system.

Engine Mount Inspection

Inspect the engine mounts for the following problems

1. Damage to the rubber portions of the mount.
2. Damage to the mounting stud.

Engine Support Fixture

Tools Required

1. J 28467-B Universal Engine Support Fixture
2. J 42478 Engine Support Fixture Adapters

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1. Remove the air inlet grill.
2. Remove the rearward strut bolts from the right and left strut towers.
3. Install the J 42478 (2) into the strut threads.
4. Place the strut adapters, J 28467-33A (1), on top of the four remaining forward strut tower bolts.
5. Install the strut tower support assemblies, J 28467-5A, over the adapters J 42478 and J 28467-33A.
6. Install the T-Bolts to the J 42478 and J 28467-33A.
7. Install the strut tower tube, J 28467-3, into the strut tower support assemblies, J 28467-5A.
8. Install the 1/2-inch x 2.5-inch quick release pin, J 28467-10 (2), through the strut tower support assembly, J 28467-5A (3) and the strut tower tube, J 28467-3 (1) on one side only.
9. Install the radiator shelf tube, J 28467-2A, on top of the strut tower tube, J 28467-3, over the rear engine lift bracket.
10. Install the round tube of the front support assembly, J 28467-4A, through the large hole in the radiator shelf tube, J 28467-2A. The hole used in the radiator shelf tube, J 28467-2A, depends on the vehicle application.
11. Place the rubber padded foot of the front support assembly, J 28467-4A, on the upper tie bar.
12. Install the 7/16-inch x 2.0-inch quick release pin, J 28467-9, through the hole in the front support assembly, J 28467-4A, in order to level the radiator shelf tube, J 28467-2A.
13. Install the cross bracket assembly, J 28467-1A.
14. Hand tighten the cross bracket assembly, J 28467-1A wing nuts.
15. Install the swivel lift hook, J 28467-8A, through the lift hook bracket, J 28467-6A.
16. Install the 1/2-inch lift hook washer and lift hook wing nut, J 28467-34, onto the swivel lift hook, J 28467-8A.
17. Install the assembled lift hook bracket, J 28467-6A (1), over the strut tower tube, J 28467-3 (2).
18. Adjust the assembled lift hook bracket, J 28467-6A (1), in order to align the hook with the front engine lift hook bracket.
19. Install the swivel lift hook, J 28467-8A, through the front engine lift hook bracket. Ensure the hook does not damage the surrounding components.
20. Install the lift hook, J 28467-7A, through the lift hook bracket, J 28467-6A.
21. Install the 1/2-inch lift hook washer and lift hook wing nut, J 28467-34 onto the lift hook J 28467-7A.
22. Install the assembled lift hook bracket, J 28467-6A (1), over the radiator shelf tube, J 28467-2A (2).
23. Adjust the assembled lift hook bracket, J 28467-6A (1), in order to align the hook with the rear engine lift hook bracket.
24. Install the lift hook, J 28467-7A, through the rear engine lift hook bracket. Ensure the hook does not damage the surrounding components.
25. Hand tighten the lift hook wing nuts, J 28467-34, securely to remove all slack from the engine support fixture assembly.

1. Remove the J 28467-B .
2. Remove the J 42478 .
3. Install the two rearward strut bolts to the right and left strut towers. Tighten the strut tower bolts to 60 N.m (44 ft lbs).
4. Install the air inlet grill.

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1. Raise and support the vehicle.
2. Support the engine assembly with a suitable jack.
3. Remove the nut securing the right engine mount to the right engine mount bracket.
4. Lower the jack allowing the engine to lower slightly.
5. Remove the bolt (4) securing the mount to the body frame rail.
6. Remove the two nuts (2) securing the mount to the body frame rail.
7. Remove the right engine mount (3).

1. Position the right engine mount (3) to the body frame rail.
2. Install the mount attaching bolt (4) and nut (1) to the body frame rail.
3. Install the two nuts (2) securing the right engine mount to the body frame rail. Tighten the right engine mount to body frame rail nuts (1, 2) to 70 N.m (52 ft lbs).
4. Raise the engine into position.
5. Install the nut securing the right engine mount to the right engine mount bracket. Tighten the right engine mount nut to 80 N.m (59 ft lbs).
6. Remove the engine support jack.
7. Lower the vehicle.

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1. Raise and support the vehicle.
2. Remove the right front fascia extension.
3. Support the engine assembly with a suitable jack.
4. Remove the nut securing the right engine mount to the right engine mount bracket.
5. Lower the jack allowing the engine to lower slightly.
6. Remove the three fasteners securing the right engine mount bracket to the engine.
7. Remove the right engine mount bracket stud.
8. Remove the right engine mount bracket.

1. Position the right engine mount bracket to the front engine mount stud and engine.
2. Apply thread lock compound GM P/N 12345493 or equivalent, to the right engine mount bracket bolts.
3. Loosely install the two lower right engine mount bracket bolts.
4. Apply thread lock compound GM P/N 12345493 or equivalent, to the right engine mount bracket stud.
5. Install the right engine mount bracket stud to the engine. Tighten the right engine mount bracket stud to 8 N.m (71 in lbs).
6. Install the right engine mount bracket nut to the engine. Tighten the right engine mount bracket fasteners to 60 N.m (44 ft lbs).
7. Raise the engine into position.
8. Install the nut securing the right engine mount to the right engine mount bracket. Tighten the right engine mount nut to 80 N.m (59 ft lbs).
9. Remove the engine support jack.
10. Install the right front fascia extension.
11. Lower the vehicle.

Scheme 53

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. Remove the MAP sensor (1).
3. Use a 16 mm (5/8 in) socket to press the access cover (2) down and rotate 1/4 turn counterclockwise.
4. Remove the access cover.
5. Remove the PCV valve (3) and the O-ring (4) from the intake manifold.

1. Install the PCV valve (3) and the O-ring (4) into the intake manifold.
2. Install the access cover (2).
3. Install the MAP sensor (1).
4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .

Scheme 54

1. Loosen the nut holding the tube to the exhaust manifold.
2. Pull upward on the tube.
3. Remove the oil level indicator and the tube.

