Engine Mechanical - 3.8l (l36) Chevrolet Monte Carlo VI

Fastener Tightening Specifications

Fastener Tightening Specifications

Engine Mechanical Specifications

Engine Mechanical Specifications

Sealers, Adhesives, and Lubricants

Sealers, Adhesives & Lubricants

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

The primary Vehicle Identification Number - VIN derivative for the 3800 - L36 and 3800 - L67 is stamped or laser etched on the left side of the engine block above the starter motor (1).

Scheme 45

The secondary Vehicle Identification Number - VIN, derivative for the 3800 - L36 and 3800 - L67 is stamped or laser etched below the water pump on the engine block (1). The Vehicle Identification Number - derivative is nine digits long and can be used to determine if a vehicle contains the original engine.

1. The first digit identifies the division.
2. The second digit identifies the model year.
3. The third digit identifies the assembly plant.
4. The fourth through ninth digit are the last six of the Vehicle Identification Number - VIN.

Diagnostic Starting Point - Engine Mechanical

Begin the system diagnosis by reviewing the Disassembled Views , Engine Component Description , Drive Belt System Description , Lubrication Description , and New Product Information . Reviewing the description and operation information 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. Refer to «Disassembled Views»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) , «Engine Component Description»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) , «Drive Belt System Description»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__drive-belt-system-description) , «Lubrication Description»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) , and «New Product Information»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__new-product-information) .

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. For a detailed explanation, refer to Strategy Based Diagnosis in General Information.

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the Engine. Refer to «Checking Aftermarket Accessories»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#wiring-systems-introduction__checking-aftermarket-accessories) in Wiring Systems.
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. «Base Engine Misfire without Internal Engine Noises»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__base-engine-misfire-without-internal-engine)
2. «Base Engine Misfire with Abnormal Internal Lower Engine Noises»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__base-engine-misfire-with-abnormal-internal)
3. «Base Engine Misfire with Abnormal Valve Train Noise»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__base-engine-misfire-with-abnormal-valve)
4. «Base Engine Misfire with Coolant Consumption»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__base-engine-misfire-with-coolant-consumption)
5. «Base Engine Misfire with Excessive Oil Consumption»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__base-engine-misfire-with-excessive-oil)
6. «Engine Compression Test»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-compression-test)
7. «Engine Noise on Start-Up, but Only Lasting a Few Seconds»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-noise-on-start-up-but-only)
8. «Upper Engine Noise, Regardless of Engine Speed»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__upper-engine-noise-regardless-of-engine)
9. «Lower Engine Noise, Regardless of Engine Speed»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__lower-engine-noise-regardless-of-engine)
10. «Engine Noise Under Load»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-noise-under-load)
11. «Engine Will Not Crank - Crankshaft Will Not Rotate»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-will-not-crank-crankshaft)
12. «Oil Consumption Diagnosis»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__oil-consumption-diagnosis)
13. «Oil Pressure Diagnosis and Testing»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36)
14. «Oil Leak Diagnosis»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__oil-leak-diagnosis)
15. «Drive Belt Chirping Diagnosis»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36)
16. «Drive Belt Squeal Diagnosis»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36)
17. «Drive Belt Whine Diagnosis»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36)
18. «Drive Belt Rumbling Diagnosis»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36)
19. «Drive Belt Vibration Diagnosis»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36)
20. «Drive Belt Falls Off Diagnosis»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36)
21. «Drive Belt Excessive Wear Diagnosis»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36)
22. «Drive Belt Tensioner Diagnosis»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__drive-belt-tensioner-diagnosis)

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire Without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire With Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Valve Train Noise

Base Engine Misfire With Abnormal Valve Train Noise

Base Engine Misfire with Coolant Consumption

Base Engine Misfire With Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Base Engine Misfire With Excessive Oil Consumption

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Engine Noise On Start-Up, But Only Lasting A Few Seconds

Upper Engine Noise, Regardless of Engine Speed

Upper Engine Noise, Regardless Of Engine Speed

Lower Engine Noise, Regardless of Engine Speed

Lower Engine Noise, Regardless Of Engine Speed

Engine Noise Under Load

Engine Noise Under Load

Engine Will Not Crank - Crankshaft Will Not Rotate

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant In Combustion Chamber

Coolant in Engine Oil

Coolant In Engine Oil

Engine Compression Test

Tools Required

J 38722 Compression Tester. See Special Tools .

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

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: Firmly install J 38722 to the spark plug hole. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . Have an assistant crank the engine through at least four compression strokes in the testing cylinder. Check and record the readings on J 38722 at each stroke. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . Disconnect J 38722 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . 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 I/P fuse block.

Cylinder Leakage Test

Tools 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.

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.
5. Apply air pressure, using the J 35667-A . Refer to the manufacturer's instructions.
6. Record the cylinder leakage readings for each cylinder.
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»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__cylinder-head-cleaning-and-inspection) .
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»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__piston-connecting-rod-and-bearings-cleaning) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-block-cleaning-and-inspection) .
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»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__cylinder-head-cleaning-and-inspection) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-block-cleaning-and-inspection) .
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. Refer to «Explanation of Scheduled Services»(/chevrolet/monte-carlo/vi-1999-2007/remont/lubrication-system/#maintenance-and-lubrication__explanation-of-scheduled-services) for the 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.

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.

Oil Leak Diagnosis

Oil Leak Diagnosis

Crankcase Ventilation System Inspection/Diagnosis

Crankcase Ventilation System Inspection/Diagnosis

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.

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 pilling. Pilling 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 misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign 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 pilling will only be a temporary repair.

Drive Belt Chirping Diagnosis

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.

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 misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign 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.

Drive Belt Squeal Diagnosis

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 operating 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.

1. 3: This test is to verify that the noise is being caused by 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.

Drive Belt Whine Diagnosis

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, complete the diagnostic table, and if 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.

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 plys 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 pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation.

Drive Belt Rumbling Diagnosis

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.

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 belts 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 fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange.
6. 9: 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 smoothness and excessive play. Compare the water pump with a known good water pump.
7. 10: Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate.

Drive Belt Vibration Diagnosis

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.

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 plys.
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 misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign 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.

Drive Belt Falls Off Diagnosis

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.

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.

Drive Belt Excessive Wear Diagnosis

Drive Belt Tensioner Diagnosis

Drive Belt Tensioner Diagnosis

Removal Procedure

1. Clean the area around the tube/oil fill cap before removing the tube/oil fill cap in order to prevent contaminants from falling into the valve rocker arm cover opening.
2. Twist counterclockwise to unlock the tube/oil fill cap from the valve rocker arm cover.
3. Lift the fuel injector sight shield up at the front and slide the tab out of the engine bracket.
4. Replace the tube/oil fill cap in the valve rocker arm cover.

Installation Procedure

1. Remove the tube/oil fill cap from the valve rocker arm cover.
2. Insert the tab of the fuel injector sight shield under the engine bracket.
3. Place the hole of the fuel injector sight shield onto the oil fill neck of the valve rocker arm cover.
4. Install the tube/oil fill cap into the valve rocker arm cover and twist clockwise in order to lock the detent on the tube into the notch in the cover.

1. Rotate the drive belt tensioner using a 15-mm box end wrench on the pulley nut.
2. Remove the drive belt.

1. Lift or rotate the drive belt tensioner using a 15-mm box end wrench on the pulley nut.
2. Install the drive belt.
3. Make sure the drive belt is properly routed.
4. Make sure the drive belt tensioner is operating properly.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
3. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
4. Remove the drive belt. Refer to «Drive Belt Replacement (L32)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
5. Remove the generator. Refer to «Generator Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
6. Remove the heater hose adapters with the heater hoses from the drive belt tensioner. Refer to «Heater Hose Replacement - Inlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) and to «Heater Hose Replacement - Outlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) in Heating, Ventilation and Air Conditioning.
7. Remove the drive belt tensioner bolts.
8. Remove the drive belt tensioner.
9. If replacing the drive belt tensioner, remove the thermostat bypass upper and lower pipe assemblies.

1. If replacing the drive belt tensioner, lubricate the thermostat bypass upper and lower pipe assembly seals with engine coolant and install the upper and lower pipe assemblies.
2. Install the drive belt tensioner.
3. Install the drive belt tensioner bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Install the heater hose adapters with the heater hoses to the drive belt tensioner. Refer to «Heater Hose Replacement - Inlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) and to «Heater Hose Replacement - Outlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) in Heating Ventilation and Air Conditioning.
5. Install the generator. Refer to «Generator Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
6. Install the drive belt. Refer to «Drive Belt Replacement (L32)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
7. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
9. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.

Engine Mount Inspection

1. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-support-fixture) . Raise the engine to release the weight from the engine mount and create slight tension in the rubber.
2. Observe the engine mount while raising the engine. Replace the engine mount if the engine mount exhibits any of the following conditions: The hard rubber surface is covered with heat check cracks. The rubber is separated from the metal plate of the engine mount. The rubber is split through the center of the engine mount.
3. If there is movement between the metal plate of the engine mount and its attaching points, lower the engine on the engine mount. Tighten the bolts or nuts attaching the engine mount to the frame or engine mount bracket. Refer to «Fastener Tightening Specifications»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__fastener-tightening-specifications) .
4. For information on the transaxle mount, refer to «TRANSAXLE MOUNT»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-trans/#automatic-transaxle-removal-installation) .

Engine Support Fixture

Tools Required

1. J 28467-90A Engine Support Adapters
2. J 28467-B Universal Engine Support Fixture

1. Raise the hood.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
3. Remove the cross vehicle brace. Refer to «Brace Replacement - Cross Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
4. Remove the hood side rear seal from the pinchweld flange (1).
5. Install the J 28467-90A onto the strut attaching studs.
6. Install the strut tower support assemblies J 28467-5A over the J 28467-90A .
7. Install the wing nuts to the J 28467-90A .
8. Install the strut tower tube J 28467-3 into the strut tower support assemblies J 28467-5A.
9. Install the 1/2 inch x 2.5 inch quick release pin J 28467-10 through the strut tower support assemblies J 28467-5A and the strut tower tube J 28467-3 on one side only.
10. Install the radiator shelf tube J 28467-2A on the top of the strut tower tube J 28467-3 on the driver side.
11. Install the round tube of the front support assembly J 28467-4A through the large hole in the radiator shelf tube J 28467-2A.
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. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
15. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
16. Install the assembled lift hook bracket J 28467-6A over the passenger side radiator shelf tube J 28467-2A.
17. Adjust the passenger side radiator shelf tube J 28467-2A and the assembled lift hook bracket J 28467-6A in order to align the hook with the left, rear of engine, lift hook bracket attached to the left exhaust manifold.
18. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
19. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
20. Install the assembled lift hook bracket J 28467-6A over the strut tower tube J 28467-3.
21. Adjust the assembled swivel lift hook bracket J 28467-8A in order to align the hook with the right, front of engine, lift hook bracket attached to the right exhaust manifold.
22. Hand tighten the cross bracket assembly J 28467-1A wing nuts.
23. Hand tighten the lift hook wing nuts J 28467-34 securely to remove all slack from the engine support fixture assembly.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
3. Disconnect the intake air temperature (IAT) sensor electrical connector.
4. Remove the air inlet duct from the throttle body.
5. Remove the right and left engine mount struts. Refer to «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) and «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
6. Remove the drive belt. Refer to «Drive Belt Replacement (L32)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
7. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
8. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/monte-carlo/vi-1999-2007/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
9. Remove the right engine splash shield.
10. Remove the power steering oil cooler pipe brackets from the frame.
11. Remove the A/C compressor and the A/C compressor bracket. DO NOT discharge the A/C system. Secure the compressor.
12. Remove the right exhaust manifold pipe stud nuts from the catalytic converter.
13. Remove the engine mount lower nuts from the frame.
14. Lower the vehicle.
15. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-support-fixture) .
16. Use the engine support fixture to raise the engine.
17. Raise the vehicle.
18. Remove the left engine mount bracket bolts from the engine.
19. Remove the right engine mount bracket bolts from the engine.
20. Support the frame with jackstands.
21. Loosen the left side frame bolts. Remove the right side frame bolts. Using the jackstands lower the frame for engine mount bracket removal.
22. Remove the engine mount bracket with the engine mount from the engine.
23. Remove the engine mount upper nuts.
24. Remove the engine mount from the engine mount bracket.

1. Install the engine mount to the engine mount bracket.
2. Install the engine mount upper nuts to the engine mount and the engine mount bracket. Tighten: Tighten the engine mount upper nuts to 43 N.m (32 lb ft).
3. Install the engine mount bracket with the engine mount to the engine.
4. Loosely install the right engine mount bracket bolts to the engine.
5. Loosely install the left engine mount bracket bolts to the engine. Tighten: Tighten the left and the right engine mount bracket bolts to 102 N.m (75 lb ft).
6. Using the jackstands raise the frame to the original position.
7. Install the right side frame bolts. Tighten: Tighten the right and the left side frame bolts to 180 N.m (133 lb ft).
8. Lower the vehicle.
9. Use the engine support fixture to lower the engine.
10. Raise the vehicle.
11. Install the engine mount lower nuts to the frame. Tighten: Tighten the engine mount lower nuts to 43 N.m (32 lb ft).
12. Install the catalytic converter to the right exhaust manifold.
13. Install the right exhaust manifold pipe stud nuts Tighten: Tighten the right exhaust manifold pipe stud nuts to 30 N.m (22 lb ft).
14. Install the A/C compressor bracket and the A/C compressor bracket bolts. Tighten: Tighten the A/C compressor bracket bolts to 50 N.m (37 lb ft).
15. Install the A/C compressor and the A/C compressor nuts. Tighten: Tighten the A/C compressor nuts to 30 N.m (22 lb ft).
16. Install the power steering oil cooler pipe brackets to the frame.
17. Install the right engine splash shield.
18. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/monte-carlo/vi-1999-2007/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
19. Lower the vehicle.
20. Remove the engine support fixture.
21. Install the right and left engine mount struts. Refer to «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) and «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
22. Install the air inlet duct to the throttle body.
23. Connect the intake air temperature (IAT) sensor electrical connector.
24. Install the drive belt. Refer to «Drive Belt Replacement (L32)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
25. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
26. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.

1. Remove the bolt and the nut from the right engine mount strut at the right engine mount strut bracket on the engine.
2. Remove the bolt and the nut from the right engine mount strut at the right engine mount strut bracket on the upper radiator support.
3. Remove the engine mount strut.
4. Inspect the rubber in the engine mount strut for the following conditions: Hardness Splitting Cracking

1. Install the engine mount strut.
2. Install the bolt and the nut to the right engine mount strut at the right engine mount strut bracket on the upper radiator support. Tighten: Tighten the engine mount strut nut to 48 N.m (35 lb ft).
3. Install the bolt and the nut to the right engine mount strut at the right engine mount strut bracket on the engine. Tighten: Tighten the engine mount strut nut to 48 N.m (35 lb ft).

1. Remove the bolt and the nut from the left engine mount strut at the left engine mount strut bracket on the engine.
2. Remove the bolt and the nut from the left engine mount strut at the left engine mount strut bracket on the upper radiator support.
3. Remove the engine mount strut.
4. Inspect the rubber in the engine mount strut for the following conditions: Hardness Splitting Cracking

1. Install the engine mount strut.
2. Install the bolt and the nut to the left engine mount strut at the left engine mount strut bracket on the upper radiator support. Tighten: Tighten the engine mount strut nut to 48 N.m (35 lb ft).
3. Position the P-clip to the left engine mount strut bracket bolt.
4. Install the bolt and the nut to the left engine mount strut at the left engine mount strut bracket on the engine. Tighten: Tighten the engine mount strut nut to 48 N.m (35 lb ft).

1. Remove the engine mount struts from the engine mount strut brackets at the upper radiator support. Refer to «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) and/or «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Remove the four bolts from the engine mount strut bracket to the upper radiator support.
3. Remove the engine mount strut bracket from the upper radiator support.

1. Position the engine mount strut bracket over the upper radiator support so the engine mount strut bracket and the engine mount strut are aligned. Align the engine mount strut bracket with the proper holes of the upper radiator support.
2. Install the four bolts through the engine mount strut bracket to the upper radiator support. Tighten: Tighten the engine mount strut bracket bolts at the upper radiator support to 28 N.m (21 lb ft).
3. Install the engine mount struts to the engine mount strut brackets at the upper radiator support. Refer to «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) and/or «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
2. Remove the engine coolant temperature sensor. Refer to «ENGINE COOLANT TEMPERATURE SENSOR»(ref-159248-S14519243622003112000000) .
3. Remove the engine mount strut at the left engine mount strut bracket. Refer to «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. Remove the engine mount strut bracket bolts.
5. Remove the engine mount strut bracket.

