GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Monte Carlo 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Engine Replacement

Removal Procedure

    Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  3. Drain the engine oil.
  4. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  5. Remove the diagonal braces. Refer to Front End Sheet Metal Diagonal Brace Replacement in Body Front End.
  6. Remove the engine mount struts from the engine mount strut brackets. Refer to Engine Mount Strut Replacement .
  7. Remove the throttle body air inlet duct and the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
  8. Remove the washer reservoir bolts and retainers.
  9. Remove the underhood accessory wiring junction block. Refer to Accessory Wiring Junction Block Replacement in Body Front End.
  10. Remove the washer reservoir.
  11. Remove the hood. Refer to Hood Replacement in Body Front End.
  12. Disconnect the radiator inlet hose from the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  13. Disconnect the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  14. Remove the A/C compressor from the engine. Suitably support the compressor. Refer to Air Conditioning Compressor Replacement in HVAC.
  15. Disconnect the starter motor wiring harness. Refer to Starter Motor Replacement in Engine Electrical.

    16. Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

  16. Disconnect the throttle and cruise cables from the bracket. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.8L.
  17. Remove the wiring harness from the top of the engine.

    18. Important: Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.8L.

  18. Disconnect the fuel lines from the fuel rail. Lay the fuel lines aside. Refer to Fuel Hose/Pipes Replacement - Filter to Engine in Engine Controls - 3.8L.
  19. Disconnect the vacuum lines.
  20. Disconnect the heater hoses. Refer to Heater Hoses Replacement in HVAC.
  21. Remove the engine mount strut brackets from the upper radiator support. Refer to Engine Mount Strut Bracket Replacement .
  22. Remove the power steering pump and reposition. Refer to Power Steering Pump Replacement in Power Steering System.
  23. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  24. Disconnect the starter motor wiring harness and remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  25. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
  26. Remove the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle 4T65-E.
  27. Remove the engine mount nuts and bolts. Refer to Engine Mount Replacement .
  28. Remove the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65-E.
  29. Remove the three-way catalytic converter pipe from the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.

    30. Object Number: 160965 Size: SH
  30. Remove the lower transaxle-to-engine bolt (6) and stud (1).
  31. Lower the vehicle.
  32. Install the engine lifting device.

    33. Object Number: 160965 Size: SH
  33. Remove the upper transaxle-to-engine bolts (3, 4 and 5) and stud (2).
  34. Remove the engine from the vehicle.
  35. Remove the flywheel. Refer to Engine Flywheel Removal .
  36. Install the engine to a engine stand.
  37. Remove the generator. Refer to Generator Replacement or Generator Replacement .
  38. Remove the ignition control module. Refer to Ignition Control Module Replacement in Engine Controls - 3.8L.
  39. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  40. Remove the engine mount bracket bolts. Refer to Engine Mount Bracket Replacement .

Installation Procedure
  1. Install the engine mount bracket bolts. Refer to Engine Mount Bracket Replacement .
  2. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  3. Install the ignition control module. Refer to Ignition Control Module Replacement in Engine Controls - 3.8L.
  4. Install the generator. Refer to Generator Replacement .
  5. Install the flywheel. Refer to Engine Flywheel Removal .
  6. Install the engine to the vehicle.

    7. Object Number: 160965 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  7. Install the upper transaxle-to-engine bolts (3, 4 and 5) and stud (2).

    8. Tighten
    Tighten the upper transaxle-to-engine bolts (3, 4 and 5) and stud (2) to 75 N·m (55 lb ft).

  8. Remove the engine lifting device.
  9. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    10. Object Number: 160965 Size: SH
  10. Install the lower transaxle-to-engine bolt (6) and stud (1).

    11. Tighten
    Tighten the lower transaxle-to-engine bolt (6) and stud (1) to 75 N·m (55 lb ft).

  11. Install the three-way catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  12. Install the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle 4T65-E.
  13. Install the engine mount lower nuts and bolts. Refer to Engine Mount Replacement .
  14. Install the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transmission - 4T65-E.
  15. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
  16. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  17. Lower the vehicle.
  18. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
  19. Install the engine mount strut brackets to the upper radiator support. Refer to Engine Mount Strut Bracket Replacement .
  20. Install the heater hoses. Refer to Heater Hoses Replacement in HVAC.
  21. Connect the vacuum lines.
  22. Install the wiring harness to the engine.

    23. Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

    In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

  23. Install the throttle and cruise cables to the bracket. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.8L.
  24. Install the starter motor wiring harness. Refer to Starter Motor Replacement in Engine Electrical.
  25. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC.
  26. Install the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  27. Install the radiator inlet hose to the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  28. Install the throttle body air inlet duct and the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
  29. Install the hood. Refer to Hood Replacement in Body Front End.
  30. Return the washer reservoir to the proper position.
  31. Install the underhood accessory wiring junction block. Refer to Accessory Wiring Junction Block Replacement in Body Front End.
  32. Install the washer reservoir bolts and retainers.
  33. Install the diagonal braces. Refer to Front End Sheet Metal Diagonal Brace Replacement in Body Front End.
  34. Fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement .
  35. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  36. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  37. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.