GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Oldsmobile 🢒 2002 🢒 Intrigue 🢒 Engine 🢒 Engine Mechanical - 3.5L 🢒 Engine Replacement

Removal Procedure
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  4. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  5. Remove the lower air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement in Engine Cooling.
  6. Lower the vehicle.
  7. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  8. Remove the left diagonal brace. Refer to Front End Sheet Metal Diagonal Brace Replacement in Body Front End.
  9. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.5L.
  10. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  11. Remove the generator. Refer to Generator Replacement in Engine Electrical.
  12. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.5L.
  13. Remove the fuel lines from the fuel rail. Position the fuel lines aside. Refer to Metal Collar Quick Connect Fitting Service or to Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.5L.
  14. Remove the fuel vapor line.
  15. Remove the throttle and cruise cables with the mounting bracket from the throttle body. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.5L.
  16. Remove the automatic range selector cable from the park/neutral position (PNP) switch. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T65-E.

    17. Object Number: 293968 Size: SH
  17. Remove the vacuum brake booster hose from the booster.
  18. Remove the transaxle oil cooler lines from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Replacement in Automatic Transaxle - 4T65-E.
  19. Remove the heater hoses from the engine. Refer to Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.
  20. If the vehicle is equipped, remove the right side AIR control valve. Refer to Secondary Air Injection Shutoff Valve Replacement - Bank 1 in Engine Controls - 3.5L.
  21. Disconnect the upper engine electrical connectors, including grounds.
  22. Raise the vehicle.

    23. Object Number: 741008 Size: SH
  23. If the vehicle is equipped, remove the lower AIR hose from the elbow (1). Discard the clamp.
  24. Disconnect the lower electrical connectors, including grounds and the harness retainers.
  25. If the vehicle is equipped, disconnect the fog lamp electrical connectors.
  26. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
  27. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  28. Scribe the torque converter to the flywheel in order to aid in installation.
  29. Remove the bolts which secure the engine flywheel to the torque converter. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65-E.
  30. Remove the engine splash shields from the inner fender. Refer to Engine Splash Shield Replacement in Body Front End.

    31. Important:  Do NOT discharge the A/C system.

  31. Remove the mounting bolts and nuts from the A/C compressor. Secure the compressor. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation and Air Conditioning.
  32. Remove the 3-way catalytic converter pipe from the rear exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.

    33. Object Number: 289515 Size: SH
  33. Remove the bolts which secure the lower transaxle to the engine.
  34. Disconnect the electrical connectors from the wheel speed sensors, and unclip the harnesses from the lower control arms.
  35. Remove the wheel drive axles from the steering knuckles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.

    36. Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

  36. Remove the pinch bolt from the intermediate steering shaft.

    37. Object Number: 294371 Size: SH
  37. Remove the intermediate shaft (1) from the steering gear (2). Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  38. Lower the vehicle.
  39. Reposition the upper and lower engine wiring harnesses.
  40. Raise the vehicle.
  41. Place J 39580 under the engine/transaxle/frame.
  42. With an assistant, lower the vehicle to the frame table in order to support the engine/transaxle/frame.
  43. Remove the bolts which secure the frame to the body. Refer to Frame Replacement in Frame and Underbody.

    44. Important: Carefully adjust the A/C compressor when the vehicle is raised.

  44. Raise the vehicle.
  45. Remove the frame table with the engine/transaxle/frame from under the vehicle.

    46. Object Number: 294001 Size: SH
  46. Remove the power steering pump from the engine and lay the pump aside. Refer to Power Steering Pump Replacement in Power Steering System.
  47. If the vehicle is equipped, remove the secondary air injection check valve/pipe. Refer to Secondary Air Injection Shutoff Valve Replacement - Bank 2 in Engine Controls - 3.5L.
  48. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  49. Remove the exhaust manifolds and crossover pipe. Refer to Exhaust Manifold Replacement - Left Side and to Exhaust Manifold Replacement - Right Side in Engine Exhaust.
  50. Install the engine lifting device to the engine.
  51. Remove the bolts which secure the engine mount bracket to the engine. Refer to Engine Front Mount Bracket Replacement .
  52. Remove the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65-E.

    53. Object Number: 289515 Size: SH
  53. Remove the bolts which secure the upper transmission to the engine.
  54. Remove the engine from the transaxle/frame.
  55. Remove the engine flywheel. Refer to Engine Flywheel Replacement .