1. Install the tube assembly to the engine. 1.1. Make sure the O-ring is in place. 1.2. Make sure you fully seat the tube assembly in the engine.
2. Slide the tube assembly under the exhaust manifold nut. Tighten the oil level indicator tube nut to 19 N.m (14 ft lbs).

Scheme 55

Scheme 56

Scheme 57

Scheme 58

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. Disconnect the manifold vacuum source.
3. Remove the evaporative emission canister purge valve and secure the hoses to the air inlet grill.
4. Disconnect the right spark plug wires from the ignition module and position aside.
5. Remove the MAP sensor.
6. Remove the engine wiring harness heat shield fasteners.
7. Remove the engine wiring harness heat shield.
8. Remove the fuel rail mounting bolts and the fuel rail with the injectors.
9. Remove the throttle body support bracket bolts.
10. Remove the throttle body support bracket.
11. Remove the air cleaner intake duct.
12. Remove the nuts securing the throttle body to the upper intake manifold.
13. Remove the throttle body and position aside.
14. Remove the throttle body gasket.
15. Remove the upper intake manifold bolts.
16. Remove the upper intake manifold.
17. Clean and inspect the upper intake manifold.
18. Clean the lower intake manifold mating surface.

Important: Do not use any sealer on the gasket.

1. Install the new upper intake manifold gasket.
2. Position the upper intake manifold to the lower intake manifold.
3. Install the upper intake manifold bolts. Tighten the upper intake manifold bolts in sequence (1-10) to 10 N.m (89 in lbs).
4. Position a new throttle body gasket to the upper intake manifold.
5. Install the throttle body to the upper intake manifold.
6. Install the nuts securing the throttle body to the upper intake manifold. Tighten the throttle body nuts to 10 N.m (89 in lbs).
7. Install the air cleaner intake duct.
8. Install the throttle body support bracket.
9. Install the throttle body support bracket bolts. Tighten the throttle body support bracket bolts to 10 N.m (89 in lbs).
10. Install the fuel rail assembly.
11. Install the engine wiring harness heat shield.
12. Install the engine wiring harness heat shield fasteners. Tighten the engine wiring harness heat shield fasteners to 10 N.m (89 in lbs).
13. Install the MAP sensor.
14. Connect the right spark plug wires to the ignition module.
15. Install the evaporative emission canister purge valve.
16. Connect the manifold vacuum source.
17. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .

Scheme 59

1. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. Remove the thermostat housing.
3. Disconnect the electrical connector from the ECT.
4. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
5. Remove the EGR valve outlet pipe.
6. Remove the lower intake manifold bolts.
7. Remove the lower intake manifold.
8. Clean and inspect the lower intake manifold.

Important: In order to install the manifold, complete the following steps

1. Clean the cylinder block, heads and the intake manifold sealing surface of all oil with a suitable solvent.
2. Apply a GM approved sealer to the ends of the intake manifold seals.
3. Clean any adhesive compound from the intake manifold bolts and the bolt holes.
4. Apply thread locking compound GM P/N 12345739 (Canadian P/N 10953541) or equivalent to the intake manifold bolt threads before assembly.

1. Install the lower intake manifold gasket.
2. Install the lower intake manifold.
3. Apply Threadlocker 272 GM P/N 12345493 (Canadian P/N 10953488) to the bolt threads.
4. Install the lower intake manifold bolts. Tighten the lower intake manifold bolts in sequence (1-10) to 15 N.m (11 ft lbs).
5. Install the EGR valve outlet pipe.
6. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
7. Connect the electrical connector from the ECT.
8. Install the thermostat housing.
9. Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .

Scheme 60

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. Disconnect the left spark plug wire harness and position aside.
3. Remove the left valve rocker arm cover bolts. Important: If the valve rocker arm cover adheres to the cylinder head, remove the valve rocker arm cover by bumping the end of the valve rocker arm cover with palm of hand or with a soft rubber mallet.
4. Remove the left valve rocker arm cover.
5. Remove the left valve rocker arm cover gasket.
6. Clean the sealing surface on the cylinder head.
7. Clean the valve rocker arm cover bolts of all thread locking adhesive.
8. Clean and inspect the valve rocker arm cover.

1. Install the new valve rocker arm cover gasket. Make sure that valve rocker arm cover gasket is seated properly in the valve rocker arm cover groove.
2. Install the left valve rocker arm cover to the cylinder head.
3. Apply thread lock compound GM P/N 12345493 or equivalent, to the valve rocker arm cover bolt threads.
4. Install the left valve rocker arm cover bolts. Tighten the valve rocker arm cover bolts to 10 N.m (89 in lbs).
5. Connect the left spark plug wire harness.
6. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .

Scheme 61

Scheme 62

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. Disconnect the right spark plug wire harness and position aside.
3. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
4. Remove the AIR valve/pipe.
5. Disconnect the vacuum brake booster hose from the vacuum connections and position aside.
6. Remove the two nuts attaching the fuel injector sight shield bracket to the right exhaust manifold studs.
7. Remove the fuel injector sight shield bracket.
8. Remove the right valve rocker arm cover bolts. Important: If the valve rocker arm cover adheres to the cylinder head, remove the valve rocker arm cover by bumping the end of the valve rocker arm cover with the palm of your hand or a soft rubber mallet.
9. Remove the right valve rocker arm cover.
10. Remove the right valve rocker arm cover gasket.
11. Clean the sealing surface on the cylinder head.
12. Clean the valve rocker arm cover bolts of all thread locking adhesive.
13. Clean and inspect the valve rocker arm cover.

1. Install the new valve rocker arm cover gasket. Make sure that the valve rocker arm cover gasket is seated properly in the valve rocker arm cover groove.
2. Install the right valve rocker arm cover to the cylinder head.
3. Apply thread lock compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the valve rocker arm cover bolt threads.
4. Install the right valve rocker arm cover bolts. Tighten the valve rocker arm cover bolts to 10 N.m (89 in lbs).
5. Install the fuel injector sight shield bracket.
6. Install the two nuts attaching the fuel injector sight shield bracket to the right exhaust manifold studs. Tighten the fuel injector sight shield bracket to right exhaust manifold stud nuts to 30 N.m (22 ft lbs).
7. Install the AIR valve/pipe.
8. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
9. Connect the vacuum brake booster hose to the vacuum connections.
10. Connect the right spark plug wire harness.
11. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .

