GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2003 🢒 Grand Prix 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Engine Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the hood. Refer to Hood Replacement in Body Front End.
  3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  6. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  7. Remove the torque converter covers. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65 - E.
  8. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  9. Remove the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65 - E.
  10. Scribe the torque converter to the flywheel for installation.
  11. Remove the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65 - E.

    12. Object Number: 50411 Size: SH
  12. Remove the engine mount lower nuts.
  13. Remove the three-way catalytic converter pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  14. Remove the oil level sensor harness retainer bolt.
  15. Remove the oil level harness retainer from the engine.
  16. Disconnect and reposition the electrical connectors from the following components:
    17. • Vehicle speed sensor (VSS)
    • Oil pressure sensor
    • 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 .
  18. Remove the engine ground nut and engine ground from the transaxle stud.

    19. Object Number: 160965 Size: SH
  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. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
  22. Disconnect the fuel lines from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.8L.
  23. Disconnect the fuel vapor line. Refer to Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.8L.
  24. Remove the accelerator and cruise control cables and bracket from the throttle body. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.

    25. Object Number: 46174 Size: SH
  25. Loosen the water pump pulley bolts.
  26. Remove the drive belt. Refer to Drive Belt Replacement .
  27. Remove the water pump pulley bolts and the water pump pulley.
  28. Remove the right and left engine mount struts. Refer to Engine Mount Strut Replacement - Right Side and Engine Mount Strut Replacement - Left Side .
  29. Remove the engine mount brackets from the radiator support. Refer to Engine Mount Strut Bracket Replacement - Upper Radiator Support .
  30. Disconnect the positive battery cable.
  31. Remove the engine cooling fans. Refer to Engine Cooling Fan Replacement in Engine Cooling.
  32. Remove the vacuum booster hose from the engine. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement in Hydraulic Brakes.
  33. Disconnect the A/C vacuum hose from the engine.

    34. Object Number: 282122 Size: SH
  34. Remove the power steering pump bolts and pump from the engine. Lay the power steering pump aside.
  35. Disconnect the upper engine electrical connectors from the following components:
    36. • 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 Inlet Hose Replacement in Engine Cooling.
  38. Remove the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  39. Remove the heater hoses from the drive belt tensioner. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.

    40. Object Number: 277915 Size: SH
  40. Remove 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. Object Number: 160965 Size: SH
  42. Remove the bolts (2,3,4,5) which secure the upper transaxle to the engine.
  43. With assistance remove the engine from the vehicle.
  44. Remove the flywheel. Refer to Engine Flywheel Removal .
  45. Install the engine to the engine stand.

Installation Procedure

    Object Number: 160965 Size: SH
  1. Remove the engine from the engine stand.
  2. Install the flywheel. Refer to Engine Flywheel Installation .
  3. With the aid of an assistant, install the engine to the vehicle.

    4. 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.

  4. Install the bolts (2,3,4,5) which secure the upper transaxle to the engine.

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

  5. Remove the engine lifting device.

    6. Object Number: 277915 Size: SH
  6. Install the A/C compressor and the A/C compressor nuts to the A/C compressor bracket.

    7. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).

  7. Install the heater hoses to the drive belt tensioner. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.
  8. Install the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  9. Install the radiator inlet hose to the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  10. Reposition the engine wiring to the engine.
  11. Connect the upper engine electrical connectors to the following components:
    12. • 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
  12. Install the upper engine wiring harness to the retaining clips.

    13. Object Number: 282122 Size: SH
  13. Install the power steering pump to the engine.

    14. Tighten
    Tighten the power steering bolts to 34 N·m (25 lb ft).

  14. Connect the A/C vacuum hose to the engine.
  15. Install the vacuum booster hose to the engine. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement in Hydraulic Brakes.
  16. Install the engine cooling fans. Refer to Engine Cooling Fan Replacement in Engine Cooling.
  17. Connect the positive battery cable.

    18. Tighten
    Tighten the cable terminal bolt to 15 N·m (11 lb ft).

  18. Install the engine mount brackets to the upper radiator support. Refer to Engine Mount Strut Bracket Replacement - Upper Radiator Support .
  19. Install the engine mount struts to the engine mount strut brackets. Refer to Engine Mount Strut Replacement - Right Side and to Engine Mount Strut Replacement - Left Side .

    20. Object Number: 46174 Size: SH
  20. Install the water pump pulley.
  21. Install the water pump pulley bolts.

    22. Tighten
    Tighten the pulley bolts to 13 N·m (116 lb in).

  22. Install the drive belt. Refer to Drive Belt Replacement .
  23. Install the accelerator cable, the cruise control cable, and the bracket to the throttle body. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.
  24. Connect the fuel vapor line. Refer to Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.8L.
  25. Connect the fuel lines to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls - 3.8L.
  26. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
  27. Raise the vehicle and remove the transaxle support.

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

    29. Tighten
    Tighten the bolt and the stud to 75 N·m (55 lb ft).

  29. Install the engine ground to the transaxle stud.

    30. Tighten
    Tighten the engine ground nut to 35 N·m (26 lb ft).

  30. Install the oil filter adapter housing. Refer to Oil Filter Adapter and Bypass Valve Assembly Replacement .
  31. Reposition and connect the electrical connectors to the following components:
    32. • Heated oxygen sensor (H02S)
    • Knock sensors
    • Oil level sensor
    • Oil pressure sensor
    • Vehicle speed sensor (VSS)
  32. Install the oil level sensor harness retainer to the engine.
  33. Install the oil level sensor harness retainer bolt.

    34. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  34. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.

    35. Object Number: 50411 Size: SH
  35. Install the engine mount lower nuts.

    36. Tighten
    Tighten the nuts to 78 N·m (58 lb ft).

  36. Install the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle - 4T65 - E.
  37. Install the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65 - E.
  38. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  39. Install the torque converter covers. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65 - E.
  40. Lower the vehicle.
  41. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  42. Install the hood. Refer to Hood Replacement in Body Front End.
  43. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  44. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  45. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  46. Inspect for leaks.
  47. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls - 3.8L.