Installation Procedure
  1. Install the engine flywheel. Refer to Engine Flywheel Replacement .
  2. Install the engine to the transaxle/frame.

    3. Object Number: 443283 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.

    Important: Return the bolts which secure the transaxle to the engine to their original position. The bolt installed in position (5) is 2 mm (0.078 in) shorter than the other bolts. Apply GM P/N 12345382 (Canadian P/N 10953489) thread sealant to the bolt (5).

  3. Install the bolts which secure the upper transmission to the engine.

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

  4. Install the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65-E.
  5. Install the bolts which secure the engine mount bracket to the engine. Refer to Engine Front Mount Bracket Replacement .
  6. Remove the engine lifting device from the engine.
  7. Install the crossover pipe and the exhaust manifolds. Refer to Exhaust Manifold Replacement - Left Side and to Exhaust Manifold Replacement - Right Side in Engine Exhaust.
  8. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement .
  9. If the vehicle is equipped, install the AIR check valve/pipe. Refer to Secondary Air Injection Shutoff Valve Replacement - Bank 2 in Engine Controls - 3.5L.
  10. Install the power steering pump to the engine. Refer to Power Steering Pump Replacement in Power Steering System.
  11. Install the frame table with the engine/transaxle/frame under the vehicle.

    12. Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

    Important: Carefully adjust the A/C compressor when the vehicle is lowered.

  12. Lower the vehicle.

    13. Object Number: 294371 Size: SH
  13. Install the bolts which secure the frame to the body. Refer to Frame Replacement in Frame and Underbody.
  14. Install the intermediate shaft (1) to the steering gear (2).
  15. Install the pinch bolt to the intermediate steering shaft (1). Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  16. Raise the vehicle.
  17. Remove J 39580 from under the vehicle.
  18. Lower the vehicle.
  19. Reposition the upper and lower engine wiring harnesses to the engine.
  20. Raise the vehicle.
  21. Install the wheel drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  22. Connect the electrical connectors to the wheel speed sensors and clip the harnesses to the lower control arms.
  23. Install the bolts which secure the lower transaxle to the engine.

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

  24. Install the 3-way catalytic converter pipe to the rear exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  25. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation and Air Conditioning.
  26. Install the engine splash shields to the inner fender. Refer to Engine Splash Shield Replacement in Body Front End.
  27. Install the bolts which secure the engine flywheel to the torque converter. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65--E.
  28. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  29. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
  30. Connect the fog lamp electrical connectors, if equipped.
  31. Connect the lower electrical connectors, including grounds and the harness retainers.

    32. Object Number: 741008 Size: SH
  32. Install the lower AIR hose to the elbow (1), if equipped. Replace the clamp.
  33. Install the lower air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement in Engine Cooling.
  34. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  35. Remove the vehicle to hoist support.
  36. Lower the vehicle.
  37. Connect the upper engine electrical connectors and grounds.
  38. Install the harnesses to the clips.
  39. Install the right AIR control valve, if equipped. Refer to Secondary Air Injection Shutoff Valve Replacement - Bank 1 in Engine Control - 3.5L.
  40. Install the heater hoses to the engine. Refer to Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.
  41. Install the transaxle oil cooler lines to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Replacement in Automatic Transaxle - 4T65-E.
  42. Install the A/C vacuum hose to the engine.

    43. Object Number: 293968 Size: SH
  43. Install the vacuum brake booster hose to the booster.
  44. Install the automatic range selector cable to the PNP switch. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T65-E.
  45. Install the throttle, and the cruise cables with the mounting bracket to the throttle body. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.5L.
  46. Install the fuel vapor line.
  47. Install the fuel lines to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service or to Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.5L.
  48. Install the generator. Refer to Generator Replacement in Engine Electrical.
  49. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  50. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.5L.
  51. Install the left diagonal brace. Refer to Front End Sheet Metal Diagonal Brace Replacement in Body Front End.
  52. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  53. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  54. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  55. Center the steering angle sensor. Refer to Steering Angle Sensor Centering in Antilock Brake System.
  56. Perform the CKP System Variation Learn Procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls - 3.5L.
  57. Inspect the front end alignment. Refer to Wheel Alignment Measurement in Wheel Alignment.