Valve Rocker Arm & Push Rod Replacement

Tools Required: J 36660-A Torque Angle Meter

Scheme 63

1. Remove the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. Remove the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
3. Remove the valve rocker arm pedestal retaining bolts.
4. Remove the pedestal. Important: Place the assemblies on a clean surface. Store the components in order. Reassemble the components in the same location and with the same mating surfaces as when removed.
5. Remove the rocker arm assembly.
6. Remove the pushrods.
7. Clean the bolts of all thread adhesive.
8. Clean and inspect the valve rocker arms and pushrods.

1. Install the pushrods.
2. Install the valve rocker arm assembly.
3. Install the pedestal. NOTE: The two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake is removed. The bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
4. Apply GM P/N 12345493 (Canadian P/N 10953488) threadlocker compound or equivalent to the valve rocker arm bolt threads.
5. Install the valve rocker arm pedestal retaining bolts. Tighten the valve rocker arm bolts to 15 N.m (11 ft lbs) + 90 degrees using J 36660-A .
6. Install the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle)
7. Install the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
8. Listen for valve train noise.

Valve Stem Oil Seal & Valve Spring Replacement

Tools Required

1. J 22794 Spark Plug Port Adapter
2. J 38606 Valve Spring Compressor
3. J 42863 Valve Stem Seal Installer

Scheme 64

Scheme 65

1. Remove the rocker arm assemblies. Refer to «Valve Rocker Arm & Push Rod Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__valve-rocker-arm-push-rod) .
2. Remove the spark plugs. Important: Rotate the engine so that the piston in the cylinder that you are servicing is at top dead center before removing the valve keys. Do this in order to eliminate the possibility of the valve falling into the cylinder.
3. Install the J 22794 into the cylinder head. Charge the cylinder with compressed air in order to hold the valves closed.
4. Use the J 38606 in order to compress the valve spring.
5. Remove the valve keys.
6. Remove the valve cap.
7. Remove the valve spring.
8. Pry up on the bottom of the seal in order to remove the valve stem oil seal.

1. Place the oil seal over the valve stem so the seal begins to contact the valve guide. Important: Use hand pressure only when installing the valve stem oil seal using the J 42863 . Using too much force may cause damage to the oil seal and possibly lead to excessive oil consumption.
2. Use the J 42863 in order to push the valve stem seal over the guide.
3. Use the J 38606 in order to install the valve spring. Install the valve cap.
4. Install the valve keys.
5. Repeat the previous steps for each valve.
6. Depressurize the cylinder.
7. Remove the J 22794 .
8. Install the spark plug.
9. Install the valve rocker arm assemblies. Refer to «Valve Rocker Arm & Push Rod Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__valve-rocker-arm-push-rod) .

Important: Keep all of the valve train parts in order. Reinstall the valve train parts in their original locations and with the same mating surfaces as when removed.

Scheme 66

1. Remove the rocker arms, pushrods, and the pedestals. Refer to «Valve Rocker Arm & Push Rod Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__valve-rocker-arm-push-rod) .
2. Remove the lower intake manifold and gaskets. Refer to «Intake Manifold Replacement - Lower»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
3. Remove the valve guide retainer bolts.
4. Remove the valve guide retainer.
5. Remove the valve lifter guides.
6. Remove the valve lifters.
7. Clean and inspect the valve lifters and guides.

1. Dip the valve lifters in prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
2. Install the valve lifters.
3. Install the valve lifter guides.
4. Install the valve guide retainer.
5. Install the valve guide retainer bolts. Tighten the valve guide retainer bolts to 30 N.m (22 ft lbs).
6. Install the lower intake manifold and gaskets. Refer to «Intake Manifold Replacement - Lower»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
7. Install the valve rocker arms, pushrods, and the pedestals. Refer to «Valve Rocker Arm & Push Rod Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__valve-rocker-arm-push-rod) .

Crankshaft Balancer Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 37096 Flywheel Holding Tool
3. J 38197-A Crankshaft Balancer Remover

Scheme 67

Scheme 68

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. Remove the right front tire and wheel.
3. Use the J 37096 in order to hold the flywheel.
4. Remove the balancer bolt. Important: Do not separate the pulley from the balancer. Service the pulley and the balancer as an assembly.
5. Use the J 38197-A in order to remove the crankshaft balancer. Attach 1/4 inch bolts to the pulley. Screw the bolts in 1/4 inch.
6. Clean and inspect the crankshaft balancer.

1. Install the crankshaft balancer. Lubricate the seal surface with engine oil.
2. Use the J 37096 in order to hold the flywheel.
3. Install the crankshaft balancer bolt. Tighten the crankshaft balancer bolt to 150 N.m (111 ft lbs). Use the J 36660-A in order to tighten the bolt an additional 76 degrees.
4. Install the right front tire and wheel.
5. Install the drive belt. Refer to «Drive Belt Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle)
6. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Engine Controls .

Crankshaft Front Oil Seal Replacement

Tools Required: J 35354 Seal Installer

Scheme 69

1. Remove the crankshaft balancer and the bolt. Refer to «Crankshaft Balancer Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__crankshaft-balancer-replacement) . Important: Do not damage the seal bore or the contact surfaces.
2. Use a screwdriver in order to pry out the crankshaft front oil seal.

1. Use the J 35354 in order to install the oil seal.
2. Use the crankshaft balancer bolt with the tool.
3. Tighten the bolt until the crankshaft front oil seal is seated in the engine front cover.
4. Remove the J 35354 .
5. Coat the inside seal surface of the crankshaft balancer with lubricant GM P/N 10522497 or equivalent.
6. Install the crankshaft balancer and the bolt. Refer to «Crankshaft Balancer Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__crankshaft-balancer-replacement) .