1. Install the engine mount strut bracket.
2. Install the engine mount strut bracket bolts. Tighten: Tighten the engine mount strut bracket bolts to 50 N.m (37 lb ft).
3. Install the engine mount strut to the left engine mount strut bracket. Refer to «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. Install the engine coolant temperature sensor. Refer to «ENGINE COOLANT TEMPERATURE SENSOR»(ref-159248-S14519243622003112000000) . Tighten: Tighten the sensor to 25 N.m (18 lb ft).
5. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
3. Remove the right engine mount strut at the upper engine mount strut bracket. Refer to «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. Remove the lower engine mount strut bracket nut.
5. Remove the lower engine mount strut bracket bolts and the lower engine mount strut bracket.
6. Remove the evaporative emission (EVAP) canister purge valve.
7. Relieve the fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-159248-S06644035342003112000000) .
8. Remove the fuel rail assembly. Refer to «FUEL RAIL & INJECTORS»(ref-159248-S20143954522003112000000) .
9. Remove the upper engine mount strut bracket bolts.
10. Remove the upper engine mount strut bracket.

1. Install the upper engine mount strut bracket.
2. Install the upper engine mount strut bracket bolts. Tighten: Tighten the upper engine mount strut bracket bolts to 50 N.m (37 lb ft).
3. Install the fuel rail assembly. Refer to «FUEL RAIL & INJECTORS»(ref-159248-S20143954522003112000000) .
4. Install the evaporative emission (EVAP) canister purge valve.
5. Install the lower engine mount strut bracket bolts. Tighten: Tighten the lower engine mount strut bracket bolts to 50 N.m (37 lb ft).
6. Install the lower engine mount strut bracket nut. Tighten: Tighten the lower engine mount strut bracket nut to 30 N.m (22 lb ft).
7. Install the right engine mount strut to the upper engine mount strut bracket. Refer to «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
8. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
9. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the lower engine mount strut bracket bolts.
3. Remove the lower engine mount bracket nut.
4. Remove the lower engine mount bracket.

1. Install the lower engine mount bracket to the exhaust manifold stud and the upper engine mount strut bracket.
2. Install the lower engine mount strut bracket bolts. Tighten: Tighten the lower engine mount bracket bolts to 50 N.m (37 lb ft).
3. Install the lower engine mount strut bracket nut. Tighten: Tighten the lower engine mount bracket nut to 30 N.m (22 lb ft).
4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Disconnect the MAP sensor electrical connector.
3. Remove the MAP sensor (1).
4. Use a 16 mm (5/8 in) socket to press the access cover (2) down and rotate 1/4 turn counterclockwise.
5. Remove the access cover.
6. Remove the PCV valve (3) and the O-ring (4) from the intake manifold.

1. Install the new O-ring (4) and the PCV valve (3).
2. Install the access cover (2).
3. Install the MAP sensor (1).
4. Connect the MAP sensor electrical connector.
5. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .

1. Remove the oil level indicator.
2. Remove the oil level indicator tube bracket nut.
3. Remove the oil level indicator tube.

1. Make sure that the O-ring is in place and install the oil indicator tube to the engine.
2. Install the oil indicator tube bracket to the exhaust manifold stud.
3. Install the oil level indicator tube bracket nut. Tighten: Tighten the nut to 19 N.m (14 lb ft).
4. Install the oil level indicator.
5. Check and fill the engine oil as necessary.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
3. Remove the air cleaner intake duct.
4. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
5. Remove the right spark plug wires from the ignition control module and reposition.
6. Relieve the fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-159248-S06644035342003112000000) .
7. Remove the fuel rail assembly. Refer to «FUEL RAIL & INJECTORS»(ref-159248-S20143954522003112000000) .
8. Remove the brake booster hose from the vacuum source manifold in the upper intake manifold.
9. Remove the exhaust gas recirculation valve (EGR) wiring harness heat shield nut, bolt and the EGR heat shield.
10. Remove the throttle body support bracket upper bolt.
11. Disconnect the electrical connectors from the following: EVAP purge solenoid Throttle position (T/P) sensor Idle air control (IAC) valve Manifold absolute pressure (MAP) sensor Mass air flow (MAF) sensor
12. Remove the EVAP purge solenoid vacuum line from the throttle body.
13. Remove the accelerator and the cruise control cables with the bracket from the throttle body. Refer to «THROTTLE BODY»(ref-159248-S22807658372003112000000) .
14. Remove the upper intake manifold bolts and stud.
15. Clean the upper intake manifold bolt threads.
16. Remove the upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket.
17. Remove the upper-to-lower intake manifold carrier gasket from the upper intake manifold.
18. If the upper intake manifold is being replaced, remove the following: Throttle body assembly. Manifold absolute pressure (MAP) sensor. Positive crankcase ventilation (PCV) valve. Vacuum source manifold.

1. If the manifold was replaced install the following: Vacuum source manifold. Positive crankcase ventilation (PCV) valve. Manifold absolute pressure (MAP) sensor. Throttle body assembly.
2. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold.
3. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
4. Install the upper intake manifold.
5. Apply thread lock compound GM P/N 12345382, (Canadian P/N 10953489) or equivalent, to the bolt threads before assembly.
6. Install the upper intake manifold bolts (1-10). Tighten: Tighten the upper intake manifold bolts in sequence to 10 N.m (89 lb in).
7. Install the accelerator and the cruise control cables with the bracket to the throttle body. Refer to «THROTTLE BODY»(ref-159248-S22807658372003112000000) .
8. Install the EVAP purge solenoid vacuum line to the throttle body.
9. Connect the electrical connectors to the following: Mass air flow (MAF) sensor Manifold absolute pressure (MAP) sensor Idle air control (IAC) valve Throttle position (T/P) sensor EVAP purge solenoid
10. Install the throttle body upper support bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
11. Install the EGR valve wiring harness heat shield, nut and the bolt. Tighten: Tighten the nut and the bolt to 10 N.m (89 lb in).
12. Install the brake booster hose to the vacuum source manifold.
13. Install the fuel rail assembly. Refer to «FUEL RAIL & INJECTORS»(ref-159248-S20143954522003112000000) .
14. Install the right spark plug wires.
15. Install the air cleaner intake duct.
16. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
18. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
19. Inspect for fluid or vacuum leaks.

1. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Remove the generator brace. Refer to «Generator Brace Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
3. Remove the drive belt tensioner with the mounting bracket and the heater water bypass inlet pipe. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. Remove the exhaust gas recirculation (EGR) outlet pipe bolt from the lower intake manifold.
5. Remove the radiator inlet hose from the water outlet housing. Refer to «Radiator Hose Replacement - Inlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
6. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
7. Remove the right upper engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement - Right Upper»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
8. Remove the generator brace bracket bolts.
9. Remove the generator brace bracket.
10. Remove the lower intake manifold bolts.
11. Remove the lower intake manifold.
12. Remove the lower intake manifold seals.
13. Remove the lower intake manifold gaskets.
14. If replacing the lower intake manifold, remove the water outlet housing bolt and stud, the water outlet housing, the gasket and the thermostat.
15. If replacing the lower intake manifold, remove the ECT sensor.
16. Inspect the flatness of inlet flanges.
17. Clean the intake manifold mating surfaces.
18. Clean the intake manifold bolts and bolt holes of adhesive compound.

1. If removed, install the ECT sensor. Tighten: Tighten the ECT sensor to 25 N.m (18 lb ft).
2. If removed, install the thermostat, the gasket, and the water outlet housing.
3. Install the water outlet housing bolt and the stud. Tighten: Tighten the bolt and stud to 27 N.m (20 lb ft).
4. Install the lower intake manifold gaskets.
5. Apply sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the ends of the intake manifold seals.
6. Install the lower intake manifold seals.
7. Install the lower intake manifold.
8. Install the lower intake manifold bolts (1-12). Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the two hidden bolts and ensure they are installed. Tighten: Tighten the lower intake manifold bolts in sequence to 15 N.m (11 lb ft).
9. Install the generator brace bracket.
10. Install the generator brace bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
11. Install the right upper engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement - Right Upper»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
12. Connect the ECT sensor electrical connector.
13. Install the radiator inlet hose to the water outlet housing. Refer to «Radiator Hose Replacement - Inlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
14. Install the EGR outlet pipe to the lower intake manifold.
15. Install the EGR outlet pipe bolt to the lower intake manifold. Tighten: Tighten the bolt to 29 N.m (21 lb ft).
16. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
17. Install the generator brace. Refer to «Generator Brace Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
18. Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
19. Inspect for leaks.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Remove the left engine lift bracket bolt and the nut.
3. Remove the left engine lift bracket.
4. Remove the right engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement - Right Upper»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
5. Remove the left spark plug wires from the left spark plugs.
6. Remove the left spark plug wire cover from the left valve rocker arm cover.
7. Remove the left valve rocker arm cover bolts.
8. Remove the left valve rocker arm cover.
9. Remove the left valve rocker arm cover gasket.
10. Clean the valve rocker arm cover mating surfaces.
11. Clean the valve rocker arm cover bolts of all thread locking adhesive.

1. Install the new valve rocker arm cover gasket. Ensure that valve the rocker arm cover gasket is seated properly in the valve rocker arm cover groove.
2. Install the left valve rocker arm cover.
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 left valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the left spark plug wire cover to the left valve rocker arm cover.
6. Install the left spark plug wires to the spark plugs.
7. Install the right engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement - Right Upper»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
8. Install the left engine lift bracket.
9. Install the left engine lift bracket bolt and the nut. Tighten: Tighten the bolt and the nut to 30 N.m (22 lb ft).
10. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
12. Check and fill crankcase as necessary.
13. Inspect for oil leaks.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
3. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. Remove the right side spark plug wires from the spark plugs.
5. Remove the right side engine lift bracket bolt and the nut.
6. Remove the right side engine lift bracket.
7. Remove the fuel injector sight shield bracket nuts.
8. Remove the fuel injector sight shield bracket.
9. Remove the right side valve rocker arm cover bolts.
10. Remove the right side valve rocker arm cover.
11. Remove the right side valve rocker arm cover gasket.
12. Clean the valve rocker arm cover mating surface.
13. Clean the valve rocker arm cover bolts of all thread locking adhesive.

1. Install the new valve rocker arm cover gasket. Ensure that the valve rocker arm cover gasket is seated properly in the valve rocker arm cover groove.
2. Install the right side valve rocker arm cover.
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: Tighten the bolts to 10 N.m (89 lb in).
5. Install the fuel injector sight shield bracket to the exhaust manifold studs.
6. Install the fuel injector sight shield bracket nuts. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
7. Install the right side engine lift bracket.
8. Install the right side engine lift bracket bolt and the nut. Tighten: Tighten the bolt and the nut to 30 N.m (22 lb ft).
9. Install the right side spark plug wires to the spark plugs.
10. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
11. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
12. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
13. Check and fill crankcase as necessary
14. Inspect for oil leaks.

Tools Required

J 45059 Torque Angle Meter

1. Remove the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) and/or «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Remove the valve rocker arm bolts.
3. Remove the valve rocker arms.
4. Remove the valve rocker arm guide plate if all of the rocker arms are removed.
5. Remove the push rods.
6. Clean the push rods, the valve rocker arms, the bolts, and the guide plates in a suitable solution.
7. Clean the valve rocker arm bolts of all thread adhesive.

1. Use compressed air in order to blow oil out of the tapped holes in the cylinder head.
2. Lubricate the ends of the push rods with new engine oil. Install the push rods to the same position the push rods was removed from.
3. Install the valve rocker arm guide plates.
4. Install the valve rocker arms.
5. Apply GM P/N 12345493, (Canadian P/N 10953488) threadlocker or equivalent to the rocker arm bolt threads
6. Install the rocker arm bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft). Use the J 45059 to rotate the bolts an additional 90 degrees.
7. Install the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) and/or «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
8. Inspect the valve train for noise.

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 23590 Spark Plug Port Adapter. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. J 38606 Valve Spring Compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
3. J 42863 Valve Stem Seal Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

1. Remove the left or the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) or «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Remove the valve rocker arms and the push rods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
3. Remove the spark plug.
4. Install the J 23590 to the spark plug port and apply compressed air in order to hold the valves closed. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
5. Install the J 38606 on the valve spring.
6. Compress the valve spring using the J 38606 .
7. Remove the valve locks.
8. Remove the valve spring and cap.
9. Remove the valve stem oil seal.
10. Inspect the valve spring for bent, cracked, or broken parts. Replace the valve spring if damaged. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__cylinder-head-cleaning-and-inspection) .

1. Place the oil seal over the stem until the seal begins to contact the valve guide.
2. Use the J 42863 to install the valve stem oil seal over the valve guide. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
3. Install the J 38606 on the valve spring.
4. Compress the valve spring using the J 38606 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
5. Install the valve spring and cap.
6. Install the valve locks.
7. Release the valve spring.
8. Release the air pressure, and remove the J 23590 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
9. Install the spark plug.
10. Install the push rods and the valve rocker arms. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
11. Install the left or the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) or «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .

1. Remove the left or the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) or «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
3. Remove the rocker arm bolts, the valve rocker arms, the push rods and the push rod guide plates. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. Remove the valve lifter guide bolts.
5. Remove the valve lifter guides.
6. Remove the valve lifters.
7. Clean all the gasket mating surfaces.
8. Clean the valve train parts.
9. Inspect the valve lifters and the cam lobes for wear. Refer to «Valve Lifters and Guides Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__valve-lifters-and-guides-cleaning-and) .

1. Dip the valve lifters in prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Install the valve lifters to the same position the valve lifters were removed.
3. Install the valve lifter guides.
4. Install the valve lifter guide bolts. Tighten: Tighten the bolts to 30 N.m (22 lb ft).
5. Install the push rod guide plates, the push rods, the valve rocker arms, and the bolts. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
6. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
7. Install the left or the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) or «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .

Crankshaft Balancer Replacement

Tools Required

1. J 37096 Flywheel Holder
2. J 38197-A Crankshaft Balancer Puller. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
3. J 45059 Torque Angle Meter

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the drive belt. Refer to «Drive Belt Replacement (L32)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/monte-carlo/vi-1999-2007/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
5. Remove the right engine splash shield retainers and the engine splash shield.
6. Remove the torque converter covers.
7. Install the J 37096 to prevent the flywheel from turning.
8. Remove the crankshaft balancer bolt and discard the bolt.
9. Install the J 38197-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
10. Remove the crankshaft balancer.
11. Remove the J 38197-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

1. Coat the engine front cover seal contact area on the crankshaft balancer, and the seal surface with engine oil.
2. Install the crankshaft balancer.
3. Install the new crankshaft balancer bolt. Use the J 45059 to prevent the flywheel from turning. Tighten: Tighten the bolt to 150 N.m (111 lb ft). Use the J 45059 to rotate the bolt an additional 76 degrees.
4. Remove the J 45059 .
5. Install the torque converter covers.
6. Install the right engine splash shield and the engine splash shield retainers.
7. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/monte-carlo/vi-1999-2007/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
8. Lower the vehicle.
9. Install the drive belt. Refer to «Drive Belt Replacement (L32)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
11. Perform the CKP system variation learn procedure. Refer to «CKP SYSTEM VARIATION LEARN PROCEDURE»(/chevrolet/monte-carlo/vi-1999-2007/remont/testing-diagnostics/#engine-control-system-self-diagnostics-38l__ckp-system-variation-learn-procedure) .

J 35354-A Seal Installer. See Special Tools .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__crankshaft-balancer-replacement) .
2. Pry out the crankshaft front oil seal with a flat-bladed tool such as a large screwdriver.
3. Inspect the crankshaft balancer and engine front cover for scratches.

1. Install the crankshaft front oil seal in the engine front cover using the J 35354-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. Tighten the bolt until the crankshaft front oil seal is seated in the engine front cover.
3. Remove the J 35354-A . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
4. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__crankshaft-balancer-replacement) .
5. Inspect for leaks.