Engine Front Cover Replacement

Tools Required: J 36660-A Torque Angle Meter

Scheme 70

1. Remove the right engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. Remove the drive belt tensioner assembly. Refer to «Drive Belt Tensioner Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
3. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__crankshaft-balancer-replacement) .
4. Remove the crankshaft sensor shield.
5. Remove the crankshaft sensor.
6. Remove the oil pan to engine front cover bolts.
7. Remove the engine front cover attaching bolts.
8. Remove the engine front cover.
9. Inspect the timing chain for overall in and out movement. Movement should not exceed 25 mm (1 in).
10. Inspect the timing sprockets for wear.
11. Clean the gasket mating surfaces at the cylinder block.
12. If the oil pan gasket is excessively swollen, the oil pan must be removed and the gasket replaced.
13. Clean and inspect the engine front cover.

1. Install the engine front cover gasket.
2. Install the engine front cover.
3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the bolt threads.
4. Install the engine front cover attaching bolts. Tighten the engine front cover bolts to 20 N.m (15 ft lbs). Use the J 36660-A in order to rotate the bolts an additional 40 degrees.
5. Install the oil pan to the engine front cover bolts. Tighten the oil pan bolts to 14 N.m (125 in lbs).
6. Install the drive belt tensioner assembly. Refer to «Drive Belt Tensioner Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) . Important: Do not adjust the crankshaft sensor.
7. Install the crankshaft sensor.
8. Install the crankshaft sensor shield.
9. Install the crankshaft balancer and bolt. Refer to «Crankshaft Balancer Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__crankshaft-balancer-replacement) .
10. Install the right engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .

Scheme 71

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-front-cover-replacement) .
2. Remove the oil filter adapter.
3. Remove the pressure regulator valve and the spring. Refer to «Oil Filter Adapter & Bypass Valve Assembly Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__oil-filter-adapter-bypass-valve) .
4. Remove the oil pump cover attaching screws.
5. Remove the oil pump cover.
6. Remove the oil pump gear set.
7. Clean and inspect the oil pump gear set and housing.

1. Lubricate the oil pump gears with petroleum jelly.
2. Install the oil pump gear set.
3. Pack the oil pump gears with petroleum jelly.
4. Install the oil pump cover.
5. Install the oil pump cover screws. Tighten the oil pump cover screws to 11 N.m (98 in lbs).
6. Install the oil filter adapter with a new gasket. Install the pressure regulator valve and the spring. Refer to «Oil Filter Adapter & Bypass Valve Assembly Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__oil-filter-adapter-bypass-valve) .
7. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-front-cover-replacement) . NOTE: Do not run the engine until the oil pressure is tested. Running the engine without measurable oil pressure will cause extensive damage. NOTE: Stop the engine and remove the oil pan if the oil pressure does not build up immediately. Check the oil pump pipe and the screen for a clogged screen, damaged pipe, or a damaged gasket. Running the engine without measurable oil pressure will cause extensive damage.
8. Inspect the oil pressure.
9. Inspect for the proper fluid levels.
10. Inspect for leaks.

Oil Filter Adapter & Bypass Valve Assembly Replacement

Tools Required

1. J 36660-A Torque Angle Meter
2. J 41772 Oil Pressure Switch Socket

Scheme 72

Scheme 73

1. Raise and support the vehicle.
2. Disconnect the electrical connector from the engine oil pressure switch (1).
3. Remove the engine oil pressure switch (1) from the oil filter adapter using the J 41712 .
4. Remove the oil filter.
5. Remove the 3 oil filter adapter bolts from the engine front cover.
6. Remove the following components: 6.1. The oil filter adapter. 6.2. The oil filter adapter gasket. 6.3. The oil pressure relief valve. 6.4. The oil pressure relief valve spring.
7. Clean all parts in a suitable solvent and allow to dry.
8. Inspect the following components: Oil pressure valve for burrs Valve bore for burrs Valve spring for loss of tension

1. Install the spring into the engine front cover.
2. Install the oil pressure valve into the engine front cover.
3. Install a new oil filter adapter gasket.
4. Install the oil filter adapter.
5. Install the oil filter adapter bolts. Tighten the oil filter adapter bolts to 15 N.m (11 ft lbs). Use the J 36660-A to tighten the oil filter adapter bolts an additional 50 degrees.
6. Lightly oil the replacement oil filter gasket with clean oil.
7. Install the new oil filter. Tighten the new oil filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface.
8. Install the engine oil pressure switch (1) to the oil filter adapter using the J 41712 . Tighten the engine oil pressure switch to 16 N.m (12 ft lbs).
9. Connect the electrical connector to the engine oil pressure switch (1).
10. Lower the vehicle.
11. Inspect for oil leaks after engine start up.
12. Adjust the engine oil level to the full mark.

Timing Chain & Sprockets Replacement

Tools Required: J 36660-A Torque Angle Meter

Scheme 74

Scheme 75

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-front-cover-replacement) .
2. Align the timing marks on the timing sprockets. Position the timing marks as close together as possible.
3. Remove the timing chain dampener.
4. Remove the camshaft sprocket bolt.
5. Remove the camshaft sprocket.
6. Remove the timing chain.
7. Clean and inspect the timing chain and sprockets.

1. Turn the crankshaft so that the number one piston is at top dead center.
2. Turn the camshaft so that the timing mark is straight down with the sprocket temporarily installed.
3. Assemble the timing chain on the sprockets. Ensure that the timing marks are in the closest together position.
4. Install the timing chain and the crankshaft sprocket.
5. Install the camshaft sprocket.
6. Install the camshaft sprocket bolt. Tighten the camshaft sprocket bolt to 100 N.m (74 ft lbs). Use the J 36660-A in order to tighten the bolt an additional 90 degrees.
7. Install the timing chain dampener.
8. Install the timing chain dampener bolt. Tighten the timing chain dampener bolt to 22 N.m (16 ft lbs).
9. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-front-cover-replacement) .

Cylinder Head Replacement - Left

Tools Required: J 36660-A Electronic Torque Angle Meter

Scheme 76

Scheme 77

1. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. Remove the left exhaust manifold.
3. Remove the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle)
4. Remove the electronic ignition module.
5. Remove the valve rocker arm assemblies and the pushrods. Refer to «Valve Rocker Arm & Push Rod Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__valve-rocker-arm-push-rod)
6. Remove the cylinder head bolts. Discard the bolts.
7. Remove the cylinder head.
8. Remove the cylinder head gasket.
9. Clean all of the gasket mating surfaces.
10. Clean and inspect the cylinder head.

Note. This engine uses special torque to yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage.

Scheme 78

1. Clean the threads in the block. Using the appropriate tap.
2. Install the head gasket with the arrow pointing to the front of the engine.
3. Install the cylinder head.
4. Install the new cylinder head bolts. Tighten the cylinder head bolts in sequence (1-8) to 50 N.m (37 ft lbs). Rotate each bolt 120 degrees in sequence (1-8). Use the J 36660-A .
5. Install the valve rocker arm assemblies and the pushrods. Refer to «Valve Rocker Arm & Push Rod Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__valve-rocker-arm-push-rod) .
6. Install the electronic ignition module.
7. Install the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
8. Install the left exhaust manifold.
9. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .

Cylinder Head Replacement - Right

Tools Required: J 36660-A Electronic Torque Angle Meter

Scheme 79

Scheme 80

1. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
2. Remove the right exhaust manifold.
3. Remove the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
4. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
5. Remove the valve rocker arm assemblies and the pushrods. Refer to «Valve Rocker Arm & Push Rod Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__valve-rocker-arm-push-rod) .
6. Remove the cylinder head bolts. Discard the bolts.
7. Remove the cylinder head.
8. Remove the cylinder head gasket.
9. Clean all of the gasket mating surfaces.
10. Clean and inspect the cylinder head.

Note. This engine uses special torque to yield head bolts. This design bolt requires a special tightening procedure. Failure to follow the given procedure will cause head gasket failure and possible engine damage.

Scheme 81

1. Clean the threads in the block. Using the appropriate tap.
2. Install the head gasket with the arrow pointing to the front of the engine.
3. Install the cylinder head.
4. Install the new cylinder head bolts. Tighten the cylinder head bolts in sequence (1-8) to 50 N.m (37 ft lbs). Rotate each bolt 120 degrees in sequence (1-8). Use the J 36660-A .
5. Install the valve rocker arm assemblies and the pushrods. Refer to «Valve Rocker Arm & Push Rod Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__valve-rocker-arm-push-rod) .
6. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
7. Install the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
8. Install the right exhaust manifold.
9. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .

Scheme 82

Scheme 83

1. Drain the engine oil.
2. Remove the right engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
3. Disconnect the electrical connector (1) from engine oil level sensor.
4. Remove the engine oil level sensor from the oil pan.
5. Remove the torque converter cover.
6. Remove the oil pan bolts.
7. Remove the oil pan.
8. Remove the oil pump pipe and screen. Refer to «Oil Pump Pipe & Screen Assembly Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
9. Remove the oil pan gasket.
10. Clean the cylinder block mating surfaces.
11. Clean and inspect the oil pan.

1. Install the oil pan gasket.
2. Install the oil pump pipe and screen. Refer to «Oil Pump Pipe & Screen Assembly Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
3. Install the oil pan.
4. Apply one drop of GM P/N 12345382 (Canadian P/N 10953489) to each bolt.
5. Install the oil pan bolts. Tighten the oil pan bolts to 14 N.m (124 in lbs).
6. Install the torque converter cover.
7. Install the engine oil level sensor into the oil pan. Tighten the engine oil level sensor to 20 N.m (15 ft lbs).
8. Connect the electrical connector (1) to the engine oil level sensor.
9. Install the right engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
10. Fill the engine oil.
11. Inspect for oil leaks after engine start up.

Engine Oil Pressure Sensor And/Or Switch Replacement

Tools Required: J 41712 Oil Pressure Switch Socket

Scheme 84

1. Raise and support the vehicle.
2. Disconnect the electrical connector from the engine oil pressure switch (1).
3. Remove the engine oil pressure switch (1) from the oil filter adapter using the J 41712 .

1. Install the engine oil pressure switch (1) to the oil filter adapter using the J 41712 . Tighten the engine oil pressure switch to 16 N.m (12 ft lbs).
2. Connect the electrical connector to the engine oil pressure switch (1).
3. Lower the vehicle.
4. Inspect for oil leaks after engine start up.
5. Adjust the engine oil level to the full mark.

Scheme 85

1. Drain the engine oil.
2. Disconnect the electrical connector (1) from engine oil level sensor.
3. Remove the engine oil level sensor from the oil pan.

1. Install the engine oil level sensor into the oil pan. Tighten the engine oil level sensor to 20 N.m (15 ft lbs).
2. Connect the electrical connector (1) to the engine oil level sensor.
3. Fill the engine oil.
4. Inspect for oil leaks after engine start up.

Scheme 86

1. Remove the oil pan.
2. Remove the oil pump pipe screen bolts.
3. Remove the oil pump screen.
4. Remove the gasket.
5. Use solvent in order to clean the screen and the housing. Blow dry the screen and the housing.
6. Clean the gasket mating surfaces.

1. Install the oil pump screen gasket.
2. Install the oil pump screen.
3. Install the oil pump screen bolts. Tighten the oil pump screen bolts to 15 N.m (11 ft lbs).
4. Install the oil pan. Refer to «Oil Pan Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .

Engine Flywheel Replacement

Tools Required

1. J 8001 Dial Indicator Set
2. J 36660-A Torque Angle Meter

Scheme 87

1. Remove the transaxle.
2. Remove the eight bolts attaching the flywheel to the crankshaft flange. Discard the bolts.
3. Remove the flywheel.
4. Inspect the crankshaft mating surfaces for burrs.
5. Clean and inspect the engine flywheel.

1. Install the flywheel.
2. Install the flywheel bolts. Tighten the new flywheel bolts to 15 N.m (11 ft lbs). Use the J 36660-A in order to tighten the bolts an additional 50 degrees.
3. Install the J 8001 to the engine block.
4. Check the flywheel runout at the three attaching bosses. Ensure that the crankshaft end-play is held in one direction when checking flywheel runout. Flywheel runout should not exceed 0.381 mm (0.015 in).
5. If flywheel runout is out of specification, tap on the high side with a mallet in order to correct runout.
6. Replace the flywheel if runout cannot be corrected.
7. Install the transaxle.