J 35354-A Seal Installer. See Special Tools .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
5. Lower the vehicle.
6. Loosen the water pump pulley bolts.
7. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
8. Remove the water pump pulley.
9. Remove the power steering pump bolts and reposition the pump.
10. Raise the vehicle.
11. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__crankshaft-balancer-replacement) .
12. Pry out the crankshaft front oil seal with a flat-bladed tool such as a large screwdriver. Use care to avoid damaging the crankshaft front oil seal bore or the crankshaft front oil seal contact surfaces.
13. Disconnect the electrical connectors from the following: Camshaft position (CMP) sensor Crankshaft position (CKP) sensor Oil pressure sensor
14. Remove the crankshaft position sensor shield.
15. Remove the radiator outlet hose from the water pump. Refer to «Radiator Hose Replacement - Outlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
16. Lower the vehicle.
17. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-support-fixture) .
18. Raise the vehicle.
19. Remove the oil filter.
20. Remove the engine mount bracket for oil pan access. Refer to «Engine Mount and Bracket Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
21. Disconnect the oil level sensor electrical connector.
22. Remove the oil level sensor.
23. Remove the oil pan-to-engine front cover bolts.
24. Loosen the remaining oil pan bolts to gain access for the engine front cover removal. DO NOT remove the remaining oil pan bolts.
25. Remove the crankshaft position sensor.
26. Remove the engine front cover bolts.
27. Remove the engine front cover with the oil filter adapter as one assembly.
28. Remove the engine front cover gasket.
29. If replacing the engine front cover, remove the oil filter adapter and pressure relief valve from the engine front cover.
30. If replacing the engine front cover, remove the water pump from the engine front cover.
31. If replacing the engine front cover, remove the oil pump cover and gear set from the engine front cover. Refer to «Oil Pump Cover and Gear Set Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
32. Inspect the oil pump cover and gear set. Refer to «Oil Pump Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__oil-pump-cleaning-and-inspection) .
33. If replacing the engine front cover, remove the camshaft position sensor from the engine front cover.
34. Inspect the timing chain for overall in and out movement. Maximum movement is 25.4 mm (1 in). Refer to «Timing Chain and Sprockets Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__timing-chain-and-sprockets-cleaning-and) .
35. Inspect the sprockets for wear.
36. Inspect the oil pan gasket. Replace the oil pan gasket if necessary.
37. Clean the engine front cover mating surfaces.

1. If replacing the engine front cover, install the camshaft position sensor to the engine front cover.
2. Install the camshaft position sensor bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. If replacing the engine front cover, install the oil pump cover and gear set to the engine front cover. Refer to «Oil Pump Cover and Gear Set Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. If replacing the engine front cover, install the water pump.
5. Install and tighten the water pump bolts. Tighten: Tighten the long water pump bolts to 34 N.m (25 lb ft). Tighten the short water pump bolts to 22 N.m (16 lb ft).
6. If replacing the engine front cover, install the pressure relief valve, the oil filter adapter and the oil filter adapter bolts to the engine front cover. Tighten: Tighten to 15 N.m (11 lb ft ) + 50 degrees.
7. Install the new engine front cover gasket. Ensure that the sealing surfaces are not damaged.
8. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the bolt threads.
9. Align the cogs on the crankshaft sprocket with the cogs on the oil pump gear set in the engine front cover.
10. Install the engine front cover to the engine.
11. Install the engine front cover bolts (1-7). Tighten: Tighten the bolts to 20 N.m (15 lb ft) + 40 degrees.
12. Install the crankshaft position sensor.
13. Install the crankshaft position sensor studs. Tighten: Tighten the studs to 30 N.m (22 lb ft).
14. Install the oil pan-to-engine front cover bolts. Tighten: Tighten the oil pan bolts to 14 N.m (125 lb in).
15. Install the oil level sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
16. Connect the oil level sensor electrical connector.
17. Install the engine mount bracket. Refer to «Engine Mount and Bracket Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
18. Install the water pump pulley and bolts. Tighten: Tighten the bolts to 13 N.m (116 lb in).
19. Install the radiator outlet hose to the water pump. Refer to «Radiator Hose Replacement - Outlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
20. Install the oil filter. Install the engine oil pan drain plug. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
21. Install the new engine front cover seal using J 35354 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
22. Tighten the bolt until the crankshaft front oil seal is seated in the engine front cover.
23. Remove the J 35354 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
24. Install the crankshaft position sensor shield.
25. Connect the electrical connectors to the following: Oil pressure sensor Crankshaft position (CKP) sensor Camshaft position (CMP) sensor
26. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__crankshaft-balancer-replacement) .
27. Lower the vehicle.
28. Install the power steering pump and the bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
29. Remove the engine support fixture.
30. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
31. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
32. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
33. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
34. Inspect for leaks.
35. Perform the CKP system variation learn procedure. Refer to «CKP SYSTEM VARIATION LEARN PROCEDURE»(/chevrolet/monte-carlo/vi-1999-2007/remont/testing-diagnostics/#engine-control-system-self-diagnostics-38l__ckp-system-variation-learn-procedure) .

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Remove the oil pump cover screws.
3. Remove the oil pump cover.
4. Remove the oil pump gear set.
5. Inspect the oil pump gear set and housing. Refer to «Oil Pump Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__oil-pump-cleaning-and-inspection) .

1. Lubricate the oil pump gear set 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: Tighten the screws to 11 N.m (98 lb in).
6. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
7. Inspect the oil pressure.
8. Inspect for leaks.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the right side wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/axle-shafts/#axle-shafts) in Wheel Drive Shafts.
4. Disconnect the oil pressure sensor electrical connector.
5. Drain the engine oil and remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
6. If equipped with an external engine oil cooler remove the following: Oil filter (2) Oil cooler lines from the engine oil cooler housing. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling. Engine oil cooler housing fitting (3) Engine oil cooler housing (4) Engine oil cooler housing O-ring (5)
7. Remove the oil filter adapter bolts.
8. Remove the following components: Oil filter adapter Oil filter adapter gasket Oil pressure valve and spring
9. Clean the parts in a suitable solvent. Dry the parts.
10. Clean the oil filter adapter gasket mating surfaces.
11. Inspect the following areas: The oil pressure valve and the valve bore for burrs The spring for loss of tension, replace the spring if necessary.
12. If replacing the oil filter adapter and valve assembly, remove the engine oil pressure sensor from the oil filter adapter and valve assembly.

1. If replacing the oil filter adapter and valve assembly, install the engine oil pressure sensor to the oil filter adapter and valve assembly. Tighten: Tighten the sensor to 16 N.m (12 lb ft).
2. Install the spring to the engine front cover.
3. Install the oil pressure valve to the engine front cover.
4. Install the oil filter adapter and a new gasket.
5. Install the oil filter adapter bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft) + 50 degrees.
6. If equipped with an external engine oil cooler install the following: Engine oil cooler housing O-ring (5) Engine oil cooler housing (4) Engine oil cooler housing fitting (3) Tighten: Tighten the fitting to 35 N.m (26 lb ft). Engine oil cooler lines to the oil cooler housing. Refer to «Engine Oil Cooler Pipe/Hose Quick Connect Fitting»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling. Oil filter (2)
7. Install the engine oil filter and the engine oil drain plug. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
8. Connect the oil pressure sensor electrical connector.
9. Install the right side wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/axle-shafts/#axle-shafts) in Wheel Drive Shafts.
10. Lower the vehicle.
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
12. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
13. Inspect for leaks.

J 45059 Torque Angle Meter

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Align the timing marks on the sprockets so that they are as close as possible.
3. Remove the timing chain dampener bolt.
4. Remove the timing chain dampener.
5. Remove the camshaft sprocket bolt.
6. Remove the camshaft sprocket and the timing chain.
7. Remove the crankshaft sprocket.
8. Remove the balance shaft drive gear in order to access the camshaft thrust plate, if required.
9. Remove the camshaft thrust plate bolts, if required.
10. Remove the camshaft thrust plate, if required.
11. Remove the balance shaft driven gear bolt, if required.
12. Remove the balance shaft driven gear, if required.
13. Clean and inspect all of the components for wear and/or damage. Refer to «Timing Chain and Sprockets Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__timing-chain-and-sprockets-cleaning-and) .
14. If the pistons have been moved in the engine, use the following procedure: Turn the crankshaft so that the number one piston is at top dead center. Turn the camshaft so that, with the sprocket temporarily installed, the timing mark is straight down.

1. Install the balance shaft driven gear, if required.
2. Prevent the balance shaft from rotating and install the balance shaft driven gear bolt, if required. Tighten: Tighten the balance shaft driven gear bolt to 22 N.m (16 lb ft). Use the J 45059 to rotate the bolt an additional 70 degrees.
3. Install the camshaft thrust plate, if required.
4. Install the camshaft thrust plate bolts, if required. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
5. Install the balance shaft drive gear.
6. Align the timing marks on the balance shaft drive gear and the balance shaft driven gear.
7. Install the crankshaft sprocket.
8. Install the timing chain and sprocket.
9. Assemble the timing chain on the sprockets with the timing marks as close together as possible.
10. Install the camshaft sprocket bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft). Use the J 45059 to rotate the bolt an additional 90 degrees.
11. Install the timing chain dampener.
12. Install the timing chain dampener bolt. Tighten: Tighten the bolt to 22 N.m (16 lb ft).
13. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .

J 45059 Angle Meter

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
5. Lower the vehicle.
6. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
7. Remove the air cleaner intake duct.
8. Remove the ignition control module and the bracket from the left cylinder head. Refer to «IGNITION CONTROL MODULE»(ref-159248-S13093826002003112000000) .
9. Remove the right engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement - Right Upper»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
10. Remove the left engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
11. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
12. Remove the left spark plugs from the left cylinder head.
13. Remove the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
14. Remove the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
15. Remove the left rocker arms and the push rods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
16. Remove the left cylinder head bolts. Discard the cylinder head bolts.
17. Remove the left cylinder head.
18. Remove the cylinder head gasket.
19. Remove the caps, the springs, the valves and the seals from the cylinder head. Refer to «Cylinder Head Disassemble»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__cylinder-head-disassemble) .
20. Clean the gasket mating surfaces on the cylinder head, the cylinder block and the intake manifold.
21. Clean the cylinder block bolt hole threads.
22. Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-block-cleaning-and-inspection) .
23. Inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__cylinder-head-cleaning-and-inspection) .

1. Install the valves, the seals, the springs and the caps to the cylinder head. Refer to «Cylinder Head Assemble»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__cylinder-head-assemble) .
2. Position 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 (1-8). Tighten: Tighten the cylinder head bolts (1-8) in the following sequence to 50 N.m (37 lb ft). Use the J 45059 to rotate the cylinder head bolts in the following sequence (1-8) an additional 120 degrees.
5. Install the left push rods and rocker arms. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
6. Install the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
7. Install the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
8. Install the left spark plugs to the left cylinder head.
9. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
10. Install the left engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
11. Install the right engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement - Right Upper»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
12. Install the ignition control module bracket and the ignition control module to the left cylinder head. Refer to «IGNITION CONTROL MODULE»(ref-159248-S13093826002003112000000) .
13. Install the air cleaner intake duct.
14. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
15. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
16. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
18. Inspect for leaks.

Cylinder Head Replacement - Right

Tools Required

1. J 41131 Engine Tilt Strap
2. J 45059 Torque Angle Meter

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
5. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
6. Remove the catalytic converter from the right exhaust manifold. Refer to «Catalytic Converter Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
7. Remove the exhaust gas recirculation (EGR) valve adapter bolt from the right exhaust manifold.
8. Lower the vehicle.
9. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
10. Remove the power steering pump bolts and reposition the power steering pump.
11. Rotate the engine to access the right cylinder head. Refer to «Rotating the Engine for Service Access»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__rotating-the-engine-for-service-access) .
12. Remove the right spark plugs from the right cylinder head.
13. Disconnect the heated oxygen sensor (HO2S) electrical connector (4).
14. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
15. Remove the EGR valve nuts.
16. Remove the EGR valve.
17. Remove the EGR valve adapter bolts from the right cylinder head.
18. Remove the EGR valve adapter from the right cylinder head.
19. Remove the right engine lift bracket bolt and the nut.
20. Remove the right engine lift bracket.
21. Remove the exhaust crossover pipe. Refer to «Exhaust Crossover Pipe Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
22. Remove the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
23. Remove the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
24. Remove the right rocker arms and push rods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
25. Remove the right cylinder head bolts. Discard the cylinder head bolts.
26. Remove the right cylinder head.
27. Remove the cylinder head gasket.
28. Remove the caps, the springs, the valves and the seals from the cylinder head. Refer to «Cylinder Head Disassemble»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__cylinder-head-disassemble) .
29. Clean the gasket mating surfaces on the cylinder head, the engine block and the intake manifold.
30. Clean the cylinder block bolt hole threads.
31. Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-block-cleaning-and-inspection) .
32. Inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__cylinder-head-cleaning-and-inspection) .

1. Install the valves, the seals, the springs and the caps to the cylinder head. Refer to «Cylinder Head Assemble»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__cylinder-head-assemble) .
2. Position 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 (1-8). Tighten: Tighten the cylinder head bolts in the following sequence (1-8) to 50 N.m (37 lb ft). Use the J 45059 to rotate the cylinder head bolts in the following sequence (1-8) an additional 120 degrees.
5. Install the right push rods and rocker arms. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
6. Install the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
7. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
8. Install the exhaust crossover pipe. Refer to «Exhaust Crossover Pipe Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
9. Install the right engine lift bracket.
10. Install the right lift bracket bolt and the nut. Tighten: Tighten the bolt and the nut to 30 N.m (22 lb ft).
11. Install the EGR valve adapter to the right cylinder head.
12. Install the EGR valve adapter bolts to the right cylinder head. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
13. Install the EGR valve.
14. Install the EGR valve nuts. Tighten: Tighten the nuts to 29 N.m (21 lb ft).
15. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
16. Connect the heated oxygen sensor (HO2S) electrical connector (4).
17. Install the right spark plugs to the right cylinder head.
18. Carefully release the J 41131 and return the engine to the original position.
19. Install the power steering pump.
20. Install the power steering pump bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
21. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
22. Install the left and the right engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) , and «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
23. Raise the vehicle.
24. Install the EGR valve pipe bolt to the right exhaust manifold. Tighten: Tighten the bolt to 29 N.m (21 lb ft).
25. Install the catalytic converter to the right exhaust manifold. Refer to «Catalytic Converter Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
26. Lower the vehicle.
27. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
28. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
29. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
30. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
31. Inspect for leaks.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
3. Remove the air cleaner intake duct.
4. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-support-fixture) .
5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
6. Remove the right exhaust manifold pipe stud nuts from the catalytic converter.
7. Drain the engine oil and remove the oil filter. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
8. Disconnect the oil level sensor electrical connector.
9. Remove the oil level sensor wiring harness bolt and reposition the oil level sensor wiring harness.
10. Remove the engine mount lower nuts from the engine mount.
11. Lower the vehicle.
12. Use the engine support fixture to raise the engine.
13. Raise the vehicle.
14. Remove the left engine mount bracket bolts from the engine.
15. Remove the right engine mount bracket bolts from the engine.
16. Remove the engine mount upper nuts.
17. Remove the engine mount and the bracket from the frame.
18. Remove the torque converter covers.
19. Remove the oil level sensor.
20. Remove the oil pan bolts.
21. Remove the oil pan.
22. Remove the oil pump pipe screen assembly and the oil pan gasket.
23. Clean the following parts: Oil pump screen mating surfaces Oil pan flanges Oil pan rail Front cover Rear main bearing cap Threaded holes

1. Install the oil pan gasket and the oil pump pipe screen assembly.
2. Install the oil pump pipe screen bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
3. Install the oil pan.
4. Clean the oil pan bolts and apply one drop of thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the oil pan bolt threads.
5. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 14 N.m (125 lb in).
6. Install the oil level sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
7. Install the torque converter covers.
8. Install the engine mount and the bracket to the frame.
9. Install the engine mount upper nuts. Tighten: Tighten the nuts to 43 N.m (32 lb ft).
10. Install the engine mount bracket to the engine.
11. Loosely install the right engine mount bracket bolts to the engine.
12. Loosely install the left engine mount bracket bolts to the engine. Tighten: Tighten the bolts to 102 N.m (75 lb ft).
13. Lower the vehicle.
14. Using the engine support fixture lower the engine.
15. Raise the vehicle.
16. Install the engine mount lower nuts. Tighten: Tighten the nuts to 43 N.m (32 lb ft).
17. Install the oil level sensor wiring harness and the oil level sensor wiring harness bolt to the engine. Tighten: Tighten the bolt to 10 N.m (89 lb in).
18. Connect the oil level sensor electrical connector.
19. Install right exhaust manifold pipe stud nuts. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
20. Install the engine oil filter.
21. Lower the vehicle.
22. Remove the engine support fixture.
23. Install the right and left engine mount struts. Refer to «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) and «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
24. Install the air cleaner intake duct.
25. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
26. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
27. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
28. Inspect for leaks.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Disconnect the engine oil pressure switch electrical connector.
3. Remove the oil pressure switch.

1. Install the engine oil pressure switch. Tighten: Tighten the switch to 16 N.m (12 lb ft).
2. Connect the engine oil pressure switch electrical connector.
3. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the engine oil drain plug in order to drain the engine oil.
3. Disconnect the oil level sensor electrical connector.
4. Remove the engine oil level sensor from the oil pan.

1. Install the engine oil level sensor to the oil pan. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
2. Connect the oil level sensor electrical connector.
3. Install the engine oil drain plug. Tighten: Tighten the plug to 30 N.m (22 lb ft).
4. Lower the vehicle.
5. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .

1. Remove the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Remove the oil pump screen bolts.
3. Remove the oil pump pipe and the screen.
4. Remove the oil pump pipe and screen gasket.
5. Clean the screen and housing with solvent and blow dry.
6. Inspect the oil pump pipe and the screen, replace if necessary.
7. Clean the gasket mating surface on the pipe flange and the cylinder block.

1. Install the new oil pump pipe and screen gasket.
2. Install the oil pump pipe and screen.
3. Install the oil pump screen bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
4. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
5. Inspect and verify that the oil pressure is within specifications.

Connecting Rod Bearing Replacement

Tools Required

1. J 41507 Connecting Rod Assembly Guide. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. J 45059 Torque Angle Meter

1. Remove the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
2. Remove the spark plugs from the cylinders that is being serviced.
3. Position the connecting rod to be serviced to bottom dead center (BDC) by rotating the crankshaft.
4. Remove the connecting rod cap bolts.
5. Remove the connecting rod cap and lower connecting rod bearing.
6. Remove the lower connecting rod bearing from the connecting rod cap.
7. Install the J 41507 to the connecting rod. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
8. Use the J 41507 , in order to push up the connecting rod and piston and access the upper connecting rod bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
9. Remove the upper connecting rod bearing.
10. Wipe the oil from the bearings.
11. Inspect the connecting rod bearings. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__piston-connecting-rod-and-bearings-cleaning) .
12. Measure the bearing clearance. Refer to «Engine Mechanical Specifications»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-mechanical-specifications) .

1. Dip the connecting rod cap bolts in clean engine oil.
2. Use clean engine oil in order to lubricate the bearing surface.
3. Install the upper connecting rod bearing.
4. Use the J 41507 , in order to pull down the piston, connecting rod and upper connecting rod bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
5. Remove the J 41507 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
6. Install the lower connecting rod bearing to the connecting rod cap.
7. Install the connecting rod cap.
8. Install the connecting rod cap bolts. Tighten: Tighten the connecting rod cap bolts to 27 N.m (20 lb ft). Use the J 45059 to rotate the connecting rod cap bolts an additional 50 degrees.
9. Pry the connecting rod back and forth in order to check for binding. If necessary, loosen and then retighten the connecting rod cap bolts.
10. Measure the connecting rod side clearance. Refer to «Engine Mechanical Specifications»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-mechanical-specifications) .
11. Install the spark plugs to the cylinders.
12. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
13. Inspect for proper oil pressure.
14. Inspect for leaks.

Engine Flywheel Replacement

Tools Required

1. J 45059 Torque Angle Meter
2. J 37096 Flywheel Holder

1. Remove the transaxle. Refer to «TRANSAXLE»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-trans/#automatic-transaxle-removal-installation) .
2. Use the J 37096 to prevent the flywheel from rotating.
3. Loosen the 8 engine flywheel bolts.
4. Remove 7 of the 8 engine flywheel bolts, leaving 1 bolt at the top of the crankshaft rotation.
5. Firmly grasp the engine flywheel and remove the remaining bolt. Do not drop the engine flywheel when removing the final bolt.
6. Remove the engine flywheel.

1. Install the engine flywheel.
2. Use the J 37096 to prevent the flywheel from rotating.
3. Install the new engine flywheel bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft). Use the J 45059 to rotate the bolts an additional 50 degrees.
4. Use the following procedure to measure engine flywheel runout: Install a dial indicator on the engine block and check the engine flywheel runout at three attaching bosses. Refer to «Engine Mechanical Specifications»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-mechanical-specifications) . If the runout is not within the specification and cannot be corrected, replace the engine flywheel.
5. Install the transaxle. Refer to «TRANSAXLE»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-trans/#automatic-transaxle-removal-installation) .

J 38196 Crankshaft Rear Oil Seal Installer. See Special Tools .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-flywheel-replacement) .
2. Remove the crankshaft rear oil seal. Insert a 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.
3. Inspect the inside diameter of the bore. Correct or replace the crankshaft rear oil seal housing as required.
4. Inspect the crankshaft for nicks or burrs on the surface that contacts the crankshaft rear oil seal.
5. Repair or replace the crankshaft if necessary.

1. Apply engine oil to the inside and the outside diameter of the new crankshaft rear oil seal. 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 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. Install the crankshaft rear oil seal using the following steps: Attach the J 38196 to the crankshaft by hand, or tighten the attaching screws. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . Tighten: Tighten the screws to 5 N.m (54 lb in). Turn the T-handle of the J 38196 so that the collar pushes the seal into the bore. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . 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. Loosen the T-handle of J 38196 until it comes to a stop. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . This will ensure that the collar will be in the proper position for installing another new crankshaft rear oil seal. Remove the attaching screws.
3. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-flywheel-replacement) .
4. Check and fill crankcase as necessary.
5. Inspect for leaks.

Crankshaft Rear Oil Seal and Housing Replacement

Tools Required

1. J 45059 Torque Angle Meter
2. J 41349 Rear Cover Aligner. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-flywheel-replacement) .
5. Remove the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
6. Remove the crankshaft rear oil seal housing bolts.
7. Remove the crankshaft rear oil seal housing.
8. Remove the crankshaft rear oil seal.
9. Remove the gasket from the crankshaft rear oil seal housing and the cylinder block.
10. Inspect the inside diameter of the bore. Correct or replace the crankshaft rear oil seal housing if necessary.
11. Inspect the crankshaft for nicks of burrs on the surface that contacts the seal.
12. Repair or replace the crankshaft if necessary.

1. Ensure 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.
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. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
6. Install the J 41349 over the crankshaft. Twisting or turning the J 41349 aids in sliding it completely over the crankshaft. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
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 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 can not 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: Tighten the crankshaft rear oil seal housing bolts to 15 N.m (11 lb ft). Use the J 45059 to rotate the crankcase rear oil seal housing bolts an additional 50 degrees.
9. Remove the J 41349 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
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 Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
12. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
13. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-flywheel-replacement) .
14. Lower the vehicle.
15. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
16. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
17. Inspect for leaks.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
2. Remove the hood. Refer to «Hood Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
3. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
5. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
6. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
7. Remove the torque converter cover.
8. Remove the starter motor. Refer to «Starter Motor Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
9. Remove the engine flywheel-to-torque converter bolts.
10. Scribe the torque converter to the flywheel for installation.
11. Remove the transaxle brace. Refer to «TRANSAXLE BRACE»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-trans/#automatic-transaxle-removal-installation) .
12. Remove the engine mount lower nuts.
13. Remove the right exhaust manifold pipe stud nuts from the catalytic converter.
14. Remove the engine oil level sensor harness retainer bolt.
15. Remove the engine oil level harness retainer from the engine.
16. Disconnect and reposition the electrical connectors from the following components: Vehicle speed sensor (VSS) Engine oil pressure sensor Engine oil level sensor Knock sensors Heated oxygen sensor (H02S)
17. Remove the oil filter adapter housing. Refer to «Oil Filter Adapter and Bypass Valve Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
18. Remove the engine ground nut and engine ground from the transaxle stud.
19. Remove the bolt (6) and the stud (1) which secure the lower transaxle to the engine.
20. Lower the vehicle while supporting the transaxle.
21. Remove the air cleaner assembly.
22. Disconnect the fuel lines (1,2) from the fuel rail. Lay the fuel lines aside. Refer to «FUEL LINE DISCONNECT FITTINGS»(ref-159248-S39980982662003112000000) .
23. Disconnect the fuel vapor line. Refer to «FUEL LINE DISCONNECT FITTINGS»(ref-159248-S39980982662003112000000) .
24. Remove the accelerator cable, the cruise control cable and the bracket from the throttle body. Refer to «FUEL LINE DISCONNECT FITTINGS»(ref-159248-S39980982662003112000000) .
25. Loosen the water pump pulley bolts.
26. Remove the drive belt. Refer to «Drive Belt Replacement (L32)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
27. Remove the water pump pulley bolts and the water pump pulley.
28. Remove the right and the left engine mount struts. Refer to «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) and to «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
29. Remove the engine mount strut brackets from the radiator support. Refer to «Engine Mount Strut Bracket Replacement - Upper Radiator Support»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
30. Disconnect the positive battery cable.
31. Remove the fan shroud. Refer to «Cooling Fan and Shroud Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
32. Remove the vacuum booster hose from the engine. Refer to «Vacuum Brake Booster Check Valve and/or Hose Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
33. Remove the A/C vacuum hose from the engine.
34. Remove the power steering pump and the power steering bolts from the engine. Lay the power steering pump aside.
35. Disconnect the upper engine electrical connectors from the following components: Fuel injectors Throttle position (T/P) sensor Idle air control (IAC) valve EVAP purge solenoid Exhaust gas recirculation (EGR) valve Manifold absolute pressure (MAP) sensor
36. Remove upper engine wiring harness from retaining clips and reposition the engine wiring harness for engine removal.
37. Remove the radiator inlet hose from the engine. Refer to «Radiator Hose Replacement - Inlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
38. Remove the radiator outlet hose from the water pump. Refer to «Radiator Hose Replacement - Outlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
39. Remove the heater hoses from the drive belt tensioner. Refer to «Heater Hose Replacement - Inlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) and to «Heater Hose Replacement - Outlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) in Heating, Ventilation and Air Conditioning.
40. Remove the A/C compressor nuts and the A/C compressor from the engine. DO NOT discharge the A/C system. Secure the compressor to the frame.
41. Install the engine lifting device.
42. Remove the bolts (2,3,4,5) which secure the upper transaxle to the engine.
43. With the aid of an assistant, remove the engine from the vehicle.
44. Remove the flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-flywheel-replacement) .
45. Install the engine to the engine stand.

1. Remove the engine from the engine stand.
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__engine-flywheel-replacement) .
3. With the aid of an assistant install the engine to the vehicle.
4. Install the bolts (2,3,4,5) which secure the upper transaxle to the engine. Tighten: Tighten the bolts to 75 N.m (55 lb ft).
5. Remove the engine lifting device.
6. Install the A/C compressor to the engine.
7. Install the mounting nuts to the A/C compressor. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
8. Install the heater hoses to the drive belt tensioner. Refer to «Heater Hose Replacement - Inlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) and to «Heater Hose Replacement - Outlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-hvac-system/#hvac-systems-automatic) in Heating, Ventilation and Air Conditioning.
9. Install the radiator outlet hose to the water pump. Refer to «Radiator Hose Replacement - Outlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
10. Install the radiator inlet hose to the engine. Refer to «Radiator Hose Replacement - Inlet (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
11. Reposition the engine wiring to the engine.
12. Connect the upper engine electrical connectors to the following components: Manifold absolute pressure (MAP) sensor Exhaust gas recirculation (EGR) valve EVAP purge solenoid Idle air control (IAC) valve Throttle position (T/P) sensor Fuel injectors
13. Install the upper engine wiring harness to the retaining clips.
14. Install the power steering pump.
15. Install the power steering pump bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
16. Connect the A/C vacuum hose to the engine.
17. Install the vacuum booster hose to the engine. Refer to «Vacuum Brake Booster Check Valve and/or Hose Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
18. Install the fan shroud. Refer to «Cooling Fan and Shroud Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
19. Connect the positive battery cable. Tighten: Tighten the positive terminal bolt to 15 N.m (11 lb ft).
20. Install the engine mount brackets to the radiator support. Refer to «Engine Mount Strut Bracket Replacement - Upper Radiator Support»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
21. Install the right and the left engine mount struts. Refer to «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) and to «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
22. Install the water pump pulley.
23. Install the water pump pulley bolts. Tighten: Tighten the bolts to 13 N.m (116 lb in).
24. Install the drive belt. Refer to «Drive Belt Replacement (L32)»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
25. Install the accelerator cable, the cruise control cable and the bracket to the throttle body. Refer to «THROTTLE BODY»(ref-159248-S22807658372003112000000) .
26. Connect the fuel vapor line. Refer to «FUEL LINE DISCONNECT FITTINGS»(ref-159248-S39980982662003112000000) .
27. Connect the fuel lines (1,2) to the fuel rail. Refer to «FUEL LINE DISCONNECT FITTINGS»(ref-159248-S39980982662003112000000) .
28. Install the air cleaner assembly.
29. Raise the vehicle and remove the transaxle support.
30. Install the bolt (6) and the stud (1) which secure the lower transaxle to the engine. Tighten: Tighten the bolt and the stud to 75 N.m (55 lb ft).
31. Install the engine ground to the transaxle stud.
32. Install the engine ground nut. Tighten: Tighten the nut to 35 N.m (26 lb ft).
33. Install the oil filter adapter housing. Refer to «Oil Filter Adapter and Bypass Valve Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
34. Reposition and connect the electrical connectors to the following components: Heated oxygen sensor (H02S) Knock sensors Engine oil level sensor Engine oil pressure sensor Vehicle speed sensor (VSS)
35. Install the engine oil level sensor harness retainer.
36. Install the engine oil level sensor harness retainer bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
37. Install the catalytic converter pipe to the right exhaust manifold.
38. Install the stud nuts to the right exhaust manifold. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
39. Install the lower nuts to the engine mount. Tighten: Tighten the nuts to 43 N.m (32 lb ft).
40. Install the transaxle brace. Refer to «TRANSAXLE BRACE»(/chevrolet/monte-carlo/vi-1999-2007/remont/automatic-trans/#automatic-transaxle-removal-installation) .
41. Install the engine flywheel-to-torque converter bolts.
42. Install the starter motor. Refer to «Starter Motor Replacement (3.8L)»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
43. Install the torque converter cover.
44. Lower the vehicle.
45. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
46. Install the hood. Refer to «Hood Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/exterior-body-panels/#body-front-end) in Body Front End.
47. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/monte-carlo/vi-1999-2007/remont/body-electrical/#battery-charging-system-starting-system) in Engine Electrical.
48. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
49. Fill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/monte-carlo/vi-1999-2007/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
50. Inspect for leaks.
51. Perform the CKP system variation learn procedure. Refer to «CKP SYSTEM VARIATION LEARN PROCEDURE»(/chevrolet/monte-carlo/vi-1999-2007/remont/testing-diagnostics/#engine-control-system-self-diagnostics-38l__ckp-system-variation-learn-procedure) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/monte-carlo/vi-1999-2007/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
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. Refer to «Oil Filter Adapter and Bypass Valve Assembly Replacement»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .

1. Lightly oil the replacement oil filter gasket with clean oil and install the new oil filter.
2. Install the new oil filter. Refer to «Maintenance Items»(/chevrolet/monte-carlo/vi-1999-2007/remont/lubrication-system/#maintenance-and-lubrication__maintenance-items) in Maintenance and Lubrication. Tighten: 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 pan drain plug. Tighten: Tighten the plug to 30 N.m (22 lb ft).
4. Remove the oil drain pan.
5. Lower the vehicle.
6. Fill the engine with new engine oil. Refer to «Capacities - Approximate Fluid»(/chevrolet/monte-carlo/vi-1999-2007/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) and «Fluid and Lubricant Recommendations»(/chevrolet/monte-carlo/vi-1999-2007/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) in Maintenance and Lubrication.
7. Start the engine.
8. Inspect for oil leaks after engine start up.
9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan.
10. Remove the oil level indicator from the oil indicator tube.
11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth.
12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube.
13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down.
14. Check the level of the engine oil on the oil level indicator.
15. If necessary, readjust the oil level by adding or draining the engine oil.
16. Check for oil leaks.

Rotating the Engine for Service Access

Tools Required

J 41131 Engine Tilt Strap

1. Remove the air cleaner intake duct.
2. Apply the parking brake.
3. Put the transaxle in the Neutral position.
4. Remove the engine mount struts. Refer to «Engine Mount Strut Replacement - Right»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) and «Engine Mount Strut Replacement - Left»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36) .
5. Install the J 41131 (2) to the engine mount strut bracket (1) and the upper radiator support (3).
6. Rotate the engine forward for component access.

Draining Fluids and Oil Filter Removal

1. Remove the oil drain plug.
2. Drain the engine oil.
3. Remove the oil filter.
4. Remove the knock sensor heat shield bolts and heat shield, if applicable.
5. Remove the knock sensor.
6. Drain the coolant.

Crankshaft Balancer Removal

Tools Required

1. J 37096 Flywheel Holder
2. J 38197-A Crankshaft Balancer Remover. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

1. Use J 37096 in order to hold the flywheel.
2. Remove the crankshaft balancer bolt.
3. Use the J 38197-A in order to remove the crankshaft balancer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . Invert J 38197-2 so the leg of the tool is facing away from the crankshaft balancer. Install the silver screws J 38197-4 to the crankshaft balancer. Turn J 38197-1 to remove the crankshaft balancer from the crankshaft. Remove J 38197-1, J 38197-2, and J 38197-4 from the crankshaft balancer.

Engine Flywheel Removal

1. Remove the flywheel bolts. Discard the bolts.
2. Remove the flywheel.

Drive Belt Tensioner Removal

1. Remove the drive belt tensioner bracket bolts.
2. Remove the drive belt tensioner bracket.

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator.
2. Remove the oil level indicator tube nut.
3. Remove the oil level indicator tube.