Crankshaft Rear Oil Seal Replacement

Tools Required: J 38196 Rear Crankshaft Seal Installer

Scheme 88

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-flywheel-replacement) .
2. Confirm the crankshaft rear oil seal leak. Important: Make sure not to damage the crankshaft OD surface or chamfer with the flat-bladed tool.
3. Remove the crankshaft rear oil seal. Insert a small flat-bladed tool through the dust lip at an angle. Pry out the crankshaft rear oil seal by moving the handle of the tool towards the end of the crankshaft. Repeat as necessary around the crankshaft rear oil seal.
4. Inspect the ID of the bore. Correct or replace the crankshaft rear oil seal housing as required.
5. Inspect the crankshaft for nicks or burrs on the surface that contacts the crankshaft rear oil seal.
6. Repair or replace the crankshaft as required.

Scheme 89

1. Apply engine oil to the inside and the outside diameter of the new crankshaft rear oil seal.
2. Slide the new crankshaft rear oil seal over the mandrel until the back of the crankshaft rear oil seal bottoms squarely against the collar of the J 38196 .
3. Install the crankshaft rear oil seal using the following steps: 3.1. Attach the J 38196 to the crankshaft by hand, or tighten the attaching screws. Tighten the screws to 5 N.m (54 in lbs). 3.2. Turn the T-handle of the J 38196 so that the collar pushes the seal into the bore. Turn the handle until the collar is tight against the case. This will ensure that the crankshaft rear oil seal is seated properly between the crankshaft and the crankshaft rear oil seal housing. 3.3. Loosen the T-handle of J 38196 until it comes to a stop. This will ensure that the collar will be in the proper position for installing another new crankshaft rear oil seal. 3.4. Remove the attaching screws.
4. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-flywheel-replacement) .
5. Inspect for proper fluid levels.
6. Inspect for leaks.

Crankshaft Rear Oil Seal & Housing Replacement

Tools Required

1. J 36660-A Electronic Torque Angle Meter
2. J 41349 Rear Cover Aligner

Scheme 90

1. Drain the engine coolant from the cooling system.
2. Remove the engine oil pan. Refer to «Oil Pan Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
3. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-flywheel-replacement) .
4. Remove the crankshaft rear oil seal housing bolts.
5. Remove the crankshaft rear oil seal housing.
6. Remove the crankshaft rear oil seal. Important: Make sure not to damage the crankshaft OD surface with any tool.
7. Remove the gasket from the crankshaft rear oil seal housing and the cylinder block.
8. Inspect the ID of the bore. Correct or replace the crankshaft rear oil seal housing as required.
9. Inspect the crankshaft for nicks of burrs on the surface that contacts the seal.
10. Repair or replace the crankshaft as required.

Scheme 91

Scheme 92

1. Make sure that the crankshaft rear oil seal is removed from the crankshaft rear oil seal housing.
2. Clean the old gasket from the crankshaft rear oil seal housing and the cylinder block.
3. Install the new gasket over the crankshaft rear oil seal housing bolt threads to aid in proper alignment of the gasket. NOTE: Correct alignment of the housing is crucial to sealing ability of the rear main and the oil pan. Take care when installing the housing to ensure that the housing is properly aligned. Failure to follow these procedures may result in oil leaks.
4. Install the crankshaft rear oil seal housing and finger tighten all the bolts, loose enough to adjust the crankshaft rear oil seal housing, to hold the crankshaft rear oil seal housing in place. Make sure the gasket is not higher than the crankshaft rear oil seal housing. Plastic inserts in the crankshaft rear oil seal housing are only used as an assembly aid and are not required for service.
5. Wipe a thin film of oil on both sides of the J 41349 to aid in installation and removal from the crankshaft.
6. Install the J 41349 over the crankshaft. Twisting or turning the J 41349 aids in sliding it completely over the crankshaft.
7. Place a straight edge on the cylinder block oil pan flange and the rear oil seal housing flange. Use a feeler gage to make sure that there is no more than a 0.1016 mm (0.004 in) step, high or low, on each side. Rotate the crankshaft rear oil seal housing to get the step equal on each side, if necessary. If the crankshaft rear oil seal housing cannot be rotated to get the step within specification, replace the crankshaft rear oil seal housing.
8. Tighten the crankshaft rear oil seal housing bolts. Tighten the crankshaft rear oil seal housing bolts to 15 N.m (11 ft lbs). Use the J 36660-A in order to rotate the crankshaft rear oil seal housing bolts an additional 50 degrees.
9. Remove the J 41349 .
10. Recheck the step height on each side to make sure that the crankshaft rear oil seal housing did not move while tightening the bolts. If the step height is beyond specification, repeat steps 4 through 8 and measure again. If excessive clearance is still present, replace the crankshaft rear oil seal housing.
11. Install the new crankshaft rear oil seal. Refer to «Crankshaft Rear Oil Seal & Housing Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__crankshaft-rear-oil-seal-housing) .
12. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-flywheel-replacement) .
13. Install the engine oil pan. Refer to «Oil Pan Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
14. Fill the cooling system with engine coolant.