Water Outlet and Thermostat Removal

1. Remove the water outlet bolt and stud.
2. Remove the water outlet.
3. Remove the thermostat.

Water Pump Removal

1. Remove the water pump pulley bolts.
2. Remove the water pump pulley.
3. Remove the water pump bolts.
4. Remove the water pump.
5. Remove the water pump gasket.

Intake Manifold Removal - Upper

1. Remove the spark plug wires.
2. Disconnect the ignition wires from the fuel injector rail.
3. Disconnect the ignition control module connector from the ignition control module assembly.
4. Remove the ignition control module assembly nuts.
5. Remove the ignition control module assembly.
6. Remove the fuel injector rail nuts.
7. Remove the fuel injector rail.
8. Remove the accelerator control cable bracket bolts.
9. Remove the accelerator control cable bracket from the intake manifold.
10. Remove the engine wiring harness heat shield bolt and nut.
11. Remove the engine wiring harness heat shield.
12. Remove the throttle body nuts.
13. Remove the throttle body.
14. Remove the throttle body gasket.
15. Remove the upper intake manifold bolts and nuts.
16. Remove the upper intake manifold.

Exhaust Gas Recirculation (EGR) and EGR Pipe Removal

1. Remove the EGR valve nuts, EGR valve and gasket.
2. Remove the EGR valve adapter inlet pipe bolt from the RH exhaust manifold.
3. Remove the EGR valve outlet pipe bolt, nut and pipe from the lower intake manifold and the EGR valve adapter assembly.
4. Remove the EGR valve adapter assembly bolts.
5. Remove the EGR valve adapter assembly from the cylinder head.

Intake Manifold Removal - Lower

1. Remove the EGR outlet pipe from the intake manifold.
2. Remove the lower intake manifold bolts.
3. Remove the lower intake manifold.
4. Remove the lower intake manifold gasket.

Exhaust Manifold Removal - Left

1. Remove the exhaust manifold heat shield nuts.
2. Remove the exhaust manifold heat shield.
3. Remove the left engine lift hook nut and bolt.
4. Remove the left engine lift hook.
5. Remove the left side spark plugs.
6. Remove the exhaust manifold bolt and studs.
7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket.
9. Remove the exhaust manifold studs.

Exhaust Manifold Removal - Right

1. Remove the heated oxygen sensor lead.
2. Remove the fuel injector sight shield mounting bracket nuts.
3. Remove the fuel injector sight shield mounting bracket.
4. Remove the right engine lift hook nut and bolt.
5. Remove the right engine lift hook bracket.
6. Remove the right side spark plugs.
7. Remove the exhaust manifold studs.
8. Remove the exhaust manifold.
9. Remove the exhaust manifold gasket.
10. Remove the exhaust manifold studs.

Valve Rocker Arm Cover Removal - Left

1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover.

Valve Rocker Arm Cover Removal - Right

1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover.

Valve Rocker Arm and Push Rod Removal

1. Remove the valve rocker arm bolts.
2. Remove the valve rocker arm.
3. Remove the push rods.
4. Remove the push rod guide plate.

Cylinder Head Removal - Left

1. Remove the cylinder head bolts.
2. Discard the cylinder head bolts.
3. Remove the cylinder head.
4. Remove the cylinder head gasket.

Cylinder Head Removal - Right

1. Remove the cylinder head bolts.
2. Discard the cylinder head bolts.
3. Remove the cylinder head.
4. Remove the cylinder head gasket.

Valve Lifter Removal

1. Remove the valve lifter guide retainer bolts.
2. Remove the valve lifter guide retainers.
3. Remove the valve lifters.

Oil Pan Removal

1. Remove the oil level sensor.
2. Remove the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil pan gasket windage tray gasket - if applicable.

Oil Pump Pipe and Screen Assembly Removal

1. Remove the oil pump pipe and screen assembly bolts.
2. Remove the oil pump pipe and screen assembly.
3. Remove the oil pump pipe and screen assembly gasket.
4. Use solvent to clean the oil pump pipe and screen.

Scheme 46

Use a screwdriver to pry out the crankshaft front oil seal.

Engine Front Cover Removal

1. Remove the crankshaft position sensor shield.
2. Remove the crankshaft position sensor studs.
3. Remove the crankshaft position sensor.
4. Remove the engine front cover bolts and stud.
5. Remove the engine front cover.
6. Remove the engine front cover gasket.

Oil Filter Adapter Removal

1. Remove the oil filter adapter bolts from the engine front cover.
2. Remove the oil filter adapter.
3. Remove the oil filter adapter gasket.
4. Remove the oil pressure relief valve.
5. Remove the oil pressure relief valve spring.

Timing Chain and Sprockets Removal

1. Align the timing marks on the sprockets.
2. Remove the timing chain dampener.
3. Remove the camshaft sprocket bolt.
4. Remove the camshaft sprocket.
5. Remove the timing chain.
6. Remove the crankshaft sprocket.
7. Remove the crankshaft balancer key.
8. Remove the balance shaft drive gear.

Balance Shaft Removal

Tools Required

J 6125-1B Slide Hammer. See Special Tools .

1. Remove the balance shaft driven gear bolt.
2. Remove the balance shaft driven gear.
3. Remove the balance shaft retainer bolts.
4. Remove the balance shaft retainer.
5. Use J 6125-1B to remove the balance shaft. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

Camshaft Removal

1. Remove the camshaft thrust plate screws.
2. Remove the camshaft thrust plate.
3. Install one 1/2-20 x 6.0 inch bolt in the camshaft front bolt hole.
4. Carefully rotate and pull the camshaft out of the bearings.

Scheme 47

Pry the crankshaft rear oil seal out with a screwdriver.

Crankshaft Rear Oil Seal and Housing Removal (First Design)

1. Remove the crankshaft rear oil seal housing bolts.
2. Remove the crankshaft rear oil seal housing and gasket.
3. Place the crankshaft rear oil seal housing face down on a clean surface and support with blocks of wood.
4. Use a suitable driving tool and hammer and lightly tap around the outer edge of the seal to remove it.

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 41507 Connecting Rod Guide Assembly. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. J 24270 Cylinder Ridge Reamer

1. Mark the connecting rod cap and the connecting rod for proper installation.
2. Use the J 24270 to remove the cylinder bore ring ridge. Turn the crankshaft until the piston is at the bottom of the stroke. Cover the piston with a cloth. Remove the cylinder ring ridge. Turn the crankshaft until the piston is at the top of the stroke. Remove the cloth. Remove the metal shavings from the cylinder and piston.
3. Remove the connecting rod bolts.
4. Remove the connecting rod cap.
5. Install J 41507 to the connecting rod. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . Hand tighten the tool to the connecting rod.
6. Use hand pressure on J 41507 to push the connecting rod towards the top of the cylinder. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
7. Remove the piston, the connecting rod, and the connecting rod bearings.

Crankshaft and Bearings Removal

Tools Required

1. J 6125-1B Slide Hammer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. J 41348 Main Bearing Cap Puller. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

1. Remove the crankshaft main bearing cap side bolts.
2. Remove the crankshaft main bearing cap bolts.
3. Install J 41348 into the crankshaft main bearing cap bolt holes. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . Tighten: Tighten the bolts on J 41348 to 12 N.m (100 lb in). See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
4. Install J 6125-1B to J 41348 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
5. Use J 6125-1B to remove the crankshaft main lower bearing caps. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
6. Remove the crankshaft.
7. Remove the upper main bearings from the engine block.

Engine Block Plug Removal

1. Remove the threaded coolant jacket plugs.
2. Remove the remaining plugs using the following procedure. Obtain a suitable self-threading screw. Drill a hole into the plug. Install the self-threading screw. Use the screw to pry out the plug.

Camshaft Bearing Removal

Tools Required

J 33049 Camshaft Bearing Remover/Installer. See Special Tools .

1. Select the expander assembly and driving washer.
2. Assemble J 33049 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
3. Drive out the camshaft bearings.

Balance Shaft Bearing and/or Bushing Removal

Tools Required

J 36995 Balance Shaft Bearing Remover/Installer. See Special Tools .

1. Use J 36995 to remove the balance shaft bearing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. Use J 36995 to remove the balance shaft bushing. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . It may take a considerable amount of force to loosen the bushing from the block bore.

Engine Block Cleaning and Inspection

Tools Required

1. J 8087 Cylinder Bore Gage. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. J 8001 Dial Indicator Set. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

1. Clean the sealing material from the gasket mating surfaces.
2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes. Clean the holes with a tap. If necessary, drill out the holes and install thread inserts. Refer to «Thread Repair»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-34l-v6-vin-e-la1__thread-repair) .
8. Use a straight edge and a feeler gage to check the deck surface for flatness. Carefully machine minor irregularities. Replace the block if more than 0.254 mm (0.010 in) must be removed.
9. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.
10. Inspect the mating surfaces of the transmission case.
11. Use the following procedure to measure the engine block flange runout at the six mounting bolt hole bosses: Temporarily install the crankshaft. Measure the crankshaft flange runout. Hold the gauge plate flat against the crankshaft flange. Place J 8001 on the transmission mounting bolt hole boss. Set the indicator to 0. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.254 mm (0.010 in). Recheck the crankshaft flange runout if the readings vary more than 0.254 mm (0.010 in).
12. Inspect the crankshaft main bearing bores. Use J 8087 to measure the bearing bore concentricity and alignment at the following locations: The camshaft The crankshaft
13. Ensure that the crankshaft main bearing caps are installed correctly. The arrows should point toward the front of the engine.
14. Replace the engine block if the bores are out of specification.
15. Use J 8087 to inspect the cylinder bores. Inspect for the following items: Wear Taper Run-out Ridging
16. Leave sufficient material to allow honing when fitting the piston.

Boring Procedure

1. Before honing or boring, measure all of the new pistons. Select the smallest piston for the piston fitting. Slightly varied pistons in a set may provide correction, if the first piston is too loosely fitted.
2. Before using any type of boring bar, file the top of the engine block to remove any dirt or burrs. If the cylinder block is not straight, the boring bar may be tilted, causing the bored cylinder wall to have incorrect right angles to the crankshaft.
3. Carefully follow the instructions furnished by the manufacturer regarding use of equipment.
4. Install all crankshaft main bearing caps to specification when boring cylinders. Cover or tape the crankshaft bearings and other internal parts to protect these parts during the boring or honing operation.
5. Leave 0.03 mm (0.001 in) on the diameter for finish honing when performing the final cut with a boring bar. Carefully perform the honing and boring operation to maintain the specified clearances between pistons, rings, and cylinder bores.

Honing Procedure

1. Follow the manufacturer's recommendations for use, cleaning, and lubrication when honing the cylinders. Use only clean, sharp stones of the proper grade for the amount of material to be removed. Dull, dirty stones cut unevenly and generate excessive heat. When using coarse or medium-grade stones, leave sufficient metal so all stone marks may be removed with the fine stones used for finishing to provide the proper clearance.
2. During the honing operation, thoroughly clean the cylinder bore. Check for the correct piston fit.
3. Make full strokes in the cylinder to eliminate taper. Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore.
4. When finish honing a cylinder bore to fit a piston, move the hone up and down at a sufficient speed to obtain a fine and uniform surface finish in a cross hatch pattern.
5. Determine the finish hone cylinder measurement by measuring the piston to be installed, and by adding the average of the clearance specification. Measure the block and the piston at normal room temperature.
6. True up the refinished cylinder bores. Final hone each cylinder bore to remove all stone or cutter marks.
7. After final honing and before the piston is checked for fit, clean the bores with hot water and detergent. Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with hot water. Do not allow any abrasive material to remain in the cylinder bores. This abrasive material will wear the new rings, the cylinder bores, and the bearings lubricated by the contaminated oil. After washing dry the bore.
8. Permanently mark the piston for the cylinder to which the piston has been fitted.
9. Apply clean engine oil to each bore to prevent rusting.

Crankshaft and Bearings Cleaning and Inspection

Tools Required

J 8087 Cylinder Bore Gage. See Special Tools .

1. Clean the crankshaft of the following elements: Oil Sludge Carbon
2. Inspect the crankshaft oil passages for obstructions.
3. Inspect the crankshaft keyway for nicks or wear.
4. Inspect the crankshaft threads.
5. Inspect the crankshaft bearing journals and the crankshaft thrust surfaces for the following conditions: Cracks Chips Gouges Roughness Grooves Overheating, discoloration
6. Inspect the corresponding crankshaft bearings for embedded foreign material and determine the source.
7. Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent crankshaft or a tapered bearing journal.
8. Inspect the outer surfaces of the crankshaft bearings for the following conditions: Wear - surface wear indicates either movement of the insert or high spots in the surrounding material, spot wear. Overheating or discoloration Looseness or rotation indicated by flattened tangs and wear grooves
9. Inspect the thrust surfaces of the main thrust bearing for the following conditions: Wear Grooving, grooves are caused by irregularities of the crankshaft thrust surface.
10. Using the J 8087 inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure: (See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) ). Tighten the bearing cap to specification. Measure the bearing bore using J 8087 for taper and out-of-round. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . No taper or out-of-round should exist.

Bearing Selection

Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods to measure bearing clearance. Method A gives more reliable results and is preferred.

1. Method A yields measurement from which the bearing clearance can be computed.
2. Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.

Method A

1. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the crankshaft bearing inserts. Tighten the bearing cap bolts to specification.
4. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.
5. Measure the crankshaft main bearing inside diameter with an inside micrometer.
6. Select a set of bearing inserts that will produce the desired clearance.
7. If the specified clearances cannot be met, the crankshaft journals must be reconditioned and undersized bearing inserts installed.

Method B

1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. Install the bearing caps. NOTE: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.
5. Install the bearing cap bolts to specification.
6. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap.
7. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Select a set of bearing inserts that will produce the desired clearance.

Crankshaft Balancer Cleaning and Inspection

1. Inspect the crankshaft balancer for damage.
2. Inspect the outside of the crankshaft balancer mounting shaft for grooves.
3. Replace the crankshaft balancer if grooves are present and appear to be causing an oil leak.

Engine Flywheel Cleaning and Inspection

1. Clean the flywheel.
2. Inspect the engine flywheel for damage and cracks.
3. Inspect the engine flywheel ring gear for damaged teeth.
4. Replace the flywheel if any damage is found.

Piston and Connecting Rod Disassemble

1. Remove the piston rings. Use a suitable tool to expand the rings. Piston rings must not be reused.
2. Remove the piston pin retaining clips.
3. Remove the piston pin.

Piston, Connecting Rod, and Bearings Cleaning and Inspection

1. Clean the piston and connecting rod in solvent.
2. Dry the components with compressed air.
3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
4. Clean the piston oil lubrication holes and slots.
5. Inspect the piston for the following conditions: Eroded areas (1) on top of the piston Scuffed or damaged skirt (2) Damage to the pin bore (3) Cracks in the piston ring lands, the piston skirt, or the pin bosses Piston ring grooves for nicks, burrs, or other warpage which may cause the piston ring to bind.
6. Inspect the piston for scoring, wear or other damage.
7. To determine the piston-to-bore clearance, use a micrometer and measure the piston pin.
8. To determine the piston pin-to-bore clearance, use an inside micrometer and measure the piston pin bore.
9. To determine the piston pin-to-bore clearance, subtract the piston pin diameter from the piston pin bore diameter.
10. Inspect the connecting rod for an out-of-round bearing bore.
11. Inspect the connecting rod for twisting.
12. Inspect the connecting rod cap bolts for stretch (compare to known good bolt) (1) is a stretched bolt, (2) is a new or good bolt.

Piston and Connecting Rod Assemble

1. Coat the piston pin with oil.
2. Install one piston pin retainer into the retaining groove.
3. Install the connecting rod and piston pin. The connecting rod can be installed in either direction. Push the piston pin in until it bottoms against the installed piston pin retainer.
4. Install the second piston pin retainer.
5. Ensure the piston pin moves freely.
6. Using the piston ring pliers, install the piston rings onto the piston. Install the oil control ring spacer into the bottom groove of the piston. Install the lower oil control ring. The oil control rings do not have a dimple or orientation mark and may be installed in either direction. Install the upper oil control ring. Install the middle compression ring with the dot facing up. Install the top compression ring in either direction. The ring has no orientation markings.

Camshaft and Bearings Cleaning and Inspection

Tools Required

J 7872 Magnetic Base Indicator Set

1. Measure the camshaft journals with a micrometer. If the camshaft journals are not within specifications, replace the camshaft. The measurement should be 47.655-46.858 mm (1.8462-1.8448 in). If the measurement is not within specifications the engine camshaft must be replaced.
2. Measure the camshaft runout using J 7872 . Mount the camshaft in V-blocks between centers. Use J 7872 to check the intermediate camshaft journal.
3. If the runout exceeds specifications, the camshaft is bent and should be replaced. If the camshaft journals are more than 0.025 mm (0.0010 in) out-of-round, then replace the engine camshaft.

Timing Chain and Sprockets Cleaning and Inspection

1. Inspect the timing chain and sprockets for damage.
2. Inspect the timing chain for overall in and out movement. Movement should not exceed 25 mm (1 in).
3. Inspect the sprockets for wear.

Valve Rocker Arm and Push Rods Cleaning and Inspection

1. Clean the components with cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the valve rocker components for the following: Valve rocker arm valve pushrod socket contact surface (1) The contact surface must be smooth with no scoring or excessive wear. Valve rocker arm roller pivot for binding or damage (2) Valve rocker arm valve stem contact surface (3) The contact surface should be smooth with no scoring or excessive wear.
4. Inspect the valve pushrods for the following: Restriction of the oil passage (1) Wear or scoring of the end contact surfaces (2) The end contact surfaces must be smooth with no scoring or excessive wear. Shaft for bends (3) Roll the valve pushrod on a flat surface to determine if the valve pushrod is bent.

Valve Lifters and Guides Cleaning and Inspection

1. Keep the valve lifters in order so they can be installed in their original position.
2. Inspect the following areas of the valve lifters: The retaining clip (1) The push rod socket for wear (2) The valve lifter body for wear and scuffing (3) The valve lifter bore for wear The valve lifter roller assembly for wear (4) The valve lifter roller pin for damage (5) The oil hole for plugging (6)
3. Inspect the valve lifter guides for cracks or damage.

Cylinder Head Disassemble

Tools Required

J 38606 Valve Spring Compressor. See Special Tools .

1. Use J 38606 to compress the valve spring. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. Remove the valve keys.
3. Remove the valve cap and spring.
4. Remove the valve stem oil seal by prying up on the bottom.

Cylinder Head Cleaning and Inspection

Tools Required

J 9666 Valve Spring Tester

1. Inspect the cylinder head gasket and the mating surfaces for leaks, corrosion, and blowby.
2. If the gasket failed, determine the cause. Gasket failure is caused by the following conditions: Improper installation A loose or warped cylinder head Missing dowel pins
3. Clean the cylinder head of all foreign material. Do not use a motorized wire brush on any gasket sealing surface.
4. Clean the threaded holes.
5. Inspect the cylinder head for cracks typically between the valve seats and inside of the exhaust ports.
6. Inspect the cylinder head deck for corrosion.
7. Inspect the following locations for flatness: The cylinder head deck The intake manifold mating surface The exhaust manifold mating surface
8. Recondition the surfaces by parallel grinding. Replace the cylinder head if more than 0.254 mm (0.010 in) is removed.
9. Measure the height from the deck surface to the cast pads. Do this to determine if the cylinder head has sufficient deck surface thickness to resurface. New cylinder heads measure from 1.372-1.676 mm (0.054-0.066 in). If the cylinder head does not meet the minimum thickness after resurfacing, replace the cylinder head.
10. Inspect all of the threaded holes for damage. Repair the threaded holes, if necessary.
11. Inspect the valve seating surfaces.
12. Inspect the cooling jacket plugs.
13. Inspect the valve guides for wear. Clean the valve guides.
14. Inspect the valve seats for excessive wear and hot spots.
15. Inspect the valve springs for squareness.
16. Inspect the valve spring ends. If the valve spring ends are not parallel, the valve spring is bent. Replace the bent valve spring.
17. Using the J 9666 test the valve spring load. Replace the spring if the valve spring load is less than 334 N.m at 43.69 mm (75 lb at 1.72 in).
18. Inspect the valve spring seating surface of the valve spring retainers for wear or gouging. If the seating surface is damaged, replace the valve spring retainers.
19. Use the following procedure to measure the valve seat concentricity: Lift the valve off its seat. Apply a dab of blue dye to the valve face. Seat and rotate the valve. The blue dye traces transferred to the valve seat are an indication of concentricity of the valve seat.
20. Use the following procedure to measure the valve runout: Clean off the blue dye. Apply blue dye to the valve seat. Seat and rotate the valve. The traces of blue dye transferred to the valve indicates valve runout. Recondition the valve seat or valve face, if needed.

Valve Guide Reaming/Valve and Seat Grinding

Tools Required

J 8001 Dial Indicator Set

1. Recondition the valve seats by grinding. Use an oscillating type valve seat grinder. Follow the grinder manufacturer's instructions. If the valve seat is too wide after grinding, use a 20 degree stone or a 70 degree stone in order to narrow the valve seat. The 20 degree stone will lower the seat. The 70 degree stone will raise the seat. Replace or recondition the valves if the seats are reconditioned.
2. After grinding the valves, measure the valve margin. Replace the valve if less than the minimum recommended specification (0.79 mm (0.031 in).
3. Clean any foreign material from the valves. Use a wire brush to remove carbon. Do not scratch the valve stem. Soak the valves in cleaning solvent to remove varnish.
4. Use a suitable tool to clean the valve guides.
5. Follow the grinder manufacturer's instructions. Ensure that the new surface is perpendicular to the valve stem.
6. Inspect the valve key grooves for chipped or worn lands (5). Replace the valve if the valve key groove is damaged.
7. Inspect the valve stem tip for wear (6). Recondition the valve stem tip by grinding.
8. Inspect the valve stem for burrs and scratches (4). Use an oil stone to remove burrs and minor scratches.
9. Inspect the valve stem for straightness (3). Use V blocks to inspect the valve head for bending or distortion. Replace any bent or distorted valves.
10. Inspect the valve face for grooving (1, 2). If the groove is so deep that refacing the valve face would result in a knife edge, replace the valve.
11. Inspect the valve face for burning, pitting, or cracking (1, 2, 3, 4). If pieces of the valve face are broken off, replace the valve and inspect the corresponding piston and cylinder head area for damage.
12. Measure the valve stem clearance: Insert the valve into the guide. Lift the valve 2 mm (1/8 in) off of the seat. Move the valve from side to side. Use J 8001 to measure the amount of movement. The intake valve stem clearance should be between 0.031-0.071 mm (0.0012-0.0028 in). The exhaust valve stem clearance should be between 0.036-0.074 mm (0.0014-0.0029 in).
13. Ream the valve guides for oversize valves if the clearance exceeds the specifications.
14. Ream the valve guide bores for the oversize valves.
15. Recondition the valve seats after reaming the valve guide bores or installing the new valve guides.
16. Inspect the valve stem for straightness. Use V blocks to inspect the valve head for bending or distortion. Replace any bent or distorted valves. It is essential that the valve guide bores are free of carbon or dirt to ensure the proper centering of the pilot in the guide. The valve seats should be concentric to within 0.05 mm (0.031 in) total indicator reading. Reface pitted valves on a valve refacing machine to ensure the correct relationship between the valve head and the valve stem. Replace the valve if the valve stem is warped (2), or if the valve stem shows signs of excessive wear. Inspect the valve key area (1) for damage and carbon build up. Replace the valve if the edge of the head is less than 0.79 mm (0.031 in) thick after grinding. Use the manufacturer's recommendations of equipment for the proper results.

Cylinder Head Assemble

Tools Required

1. J 38606 Valve Spring Compressor. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. J 42863 Valve Seal Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

1. Install the valves. The valves are available in standard size and 0.381 mm (0.015 in) oversize. Use oversize valve seals if oversized valves are used.
2. Use the following procedure to measure the valve stem height: Place the valve on the guide. Hold the valve in the closed position. Use a valve stem height gauge to measure the valve stem height. The measurement should be 49-50 mm (1.93-1.97 in).
3. Use the following procedure to measure the valve spring installed height: Place the valve in the valve guide. Install the valve spring cap and the valve cap keys. Seat the valve spring retainer by pulling up. Use a steel machinists' rule to measure the distance from the spring seat to the bottom of the valve spring cap. The measurement should be 42-44 mm (1.69-1.75 in). If the measurement is not within specifications add shims under the valve spring.
4. Place the valve stem oil seal over the valve stem so the seal begins to contact the valve guide.
5. Use J 42863 to push the valve stem oil seal over the valve guide. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
6. Use J 38606 to install the valve spring and the valve cap. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
7. Install the valve keys.

Oil Pump Disassemble

1. Remove the oil pump cover screws.
2. Remove the oil pump cover.
3. Remove the oil pump gears.

Oil Pump Cleaning and Inspection

1. Use a suitable solvent to clean the oil pump.
2. Remove all old gasket material from the engine front cover and from the engine block.
3. Inspect the oil pump cover and the engine front cover for the following damage: Cracks Scoring Porous or damaged casting Damaged threads Excessive wear
4. Inspect the pressure regulator valve for the following damage: Scoring Sticking in the bore Burrs Foreign material
5. Inspect the pressure regulator spring for loss of tension or bending. Replace the pressure regulator spring if damaged.
6. Inspect the oil pump gears for the following conditions: Chipping Galling Scoring Excessive wear
7. Measure the inner oil pump gear tip clearance. If the clearance for the inner oil pump gear tip is greater than 0.152 mm (0.006 in) the oil pump must be replaced.
8. Measure the outer oil pump gear diameter clearance. If the outer oil pump gear diameter clearance is greater than 0.381 mm (0.015 in) the oil pump must be replaced.
9. Measure the oil pump gear end clearance.
10. Measure the pressure regulator valve-to-bore clearance. If the pressure regulator valve-to-bore clearance is greater than 0.076 mm (0.003 in) the oil pump must be replaced.

Engine Front Cover Cleaning and Inspection

1. Clean the engine front cover mating surface.
2. Clean the engine front cover.
3. Inspect the engine front cover threaded holes.
4. Inspect the engine front cover for damage.
5. Inspect the engine front cover mating surfaces for nicks.
6. Repair or replace the engine front cover as necessary.

Oil Pump Assemble

1. Lubricate the oil pump gears with petroleum jelly.
2. Install the oil pump gears.
3. Pack the oil pump cavity with petroleum jelly.
4. Install the oil pump cover.
5. Install the oil pump cover screws. Tighten: Tighten the screws to 11 N.m (98 lb in).

Valve Rocker Arm Cover Cleaning and Inspection

1. Clean the valve rocker arm cover mating surface.
2. Clean the valve rocker arm cover. Remove all the sludge and the oil deposits.
3. Inspect the valve rocker arm cover for damage. Replace the valve rocker arm cover if any damage is found.

Oil Pan Cleaning and Inspection

1. Clean the oil pan sealing surface.
2. Clean the oil pan. Remove all the sludge oil deposits, and sealer.
3. Inspect the threads for the oil level sensor and the engine oil drain plug.
4. Inspect the oil pan for dents, cracks, or distortion.
5. Repair or replace the oil pan as necessary.

Intake Manifold Cleaning and Inspection - Upper

1. Clean the upper intake manifold mating surfaces.
2. Clean the upper intake manifold.
3. Inspect the upper intake manifold for damage.
4. Replace the upper intake manifold as necessary.

Intake Manifold Cleaning and Inspection - Lower

1. Clean the lower intake manifold mating surfaces.
2. Clean the lower intake manifold.
3. Inspect the threaded holes for damage.
4. Inspect the lower intake manifold for damage or nicks in the mating surfaces.
5. Replace or repair the lower intake manifold as necessary.

Exhaust Manifold Cleaning and Inspection

1. Clean the exhaust manifold mating surfaces.
2. Clean the exhaust manifold.
3. Inspect the exhaust manifold mating surfaces for damage.
4. Inspect the exhaust manifold flange for straightness, using a straight edge and a feeler gage.
5. If the exhaust manifold flange is warped more than 0.05 mm (0.002 in) replace the exhaust manifold.

Water Pump Cleaning and Inspection

1. Clean the water pump mating surface.
2. Clean the water pump.
3. Inspect the water pump shaft for looseness.
4. Inspect the water pump vanes for damage.
5. Inspect the water pump mating surfaces for nicks.
6. Repair or replace the water pump as necessary.

Balance Shaft Cleaning and Inspection

1. Clean the balance shaft.
2. Inspect the balance shaft bearing/bushing journals for excessive wear.
3. Inspect the balance shaft driven gear and the balance shaft drive gear for nicks and burrs.
4. Inspect the balance shaft retainer for damage.
5. Inspect the balance shaft threads for damage.
6. Repair or replace the balance shaft components as necessary.

Thread Repair

General purpose thread repair kits are available commercially.

1. Determine the size, the pitch, and the depth of the damaged thread.
2. Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.
8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the thread insert onto the end of the mandrel.
9. Lubricate the thread insert with clean engine oil - except when installing in aluminum - and install the thread insert.
10. If the tang of the thread insert does not break off when backing out the thread insert installer, break off the tang using a drift punch.

Service Prior to Assembly

Dirt will cause premature wear of the rebuilt engine. Clean all of the components. Use the proper tools in order to measure components when inspecting for excessive wear. Repair or replace the components that are not within the manufacturers specification. When components are reinstalled into an engine, return the components to their original location, position, and direction. During assembly, lubricate all of the moving parts with clean engine oil or engine assembly lubricant unless otherwise specified. This will provide initial lubrication when the engine is first started.

Engine Prelubing

Tools Required

J 45299 Engine Preluber

1. Remove the engine oil filter, fill with clean engine oil.
2. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
3. Locate the oil pressure sensor on left side of engine and remove.
4. Install the 1/4 inch adapter P/N 509373.
5. Install the flexible hose to the adapter and open the valve.
6. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
7. Close the valve and remove the flexible hose and adapter from the engine.
8. Install the oil pressure sensor. Tighten: Tighten the oil pressure sensor to 16 N.m (12 lb ft).
9. Top off the engine oil to the proper level.

Balance Shaft Bearing and/or Bushing Installation

Tools Required

1. J 21465-13 Drive Handle Extension. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. J 36995 Balance Shaft Bearing Remover/Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

1. Dip the balance shaft bushing in clean engine oil.
2. Use the balance shaft bushing installers to install the balance shaft bushing.
3. Remove J 36995 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
4. Dip the balance shaft bearing into clean engine oil.
5. Use J 21465-13 and J 36995 to install the balance shaft bearing into the engine block. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

Camshaft Bearing Installation

Tools Required

J 33049 Camshaft Bearing Service Set

1. Select the camshaft bearings.
2. Use the following procedure to install the camshaft bearings: Assemble J 33049 according to the manufacturer's instructions. Place the bearing on the tool. NOTE: Severe engine damage may result if the oil holes are not correctly aligned. Index the bearing oil holes with the engine block oil passages.

Engine Block Plug Installation

1. Install the threaded oil gallery plugs. Tighten: Tighten the oil gallery plugs to 30 N.m (22 lb ft).
2. Install the remaining oil gallery plugs using GM P/N 12346004 (Canadian P/N 10953480) or the equivalent.
3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or the equivalent to the threads of the knock sensor.
4. Install the knock sensors. Tighten: Tighten the knock sensors to 18 N.m (13 lb ft).
5. Install the knock sensor heat shield and bolts, if applicable. Tighten: Tighten the knock sensor heat shield bolts to 50 N.m (37 lb ft).

Crankshaft and Bearings Installation

Tools Required

J 36660-A Torque Angle Meter

1. Install the upper crankshaft main bearings.
2. Install the crankshaft. Lubricate the crankshaft to crankshaft main bearing contact areas with engine oil or engine assembly lubricant.
3. Install the lower crankshaft main bearings into the main bearing caps.
4. Install the crankshaft main bearing cap bolts. Start the crankshaft main bearing cap bolts by hand. Ensure the bottom of the crankshaft main bearing cap is parallel to the bottom of the channel. Tighten: Tighten the crankshaft main bearing cap bolts in equal increments. Do not completely tighten one bolt at a time to prevent the cap from being cocked. Tighten the bolts to 70 N.m (52 lb ft) to fully seat the crankshaft main bearing caps. Loosen the bolts 360 degrees counterclockwise. Tighten the bolts to 20 N.m (15 lb ft), then 40 N.m (30 lb ft). Use J 36660-A to tighten the bolts in steps: 35 degrees + 35 degrees + 40 degrees for a total of 110 degrees.
5. Install the side main bolts. Apply GM P/N United States 12345493, GM P/N Canada 10953488 or the equivalent to the side main bolts. Tighten: Tighten the side crankshaft main bearing cap bolts to 15 N.m (11 lb ft). Use J 36660-A to tighten the bolts an additional 45 degrees.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 36660-A Torque Angle Meter
2. J 8037 Piston Ring Compressor
3. J 41507 Connecting Rod Guide Assembly. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

1. Position the crankshaft so the connecting rod journal is opposite the piston and connecting rod assembly being installed. This will aid in the installation of the connecting rod assembly.
2. Lubricate the cylinder wall with engine oil.
3. Install the connecting rod bearing inserts.
4. Lubricate the connecting rod bearing insert surface with engine oil.
5. Install J 41507 to the connecting rod. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . Hand tighten the tool to the connecting rod.
6. Install J 8037 to the piston.
7. Use J 8037 to compress the piston rings for installation of the piston and connecting rod assembly.
8. Install the piston and connecting rod assembly into the engine. IMPORTANT: Ensure the arrow on top of the piston or the markings made during removal face towards the front of the engine or are in the same location as when removed.
9. Use J 41507 to pull the connecting rod into place. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
10. Remove J 41507 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
11. Install the connecting rod bearing cap.
12. Install the connecting rod bearing cap bolts. Tighten: Tighten the connecting rod bearing cap bolts to 27 N.m (20 lb ft) + 50 degrees using J 36660-A .
13. Pry the connecting rod back and forth and check for binding. If necessary loosen and retighten the connecting rod bearing cap.
14. Measure the connecting rod side clearance.