Engine Replacement

Tools Required: J 38185 Hose Clamp Pliers

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

1. Remove the hood.
2. Disconnect the battery negative cable.
3. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
4. Disconnect the vacuum brake booster hose from the vacuum connections and position aside.
5. Disconnect the fuel feed and return lines from the fuel rail and secure to the air inlet grill.
6. Remove the evaporative emission canister purge valve and secure the hose to the air inlet grill.
7. Push the lock release and remove the cruise control cable from the throttle body bracket and lever.
8. Disconnect the electrical connector from the cruise control module.
9. Remove the retaining nuts (2) and the cruise control module (1) from the mounting studs. CAUTION: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
10. Remove the accelerator control cable.
11. Remove the drive belt. Refer to «Drive Belt Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
12. Raise and support the vehicle.
13. Remove the bolt securing both the battery negative cable and the engine harness ground lead to the engine block.
14. Disconnect the wiring harness connectors from the following components: The A/C compressor clutch (1). The A/C pressure sensor (2). The knock sensor #1 (3). The engine coolant block heater (4). The oil level sensor (7).
15. Disconnect the wiring harness from the harness clip at the rear of the A/C compressor.
16. Remove the torque converter cover.
17. Remove the starter motor.
18. Remove the bolts securing the flywheel to the torque converter.
19. Disconnect and secure the following wiring harness electrical connectors to the cowl: The knock sensor #2 (located behind the right exhaust manifold). The oil pressure sensor (2). The vehicle speed sensor (VSS) (3).
20. Remove the two bolts securing the transaxle brace to the transaxle. CAUTION: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.
21. Remove the two nuts attaching the exhaust manifold pipe to the right exhaust manifold.
22. Remove the exhaust manifold pipe from the right exhaust manifold studs, allowing it to rest on top of the power steering gear heat shield. Remove the gasket. Do not reuse the gasket.
23. Remove the right front fascia extension.
24. Remove the front A/C compressor mounting nuts.
25. Remove the rear A/C compressor mounting bolt.
26. Slide the A/C compressor forward off of the mounting studs and allow the compressor to rest on top of the engine frame.
27. Lower the vehicle.
28. Remove the bolt securing the PCM ground located at the left front cylinder head.
29. Disconnect the wiring harness electrical connectors from the following components on the left side of the engine: The fuel injectors. The ignition harness. The boost control solenoid (L67 only). The engine coolant temperature (ECT) sensor. The throttle position (TP) sensor. The idle air control (IAC) valve. The mass air flow (MAF) sensor.
30. Disconnect the wiring harness connectors from the following components on the right side of the engine: Fuel injectors. Exhaust gas recirculation (EGR) valve. Manifold absolute pressure (MAP) sensor. Heated oxygen sensor (HO2S). AIR solenoid (if equipped with NC8). Generator.
31. Secure the engine wiring harness rearward to the air inlet grill.
32. Remove the generator.
33. Remove the air cleaner intake duct.
34. Install the engine support fixture. Refer to «Engine Support Fixture»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-support-fixture) .
35. Remove the two front power steering pump mounting bolts.
36. Raise and support the vehicle.
37. Remove the side power steering pump mounting bolt.
38. Position the power steering pump against the cowl, allowing it to rest on top of the transaxle housing.
39. Remove the right engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
40. Remove the right lower engine to transaxle mounting bolt (1).
41. Drain the cooling system.
42. Lower the vehicle.
43. Position the J 38185 to the clamp in order to remove the radiator inlet hose from the water pump.
44. Position the J 38185 to the clamp in order to remove the radiator outlet hose from the thermostat housing.
45. Remove the heater hoses from the drive belt tensioner fittings.
46. Using a block of wood between a floor jack and the transaxle, support the transaxle at the pan.
47. Remove the engine support fixture. Refer to «Engine Support Fixture»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-support-fixture) .
48. Install a engine lift chain to the engine lift brackets and attach to an engine lift devise.
49. Remove the remaining engine to transaxle mounting bolts. Important: Ensure clearance is maintained between the engine and the following: A/C accumulator. A/C accumulator hose. A/C compressor. A/C compressor hose. Engine wiring electrical harness. Vacuum brake booster.
50. Carefully raise the engine from the engine compartment.
51. Drain the engine oil.
52. Remove the two bolts securing the transaxle brace to the engine.
53. Remove the exhaust manifold pipe.

1. Loosely install the two bolts securing the transaxle brace to the engine. Do not tighten at this time.
2. Install the exhaust manifold pipe. Important: Ensure clearance is maintained between the engine and the following: The A/C accumulator. The A/C accumulator hose. The A/C compressor. The A/C compressor hose. The engine wiring electrical harness. The vacuum brake booster.
3. Carefully lower the engine into the engine compartment.
4. Align the engine dowels to the transaxle cover.
5. Install the five upper engine to transaxle mounting bolts. Tighten the engine to transaxle mounting bolts to 75 N.m (55 ft lbs).
6. Remove the engine lift chain from the engine lift brackets.
7. Install the engine support fixture. Refer to «Engine Support Fixture»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-support-fixture) .
8. Remove the support jack from under the transaxle.
9. Connect the heater hoses to the drive belt tensioner fittings.
10. Position the J 38185 to the clamp in order to connect the radiator outlet hose to the thermostat housing.
11. Position the J 38185 to the clamp in order to connect the radiator inlet hose to the water pump.
12. Fill the cooling system.
13. Raise and support the vehicle.
14. Install the right lower engine to transaxle mounting bolt (1). Tighten the engine to transaxle mounting bolt to 75 N.m (55 ft lbs).
15. Install the right engine mount bracket. Refer to «Engine Mount Bracket Replacement - Right»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
16. Position the power steering pump to the engine.
17. Loosely install the side power steering pump mounting bolt. Do not tighten at this time.
18. Lower the vehicle.
19. Install the two front power steering pump mounting bolts. Tighten the power steering pump mounting bolts to 27 N.m (20 ft lbs).
20. Remove the engine support fixture. Refer to «Engine Support Fixture»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle__engine-support-fixture) .
21. Install the air cleaner intake duct.
22. Install the generator.
23. Position the engine wiring electrical harness to the engine.
24. Connect the wiring harness electrical connectors to the following components on the right side of the engine: The fuel injectors. The exhaust gas recirculation (EGR) valve. The manifold absolute pressure (MAP) sensor. The heated oxygen sensor (HO2S). The AIR solenoid (if equipped with NC8). The generator.
25. Connect the wiring harness electrical connectors to the following components on the left side of the engine: The fuel injectors. The ignition harness. The boost control solenoid (L67 only). The engine coolant temperature (ECT) sensor. The throttle position (TP) sensor. The idle air control (IAC) valve. The mass air flow (MAF) sensor.
26. Install the bolt securing the PCM ground to the left front cylinder head. Tighten the PCM ground lead bolt to 50 N.m (37 ft lbs).
27. Raise and support the vehicle.
28. Tighten the side power steering pump mounting bolt previously installed in step 14 . Tighten the power steering pump mounting bolt to 27 N.m (20 ft lbs).
29. Slide the A/C compressor rearward over the mounting studs.
30. Install the rear A/C compressor mounting bolt.
31. Install the front A/C compressor mounting nuts. Tighten the A/C compressor mounting fasteners to 50 N.m (37 ft lbs).
32. Place a NEW exhaust manifold pipe gasket over the right exhaust manifold studs.
33. Position the exhaust manifold pipe to the right exhaust manifold.
34. Install the two nuts attaching the exhaust manifold pipe to the right exhaust manifold. Tighten the exhaust manifold pipe nuts to 40 N.m (30 ft lbs).
35. Install the two bolts securing the transaxle brace to the transaxle. Tighten the two bolts previously installed in step 1 . Tighten the transaxle brace bolts to 65 N.m (48 ft lbs).
36. Connect the wiring harness electrical connectors to the following components The knock sensor #2 (located behind the right exhaust manifold). The oil pressure sensor (2). The vehicle speed sensor (VSS) (3).
37. Install the bolts securing the flywheel to the torque converter. Tighten the flywheel to torque converter bolts to 63 N.m (46 ft lbs).
38. Install the starter motor.
39. Install the torque converter cover.
40. Connect the wiring harness to the harness clip at the rear of the A/C compressor.
41. Connect the wiring harness connectors to the following components: A/C compressor clutch (1). A/C pressure sensor (2). Knock sensor #1 (3). Engine coolant block heater (4). Oil level sensor (7).
42. Install the bolt in order to secure both the battery negative cable and the engine harness ground lead to the engine block. Tighten the battery negative cable to engine block bolt to 25 N.m (18lb ft).
43. Install the right front fascia extension.
44. Lower the vehicle.
45. Install the drive belt. Refer to «Drive Belt Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) CAUTION: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
46. Remove the accelerator control cable.
47. Position the cruise control module (1) to the mounting studs on the cowl. Install the two cruise control module bracket retaining nuts (2). Tighten the cruise control module bracket retaining nuts to 9 N.m (80 ft lbs).
48. Connect the electrical connector to the cruise control module.
49. Install the cruise control cable to the throttle body lever.
50. Slide the cruise control cable fully into the throttle body bracket until it snaps into place.
51. Install the evaporative emission canister purge valve.
52. Connect the fuel feed and return lines to the fuel rail.
53. Connect the vacuum brake booster hose to the vacuum connections.
54. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/buick/lesabre/viii-2000-2005/remont/mechanical/#engine-mechanical-38l-on-vehicle) .
55. Connect the battery negative cable.
56. Install the hood.
57. Fill the engine oil.