Crankshaft Rear Oil Seal and Housing Installation

Tools Required

1. EN-47623 Rear Main Seal Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. J 8092 Drive Handle. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
3. J 45059 Angle Meter

1. Carefully remove protection sleeve from the new rear oil seal assembly.
2. Clean and inspect the crankshaft rear oil seal housing making sure it is free of any foreign material.
3. With all bolts removed from the housing, place it face up on a flat clean surface.
4. Lubricate the inner diameter and outer diameter of the new seal with engine oil.
5. Lubricate the outer diameter of EN-47623 with engine oil. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
6. Install the seal onto EN-47623 by placing the seal on an angle and using a twisting motion until it is fully seated. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
7. Place EN-47623 along with J 8092 onto the housing as shown and apply a constant downward force until the seal is fully seated. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
8. Clean the crankshaft sealing surface with a clean, lint free towel. Inspect the crankshaft sealing surface and leading edge of the crankshaft for burrs/sharp edges that could damage the rear main oil seal. Remove any burrs or sharp edges with crocus cloth before proceeding.
9. Install the crankshaft rear oil seal housing gasket and housing onto the engine.
10. Install the crankshaft rear oil seal housing bolts and finger tighten.
11. Place a straight edge on the engine block oil pan flange and the crankshaft rear oil seal housing flange. Use a feeler gage to ensure there is no more than 0.10 mm (0.004 in) step on each side. If necessary, gently rotate the crankshaft rear oil seal housing to make the step equal on each side.
12. Tighten the crankshaft rear oil seal housing bolts. Tighten: Tighten the crankshaft rear oil seal housing bolts to 15 N.m (11 lb ft). Use J 45059 to tighten the bolts an additional 50 degrees.
13. Recheck the step height on each side to ensure the crankshaft rear oil seal housing did not move. If the step height is beyond specification, reinstall the crankshaft rear oil seal housing and measure the step again. Replace the crankshaft rear oil seal housing if the clearance is still beyond specification.
14. Continue with oil pan installation as outlined in the Service Information Manual.

Crankshaft Rear Oil Seal Installation

Tools Required

J 38196 Rear Crankshaft Seal Installer. See Special Tools .

1. Apply engine oil to the inside diameter and the outside diameter of the crankshaft rear oil seal.
2. Slide the crankshaft rear oil seal over the mandrel until the back bottoms squarely against the collar of the tool.
3. Use the following procedure to install the seal: NOTE: Refer to «Fastener Notice»(/chevrolet/monte-carlo/vi-1999-2007/remont/oem-general-information/#cautions-and-notices__fastener-notice) in Cautions and Notices. Attach J 38196 to the crankshaft by hand or tighten attaching screws to 5 N.m (54 lb in). See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . Turn the T handle of J 38196 so the collar pushes the crankshaft rear oil seal into the bore. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . Turn the handle until the tool is bottomed out. Ensure the crankshaft rear oil seal is seated properly. Loosen the T handle of J 38196 until it comes to a stop. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) . Remove the attaching screws.

Camshaft Installation

1. Coat the camshaft with prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
2. Install the camshaft.
3. Install the camshaft thrust plate.
4. Install the camshaft thrust plate bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).

Balance Shaft Installation

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. J 21465-13 Drive Handle Extension. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
3. J 36660-A Torque Angle Meter. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
4. J 36996 Balance Shaft Installer. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

1. Use J 21465-13 and J 36996 to install the balance shaft into the engine block. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
2. Install the balance shaft retainer.
3. Install the balance shaft retainer bolts. Tighten: Tighten the balance shaft retainer bolts to 30 N.m (22 lb ft).
4. Install the balance shaft driven gear.
5. Install the balance shaft driven gear bolt. Tighten: Tighten the balance shaft driven gear bolt to 22 N.m (16 lb ft). Use J 36660-A to tighten the bolt an additional 70 degrees.
6. Using J 8001 measure the balance shaft end play. End play must not exceed 0.028 mm (0.008 in).
7. Using J 8001 measure the balance shaft radial play at the rear. Radial play must be between 0.0127-0.119 mm (0.0005-0.0047 in).
8. Install the balance shaft drive gear.
9. Install the camshaft sprocket.
10. Turn the camshaft so the timing mark on the camshaft sprocket is straight down.
11. Remove the camshaft sprocket and balance shaft drive gear.
12. Turn the balance shaft so the timing mark on the balance shaft driven gear points straight down.
13. Partially install the balance shaft drive gear so the gear teeth are not engaged.
14. Align the marks on the balance shaft driven gear and the balance shaft drive gear. Do this by turning the balance shaft.
15. Once marks are aligned, fully seat balance shaft drive gear and engage gear teeth.
16. Turn the crankshaft so the number one piston is at top dead center.
17. Install the timing chain and camshaft sprocket.
18. Using J 8001 measure the gear lash at four places. Measure every quarter turn. Gear lash must be between 0.050-0.127 mm (0.002-0.005 in).

Timing Chain and Sprockets Installation

Tools Required

J 36660-A Torque Angle Meter

1. Install the crankshaft balancer key into the crankshaft keyway. The crankshaft balancer key should be parallel to the crankshaft or with a slight incline.
2. Install the timing chain on the sprockets. Align the timing marks.
3. Install the timing chain, the crankshaft sprocket, and the camshaft sprocket.
4. Install the camshaft sprocket bolt. Tighten: Tighten the camshaft sprocket bolt to 100 N.m (74 lb ft). Use J 36660-A to tighten the camshaft sprocket bolt an additional 90 degrees.
5. Install the timing chain dampener. Tighten: Tighten the timing chain dampener bolt to 22 N.m (16 lb ft).

Oil Filter Adapter Installation

Tools Required

J 36660-A Torque Angle Meter

1. Install the oil pressure relief valve spring into the engine front cover.
2. Install the oil pressure relief 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: Tighten the oil filter adapter bolts to 15 N.m (11 lb ft). Using J 36660-A rotate each bolt an additional 50 degrees.
6. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).

Engine Front Cover Installation

Tools Required

J 36660-A Torque Angle Meter

1. Install the engine front cover gasket.
2. Install the engine front cover. Align the cogs on the crankshaft sprocket with the cogs on the oil pump in the engine front cover.
3. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or the equivalent to the engine front cover bolt threads.
4. Install the engine front cover bolts. Tighten: Tighten the engine front cover bolts to 20 N.m (15 lb ft). Use the J 36660-A to tighten the engine front cover bolts an additional 40 degrees.
5. Install the oil pan to engine front cover bolts. Tighten: Tighten the oil pan bolts to 14 N.m (125 lb in).
6. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
7. Install the crankshaft position sensor. Tighten: Tighten the crankshaft position sensor studs to 30 N.m (22 lb ft).
8. Install the crankshaft position sensor shield.

Crankshaft Front Oil Seal Installation

Tools Required

J 35354 Seal Installer. See Special Tools .

1. Coat the inside diameter of the crankshaft front oil seal with lubricant GM P/N 12345616 (Canadian P/N 993182) or the equivalent.
2. Use J 35354 and a soft faced hammer to install the crankshaft front oil seal. See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .
3. Remove J 35354 . See «Special Tools»(/chevrolet/monte-carlo/vi-1999-2007/remont/mechanical/#engine-mechanical-38l-l36__special-tools) .

Oil Pump Pipe and Screen Assembly Installation

1. Install the oil pump pipe and screen assembly gasket.
2. Install the oil pan gasket.
3. Install the oil pump pipe and screen assembly.
4. Install the oil pump pipe and screen assembly bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).

Oil Pan Installation

1. For steel oil pans, apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) to the topside of the new windage tray gasket. Apply the RTV sealant directly over the sealing bead.
2. Install the NEW windage tray gasket onto the engine.
3. Apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) to the bottom side of the new windage tray gasket. Apply the RTV sealant directly over the sealing bead.
4. For aluminum oil pans, apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148), ensuring that the sealer also completely fills the groove in the oil pan.
5. To ensure proper sealing, apply additional sealer at the four points called out in the illustration (1).
6. Install the oil pan and oil pan windage tray gasket - if applicable.
7. Clean the oil pan bolts of all debris.
8. Apply one drop of GM P/N 12345382 (Canadian P/N 10953489) to each bolt.
9. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 14 N.m (125 lb in).
10. Install the oil level sensor. Tighten: Tighten the oil level sensor to 20 N.m (15 lb ft).

Valve Lifter Installation

1. Dip the valve lifters in prelube GM P/N 12345501 (Canadian 992704) or the equivalent.
2. Install the valve lifters.
3. Install the valve lifter guides.
4. Install the valve lifter guide bolts. Tighten: Tighten the valve lifter guide bolts to 30 N.m (22 lb ft).

Cylinder Head Installation - Right

Tools Required

J 36660-A Torque Angle Meter

1. Install the cylinder head gasket. Ensure the arrows point towards the front of the engine. The right cylinder head gasket has the letter R stamped next to the arrow.
2. Install the cylinder head.
3. Install new cylinder head bolts. Tighten: Tighten the cylinder head bolts to 50 N.m (37 lb ft) in sequence. Using J 36660-A rotate each cylinder head bolt an additional 120 degrees.

Cylinder Head Installation - Left

Tools Required

J 36660-A Torque Angle Meter

1. Install the cylinder head gasket. Ensure the arrows point towards the front of the engine. The left cylinder head gasket has the letter L stamped next to the arrow.
2. Install the cylinder head.
3. Install new cylinder head bolts. Tighten: Tighten the cylinder head bolts to 50 N.m (37 lb ft) in sequence. Using J 36660-A rotate each cylinder head bolt an additional 120 degrees.

Valve Rocker Arm and Push Rod Installation

Tools Required

J 36660-A Torque Angle Meter

1. Install the pushrod guide plate.
2. Install the push rods.
3. Install the valve rocker arm bearing retainer.
4. Coat the valve stem tip and pushrod tip with prelube GM P/N 1052367 (Canadian P/N 992869) or the equivalent.
5. Install the valve rocker arms.
6. Apply GM P/N 12345493 (Canadian P/N 10953488) threadlocker or the equivalent to the valve rocker arm bolt threads.
7. Install the valve rocker arm bolts. Tighten: Tighten the valve rocker arm bolts to 15 N.m (11 lb ft) + 90 degrees using J 36660-A .

Valve Rocker Arm Cover Installation - Right

1. Install the valve rocker arm cover.
2. Apply GM P/N 12345382 (Canadian P/N 10953489) threadlocker or the equivalent to the threads.
3. Install the valve rocker arm cover bolts. Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).

Valve Rocker Arm Cover Installation - Left

1. Install the valve rocker arm cover.
2. Apply GM P/N 12345382 (Canadian P/N 10953489) threadlocker or the equivalent to threads.
3. Install the valve rocker arm cover bolts. Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
4. Install the engine mount strut upper bracket bolts (1) if applicable. Tighten: Tighten the engine mount strut upper bracket bolts (1) to 50 N.m (37 lb ft).
5. Install the engine mount strut bracket and nuts (2), if applicable. Tighten: Tighten the engine mount strut bracket and nuts (2) to 50 N.m (37 lb ft).

Exhaust Manifold Installation - Right

1. Install the exhaust manifold studs. Tighten: Tighten the exhaust manifold studs to 10 N.m (89 lb in).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold.
4. Install the exhaust manifold bolts and nuts. Tighten: Tighten the exhaust manifold bolts and nuts to 30 N.m (22 lb ft).
5. Install the right side spark plugs. Tighten: Tighten the spark plugs to 27 N.m (20 lb ft) when installing the spark plugs in to a new cylinder head. Tighten the spark plugs to 15 N.m (13 lb ft) when re-installing the spark plugs after initial installation.
6. Install the fuel injector sight shield cover bracket.
7. Install the fuel injector sight shield cover bracket nuts. Tighten: Tighten the fuel injector sight shield bracket nuts to 30 N.m (22 lb ft).
8. Install the right engine lift hook.
9. Install the right engine lift hook nut and bolt. Tighten: Tighten the right engine lift hook nut and bolt to 30 N.m (22 lb ft).
10. Coat the threads of the heated oxygen sensor with anti-seize compound.
11. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).
12. Install the heated oxygen sensor lead.

Exhaust Manifold Installation - Left

1. Install the exhaust manifold studs. Tighten: Tighten the exhaust manifold studs to 10 N.m (89 lb in).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold.
4. Install the exhaust manifold bolts and nuts. Tighten: Tighten the exhaust manifold bolts and nuts to 30 N.m (22 lb ft).
5. Install the left side spark plugs. Tighten: Tighten the spark plugs to 27 N.m (20 lb ft) when installing the spark plugs in to a new cylinder head. Tighten the spark plugs to 15 N.m (13 lb ft) when re-installing the spark plugs after initial installation.
6. Install the left engine lift hook.
7. Install the left engine lift hook nut and bolt. Tighten: Tighten the left engine lift hook nut and bolt to 30 N.m (22 lb ft).
8. Install the engine mount strut lower bracket.
9. Install the engine mount strut lower bracket nut and bolts. Tighten: Tighten the engine mount strut lower bracket bolts to 50 N.m (37 lb ft). Tighten the engine mount strut lower bracket nut to 25 N.m (18 lb ft)
10. Install the left exhaust manifold heat shield.
11. Install the left exhaust manifold heat shield nuts. Tighten: Tighten the left exhaust manifold heat shield nuts to 20 N.m (15 lb ft).

Intake Manifold Installation - Lower

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) or the equivalent to the bolt threads.
4. Install the lower intake manifold bolts. Tighten: Tighten the lower intake manifold bolts in sequence to 15 N.m (11 lb ft).

Exhaust Gas Recirculation (EGR) and EGR Pipe Installation

1. Install the EGR inlet pipe into the RH exhaust manifold as the EGR valve adapter assembly is installed onto the cylinder head.
2. Install the EGR valve adapter assembly to cylinder head bolts and the EGR inlet pipe to RH exhaust manifold bolt. Tighten: Tighten the EGR valve adapter assembly to cylinder head bolts to 50 N.m (37 lb ft). Tighten the EGR inlet pipe to RH exhaust manifold bolt to 29 N.m (21 lb ft).
3. Install the EGR valve outlet pipe to the lower intake and the EGR valve adapter assembly.
4. Install the EGR valve outlet pipe bolt and nut. Tighten: Tighten the EGR valve outlet pipe bolt and nut to 29 N.m (21 lb ft).
5. Install the EGR valve gasket and EGR valve.
6. Install the EGR valve nuts. Tighten: Tighten the EGR valve nuts to 29 N.m (21 lb ft).
7. Install the lower right exhaust manifold heat shield.
8. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
9. Install the upper right exhaust manifold heat shield.

Intake Manifold Installation - Upper

1. Install the upper intake manifold gasket.
2. Install the upper intake manifold.
3. Install the upper intake manifold bolts. Tighten: Tighten the upper intake manifold bolts in sequence to 10 N.m (89 lb in).
4. Install the throttle body gasket.
5. Install the throttle body.
6. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the threads.
7. Install the throttle body nuts. Tighten: Tighten the throttle body nuts to 10 N.m (89 lb in).
8. Install the engine wiring harness heat shield.
9. Install the engine wiring harness heat shield bolt and nut. Tighten: Tighten the engine wiring harness heat shield bolt and nut to 10 N.m (89 lb in).
10. Install the accelerator control cable bracket.
11. Install the accelerator control cable bracket bolts. Tighten: Tighten the accelerator control cable bracket bolts to 16 N.m (12 lb ft).
12. Install the fuel injector rail.
13. Install the fuel injector rail nuts. Tighten: Tighten the fuel injector rail nuts to 10 N.m (89 lb in).
14. Install the ignition control module assembly.
15. Install the ignition control module assembly bracket nuts. Tighten: Tighten the ignition control module assembly bracket nuts to 50 N.m (37 lb ft).
16. Connect the ignition control module connector to the ignition control module assembly.
17. Connect the ignition wires to the fuel injector rail.
18. Install the spark plug wires.

Water Pump Installation

1. Install the water pump gasket.
2. Install the water pump.
3. Install the water pump bolts. Tighten: Tighten the small water pump bolts to 22 N.m (16 lb ft). Tighten the large water pump bolts to 34 N.m (25 lb ft).
4. Install the water pump pulley.
5. Install the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 13 N.m (116 lb in).

Water Outlet and Thermostat Installation

1. Install the thermostat.
2. Install the water outlet.
3. Install the water outlet bolt and stud. Tighten: Tighten the water outlet bolt and stud to 27 N.m (20 lb ft).

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube. Lubricate the O-ring with engine oil and make sure it is in place. Make sure the assembly is fully seated in the engine block.
2. Install the oil level indicator tube nut. Tighten: Tighten the nut to 19 N.m (14 lb ft).
3. Install the oil level indicator.

Drive Belt Tensioner Installation

1. Install the drive belt tensioner bracket.
2. Install the drive belt tensioner bracket bolts. Tighten: Tighten the drive belt tensioner bolts to 50 N.m (37 lb ft).

Engine Flywheel Installation

Tools Required

J 45059 Angle Meter

1. Install the flywheel.
2. Install the new flywheel bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft). Use the J 45059 to tighten the bolts an additional 50 degrees.

Crankshaft Balancer Installation

Tools Required

1. J 37096 Flywheel Holder
2. J 45059 Angle Meter

1. Lubricate the seal surface of the crankshaft balancer with engine oil.
2. Install the crankshaft balancer.
3. Use J 37096 to hold the flywheel.
4. Install the crankshaft balancer bolt. Tighten: Tighten the crankshaft balancer bolt to 150 N.m (111 lb ft). Use J 45059 to tighten the crankshaft balancer bolt an additional 76 degrees.

Scheme 48

The Crankcase Ventilation System is used to consume crankcase vapors (1) in the combustion process instead of venting them to atmosphere. 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 intake manifold.

Scheme 49

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 crankshaft balancer pulley
4. The accessory drive components: The power steering pump The generator The A/C compressor The water pump

The drive belt system uses one belt. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belt is made of different types of rubbers - chloroprene or EPDM - and have different layers or plys 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.

Engine Construction

Starting at the front of the engine, the cylinders of the left bank are numbered 1-3-5 and the cylinders of the right bank are numbered 2-4-6. The crankshaft is supported in the engine block by four bearings. The crankshaft is counterbalanced by the flywheel, the crankshaft balancer, and the weights cast into the crankshaft. Additional counterbalancing is obtained from the balance shaft which rides in the engine block above the camshaft and is driven by the camshaft. All 3800 engines are even-firing, the cylinders fire at equal 120 degree intervals of crankshaft rotation. The location of the crankshaft journals has been offset by 30 degrees to fire the cylinders at 120 degree intervals of crankshaft rotation. The camshaft lobes and timing also reflect the 120 degree intervals. The even firing crankshaft provides an equal interval of 120 degrees between ignition of each of the cylinders throughout the firing order. The firing order is 1-6-5-4-3-2. The aluminum alloy pistons have slipper skirts and are cam turned. Four drilled holes or casted slots in the oil ring grooves permit drain back of the oil collected by the oil ring. The camshaft is supported by four bearings in the engine block and is driven by the crankshaft through sprockets and a timing chain. The cylinder heads are cast iron and incorporate integral valve stem guides. Right and left cylinder heads are identical and are interchangeable, but it is good practice to reinstall the cylinder heads on the side from which they are removed. The intake manifold is bolted to the inner faces of both cylinder heads so it connects with all inlet ports.

Each exhaust and intake valve has a valve spring to insure positive seating throughout the operating speed range. The valve rocker arms for each bank of the cylinders pivot on pedestals bolted to the cylinder head. Hydraulic roller valve lifters and tubular push rods are used to operate overhead rocker arms and valves of both banks of the cylinders from a single camshaft. This system requires no lash adjustment at the time of assembly or service.

In addition to its normal function of a cam follower, each valve lifter also serves as an automatic adjuster which maintains zero lash in the valve train under all operating conditions. By eliminating all lash in the valve train and also providing a cushion of oil to absorb operating shocks, the valve lifter promotes quiet valve operation. It also eliminates the need for periodic valve adjustment to compensate for wear of parts. Oil is supplied to the valve lifter through a hole in the side of the valve lifter body which indexes with a groove and a hole in the valve lifter plunger. Oil is then metered past the oil metering valve in the valve lifter, through the push rods to the valve rocker arms. When the valve lifter begins to move up the camshaft lobe, the check ball is held against its seat in the plunger by the check ball spring which traps the oil in the base of the valve lifter body below the plunger.

The plunger and the valve lifter body then raise as a unit, pushing up the push rod to open the valve. The force of the valve spring which is exerted on the plunger through the valve rocker arm and push rod, causes a slight amount of leakage between the plunger and the valve lifter body. This leakage allows a slow escape of trapped oil in the base of the valve lifter body. As the valve lifter rolls down the other side of the camshaft lobe and reaches the base circle or valve closed position, the plunger spring quickly moves the plunger back (up) to its original position. This movement causes the check ball to open against the ball spring, and any oil inside the plunger is drawn into the base of the valve lifter. This restores the valve lifter to the zero lash.

New Product Information

The purpose of New Product Information is to highlight or indicate important product changes from the previous model year.

Changes may include one or more of the following items

1. A component comparison from the previous year
2. Fastener changes
3. Torque values and/or fastener tightening strategies
4. Changed engine specifications
5. New sealants and/or adhesives
6. Disassembly and assembly procedure revisions
7. Engine mechanical diagnostic procedure revisions
8. New special tools required

Component Comparison

Air injection has been deleted.

Fastener Changes

No fastener changes for 2003.

Torque Values and/or Fastener Tightening Strategies

No torque value changes for 2003.

Changed Engine Specifications

A new Engine Mechanical Specifications chart has been implemented into the 2003 service manual.

New Sealants and/or Adhesives

No new sealants and or adhesives for 2003.

Disassembly and Assembly Procedure Revisions

EGR and Pipe Removal and Installation has been added.

Engine Mechanical Diagnostic Procedure Revisions

1. Coolant in Combustion Chamber Diagnostic Procedure has been added.
2. Coolant in Engine Oil Diagnostic Procedure has been added.

New Special Tools Required

J 45299 Engine Preluber has been added.

Scheme 50

The engine lubrication system is of the force-feed type. The oil is supplied under full pressure to the crankshaft, connecting rods, valve lifters, camshaft, and rear balance shaft bearing. A controlled volume of oil is supplied to the valve rocker arms and push rods. All other moving parts are lubricated by gravity flow or splash. The engine oil is stored in the lower crankcase (oil pan) which is filled through a filler opening in the valve rocker arm cover. A removable oil level indicator, on the left side of the engine block, is provided to check the oil level. The oil pump is located in the engine front cover and is driven by the crankshaft. It is a gerotor-style pump which is a combination of a gear and a rotor pump. It is connected by a passage in the cylinder block to an oil screen and pipe assembly. The screen is submerged in the oil supply and has ample volume for all operating conditions. If the screen becomes clogged, oil may be drawn into the system through the oil pressure relief valve in the oil filter adapter. Oil is drawn into the pump through the screen and pipe assembly, and a passage in the crankcase, connecting to the passages in the engine front cover. Oil is discharged from the oil pump to the oil filter adapter. The oil filter adapter consists of an oil filter bypass valve and a nipple for installation of an oil filter. The spring-loaded oil pressure relief valve, located in the engine front cover, limits the oil pressure. The oil filter bypass valve opens when the oil filter is restricted to approximately 68.95 kPa (10 psi) of pressure difference between the oil filter inlet and discharge. The oil will then bypass the oil filter and channel unfiltered oil directly to the main oil galleries of the engine. A full-flow oil filter is externally mounted to the oil filter adapter on the lower right front side of the engine. If the filter element becomes restricted, not allowing engine oil to pass through, a spring-loaded bypass valve opens. The main oil galleries run the full length of the engine block and cut into the valve lifter guide holes to supply oil at full pressure to the valve lifters. Holes, drilled from the crankshaft bearings to the main oil gallery, intersect the camshaft bearing bores to supply oil to the cam bearings.

Oil is transferred from the crankshaft bearings to the connecting rod bearings through holes drilled in the crankshaft. Pistons, piston pins, and cylinder walls are lubricated by oil splash from the crankshaft and connecting rods.

Each valve rocker arm and valve is supplied with oil through the tubular push rod. The oil comes from the inside of the valve lifter passing around the metering valve and through a hole in the push rod seat. Oil from the push rod passes through a hole in the push rod seat, and emerges on top of the push rod seat boss.

Cleanliness and Care

An automobile engine is a combination of many of the following surfaces

1. Machined
2. Honed
3. Polished
4. Lapped

The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service any internal engine part, cleanliness and care are important. Apply a liberal coating of engine oil to the friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, practice proper cleaning and protection procedures to the machined surfaces and to the friction areas.

Note. Engine damage may result if an abrasive paper, pad, or motorized wire brush is used to clean any engine gasket surfaces.

Whenever you remove the valve train components, keep the components in order. Follow this procedure in order to install the components in the same locations and with the same mating surfaces as when removed.

Disconnect the negative battery cables before you perform any major work on the engine. For more information on the disconnection of the battery, refer to Engine Electrical.

Separating Parts

The components of an internal combustion engine develop wear patterns with their mating components. During disassembly of the engine, parts should be separated and kept in order so they may be reinstalled in the same location from which they were removed.

Replacing Engine Gaskets

1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in the service procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service procedure.
2. Use a rubber mallet in order to separate components. Bump the part sideways in order to loosen the components. Perform the bumping at the bends or at the reinforced areas in order to prevent the distortion of components.
3. Remove all of the gasket and the sealing material from the component using a plastic or a wood scraper. Do not gouge or scrape the sealing surfaces.
4. When assembling components, use only the sealant specified in the service procedure. Ensure that the sealing surfaces are clean and free of debris or oil. When applying sealant to a component, apply a bead size as specified in the service procedure.
5. Tighten the bolts to the specifications.

Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealer

The following 2 types of sealer are commonly used in engines

1. The RTV sealer
2. The anaerobic gasket eliminator sealer

Follow the service procedure instructions. Use the correct sealer in the proper place in order to prevent oil leaks. Do not interchange the 2 types of sealers. Use the sealer recommended in the service procedure.

Applying RTV Sealer

1. Do not use the room temperature vulcanizing (RTV) sealant in areas where extreme temperatures are expected. These areas include the following locations: The exhaust manifold The head gasket The other surfaces where gasket eliminator is specified
2. Use a rubber mallet in order to separate the components sealed with RTV sealant. Bump the part sideways in order to shear the RTV sealer. Perform the bumping at the bends or the reinforced areas in order to prevent distortion of the components. The RTV sealant is weaker in shear (lateral) strength than in tensile (vertical) strength.
3. Do not use the following items in order to clean the gasket surfaces: Abrasive pads Sand Paper Power tools

These methods of cleaning may damage the part.

Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.

1. Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite® brand gasket remover P/N 4MA or the equivalent. Follow all of the safety recommendations and the directions that are on the container. IMPORTANT: Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions: Prevent you from properly seating the bolt Cause damage when you tighten the bolt
2. Apply the RTV sealant to a clean surface. Use a bead size as specified in the procedure. Apply the bead to the inside of any bolt holes.
3. Assemble the components while the RTV sealant is still wet (within 3 minutes). Do not wait for the RTV sealant to skin over.
4. Tighten the bolts to specifications.

Applying Anaerobic Sealer

The anaerobic gasket eliminator hardens in the absence of air. This type of sealer is used where 2 rigid parts (such as castings) are assembled together. When 2 rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.

Do not use the following items in order to clean the gasket surfaces

1. Abrasive pads
2. Sand paper
3. Power tools

These methods of cleaning may damage the part.

Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.

1. Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite® brand gasket remover P/N 4MA or the equivalent. Follow all of the safety recommendations and the directions that are on the container.
2. Apply a continuous bead of the gasket eliminator to 1 flange. Clean and dry any surfaces that you will reseal.
3. Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions: Prevent you from properly seating the bolt Cause damage when you tighten the bolt
4. Spread the sealer evenly in order to get a uniform coating on the sealing surface.
5. Tighten the bolts to the specifications.
6. Remove the excess sealer from the outside of the joint.

Tools and Equipment

Work in a clean and well-lit area. Have the following components available before you begin to work

1. A suitable parts cleaning tank
2. A compressed air supply
3. Trays, in order to keep the parts and the fasteners organized
4. An adequate set of hand tools

An approved engine repair stand will prevent personal injury or damage to the engine components. The special tools are designed in order to quickly and safely accomplish the operations for which the tools are intended. Using the tools will minimize possible damage to the engine components. Precision measuring tools are required for the inspection of certain critical components. Torque wrenches are needed for the correct assembly of various parts.

Special Tools

Special Tools Illustration Tool Number/Description EN 47623 Rear Main Seal Installer J 6125-1B Slide Hammer J 7872 Magnetic Base Indicator Set J 8001 Dial Indicator Set J 8037 Piston Ring Compressor J 8087 Cylinder Bore Gage J 8092 Drive Handle J 9666 Valve Spring Tester J 21465-13 Drive Handle Extension J 23590 Spark Plug Port Adapter J 24270 Cylinder Ridge Reamer J 25087-C Oil Pressure Test and Pump Primer J 28428-E High Intensity Black Light J 28467-B Universal Engine Support Fixture J 28467-90A Engine Support Adapters J 33049 Camshaft Bearing Service Set J 35354-A Seal Installer J 35667-A Cylinder Head Leakdown Tester J 36660-A Torque Angle Meter J 36995-A Balance Shaft Bearing Remover/Installer J 36996 Balance Shaft Installer J 37096 Flywheel Holder J 38196 Rear Crankshaft Seal Installer J 38197-A Crankshaft Balancer Remover J 38606 Valve Spring Compressor J 38722 Compression Tester J 41131 Engine Tilt Strap J 41348 Main Bearing Cap Puller J 41349 Rear Cover Aligner J 41507 Connecting Rod Assembly Guide J 42863 Valve Stem Seal Installer J 45299 Engine Preluber

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

See also:
• Strategy Based Diagnosis
• Checking Aftermarket Accessories
• Diagnostic Starting Point - Engine Cooling
• KNOCK SENSOR
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Electrical Center Identification Views
• Battery Disconnect Caution
• Explanation of Scheduled Services
• Belt Dressing Notice
• Diagnostic Starting Point - Vibration Diagnosis and Correction
• Cooling Fan and Shroud Replacement
• Battery Negative Cable Disconnect/Connect Procedure
• Heater Hose Replacement - Inlet (3.8L)
• Fastener Notice
• TRANSAXLE MOUNT
• Brace Replacement - Cross Vehicle
• Lifting and Jacking the Vehicle
• Tire and Wheel Removal and Installation
• Special Fastener Notice
• CKP SYSTEM VARIATION LEARN PROCEDURE
• Wheel Drive Shaft Replacement
• Exhaust Manifold Replacement - Left (3.8L)
• Engine Emission Notice
• Vacuum Brake Booster Check Valve and/or Hose Replacement
• Maintenance Items
• Capacities - Approximate Fluid
• Fluid and Lubricant Recommendations
• Thread Repair
• Cleaning Solvent Caution
• Safety Glasses and Compressed Air Caution
• Safety Glasses Caution
• Disassembled Views
• Drive Belt System Description
• New Product Information
• Base Engine Misfire without Internal Engine Noises
• Base Engine Misfire with Abnormal Internal Lower Engine Noises
• Base Engine Misfire with Abnormal Valve Train Noise
• Base Engine Misfire with Coolant Consumption
• Base Engine Misfire with Excessive Oil Consumption
• Engine Compression Test
• Engine Noise on Start-Up, but Only Lasting a Few Seconds
• Upper Engine Noise, Regardless of Engine Speed
• Lower Engine Noise, Regardless of Engine Speed
• Engine Noise Under Load
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Oil Consumption Diagnosis
• Oil Leak Diagnosis
• Drive Belt Tensioner Diagnosis
• Engine Flywheel Replacement
• Crankshaft Balancer Replacement
• Cylinder Leakage Test
• Cylinder Head Cleaning and Inspection
• Cylinder Head Replacement - Right
• Special Tools
• Piston, Connecting Rod, and Bearings Cleaning and Inspection
• Engine Block Cleaning and Inspection
• Fastener Tightening Specifications
• Engine Support Fixture
• Valve Lifters and Guides Cleaning and Inspection
• Oil Pump Cleaning and Inspection
• Timing Chain and Sprockets Cleaning and Inspection
• Cylinder Head Disassemble
• Cylinder Head Assemble
• Rotating the Engine for Service Access
• Engine Mechanical Specifications