Engine Final Test & Inspection

Complete the following procedure after the engine is installed in the vehicle

1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
4. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
5. While the engine continues to idle raise and support the vehicle.
6. Inspect for oil, coolant and exhaust leaks while the engine is idling.
7. Lower the vehicle.
8. Perform the CKP variation learn.
9. Perform a final inspection for the proper engine oil and coolant levels.
10. Road test the vehicle.

Scheme 111

1. Raise and support the vehicle.
2. Position the oil drain pan under the engine oil drain plug.
3. Remove the engine oil drain plug.
4. Clean and inspect the engine oil drain plug, repair or replace if necessary.
5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or replace oil pan if necessary.
6. Remove the oil filter.
7. Clean and inspect the oil filter sealing area on the oil filter adapter, repair or replace if necessary.

1. Lightly oil the replacement oil filter gasket with clean oil.
2. Install the new oil filter. Tighten the new oil filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface.
3. Install the engine oil drain plug. Tighten the engine oil drain plug to 30 N.m (22 ft lbs).
4. Lower the vehicle.
5. Fill the engine with new engine oil.
6. Inspect for oil leaks after engine start up.

Purpose

A crankcase ventilation system is used to consume crankcase vapors in the combustion process instead of venting them to atmosphere.

Scheme 112

Fresh air from the throttle body is supplied to the crankcase, mixed with blow-by gases and then passed through a crankcase ventilation valve into the supercharger inlet (L67) or into the intake manifold (L36).

Scheme 113

The primary control is through the crankcase ventilation valve (1) which meters the flow at a rate depending on inlet vacuum. To maintain idle quality, the crankcase ventilation valve restricts the flow when inlet vacuum is high. If abnormal operating conditions arise, the system is designed to allow excessive amounts of blow-by gases to back flow through the crankcase vent into the throttle body to be consumed by normal combustion.

Drive Belt System Description

The drive belt system consists of the following components

1. The drive belt.
2. The drive belt tensioner.
3. The drive belt idler pulley.
4. The crankshaft balancer pulley.
5. The accessory drive component mounting brackets.
6. The accessory drive components. The power steering pump, if belt driven. The generator. The A/C compressor, if equipped. The engine cooling fan, if belt driven. The water pump, if belt driven. The vacuum pump, if equipped. The air compressor, if equipped.

The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers - chloroprene or EPDM - and have different layers or plies containing either fiber cloth or cords for reinforcement.

Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth.

The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft.

The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory.

Tools & Equipment

1. Special tools are listed and illustrated throughout this section with a complete listing at the end of the section. These tools (or their equivalents) are specially designed to quickly and safely accomplish the operations for which they are intended. The use of these special tools will also minimize possible damage to engine components. Some precision measuring tools are required for inspection of certain critical components. Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners.
2. To properly service the engine assembly, the following items should be readily available: Approved eye protection and safety gloves. A clean, well-lit, work area. A suitable parts cleaning tank. A compressed air supply. Trays or storage containers to keep parts and fasteners organized. An adequate set of hand tools. Approved engine repair stand. An approved engine lifting device that will adequately support the weight of the components.

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

See also:
• Symptoms - Engine Mechanical
• Engine Compression Test
• Oil Consumption Diagnosis
• Valve Rocker Arm & Push Rod Replacement
• Crankshaft Balancer Replacement
• Engine Front Cover Replacement
• Oil Filter Adapter & Bypass Valve Assembly Replacement
• Engine Flywheel Replacement
• Crankshaft Rear Oil Seal & Housing Replacement
• Engine Support Fixture