Buick Regal: Engine Front Cover Installation

Special Tools

• EN-45059 Angle Meter
• EN-50820 Front Crankshaft Seal Installer

For equivalent regional tools, refer to Special Tools.

1.

Using EN-50820 installer, install the front crankshaft seal (1) into the engine front cover.

2.

Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant.

NOTE:

• The engine front cover surface must be free of contamination prior to applying the sealer.

  Install and align the cover within 20 minutes of applying the sealer.

• The cover must be fastened to final torque specification within 60 minutes of applying the sealer.
• Additional sealant is necessary to reduce the possibility of leakage where the cylinder head to engine block interface along the bead path flange on the front cover.

3. Apply a 5 mm bead of sealer directly in the flange (1) of the engine front cover perimeter mating surface. Also apply a 5 mm bead of sealer directly to the locations indicated (2). Finally, apply a 14 mm dab of sealant at the locations indicated (3). Refer to Adhesives, Fluids, Lubricants, and Sealers.

4.

Install the engine front cover (1).

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component.

Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

5. Install by hand 3 NEW M10 bolts (3, 5, 6) in the engine front cover, as shown.

6. Hand start the remaining engine front cover bolts (2, 4, 7, 8).

7.

CAUTION: Refer to Fastener Caution.

Tighten the engine front cover bolts in sequence to final torque twice:

1. Tighten sequence 1 - 3 bolts a first pass to 15 N.m (11 lb ft).
2. Tighten sequence 1 - 3 bolts a final pass 130 degrees using EN-45059 meter.
3. Tighten sequence 4 - 15 bolts to 25 N.m (18 lb ft).
4. Tighten sequence 16 - 17 bolts to 10 N.m (89 lb in).
5. Tighten sequence 18 - 19 bolts to 10 N.m (89 lb in).
6. Tighten sequence 20 bolt to 25 N.m (18 lb ft).

8.

Install the accessory drive belt tensioner (2).

9. Install the accessory drive belt tensioner bolt (1) and tighten to 58 N.m (43 lb ft).

CAMSHAFT COVER INSTALLATION (1ST DESIGN TAMPER-PROOF PCV SYSTEM)

1.

NOTE: Ensure all camshaft cover gaskets are replaced, including the inner gaskets.

Assemble the camshaft cover (2) and NEW gaskets (4). Ensure each gasket is located in the correct retaining groove in the camshaft cover.

2. Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant.

3. Add a 14 mm bead of sealant at the right and left T-joint where the front cover meets the cylinder head and at the rear of the camshaft cover at the right and left T-joint where the vacuum pump bolts on. Refer to Adhesives, Fluids, Lubricants, and Sealers.

4. Install the cover on the cylinder head and hand start the bolts (1, 3).

5.

CAUTION: Refer to Fastener Caution.

Tighten the camshaft cover bolts in sequence to 10 N.m (89 lb in).

6.

NOTE: Ensure the vacuum pump seal does not need to be replaced, and the sealing surface is clean prior to installing the gasket and pump.

Inspect the vacuum pump seal. Refer to Camshaft Cover and Compressor Air Intake Turbocharger Cleaning and Inspection.

7. Install a NEW vacuum pump assembly gasket (3) on the vacuum pump assembly (2).

8. Install the vacuum pump assembly (2) and bolts (1). Tighten the bolts to 10 N.m (89 lb in).

9.

Install the camshaft position actuator solenoid valves (2) and bolts (1). Tighten the bolts to 10 N.m (89 lb in).

10.

Inspect the inside of the ignition coil rubber boot for a thin, even coat of grease. If there is no grease present or additional grease is necessary, complete the following procedure:

1. Apply a thin coating of dielectric grease evenly to the inside of the ignition coil rubber boot, up to a depth of 15 mm from the end of the boot. Refer to Adhesives, Fluids, Lubricants, and Sealers.
2. Remove any excess grease from around the end of the boot, and ensure there is not an excessive amount within the boot.

11. Install the ignition coils (2) and bolts (1). Tighten the bolt to 10 N.m (89 lb in).

12.

Install the front lift bracket (2).

13. Install the front lift bracket bolts (1) and tighten to 25 N.m (18 lb ft).

14.

Install the rear lift bracket (1).

15. Install the rear lift bracket bolts (2) and tighten to 25 N.m (18 lb ft).

16.

Install the camshaft cover heat shield (2) and bolts (1). Tighten the bolts to 10 N.m (89 lb in).

17. Inspect the oil level indicator O-ring seals (4) and replace if necessary. Install the oil level indicator (3).

18.

Inspect the O-ring (4) on the engine coolant air bleed pipe. Replace if necessary.

19. Install the engine coolant air bleed hose (3), if necessary.

20. Install the engine coolant air bleed pipe (2).

21. Install the pipe bolt (1) and tighten to 10 N.m (89 lb in).

FUEL RAIL AND INJECTORS INSTALLATION

Special Tools

EN-47909 Injector Bore and Sleeve Cleaning Kit

For equivalent regional tools, refer to Special Tools.

1.

Clean the fuel injector bore in the cylinder head using the EN-47909 kit.

2. Replace the fuel rail insulators, if necessary. Refer to Fuel Rail and Injectors Cleaning and Inspection.

Replace the fuel rail bolts, if necessary.

3. Replace fuel injector Teflon seals with NEW when transferring fuel rail and injectors on to service engine assembly. Refer to Fuel Rail and Injectors Cleaning and Inspection.

4. Install the fuel rail (1) with injectors into the cylinder head evenly.

NOTE: Mount the bolts evenly to avoid cocking of the fuel injectors during installation.

NOTE: Avoid contamination and contact damage of fuel injectors nozzle tips.

5. Hand start the 2 outer fuel rail bolts (2) to seat the injectors into the injector bores.

6. Hand start the remaining fuel rail bolts.

Fig. 14: Fuel Rail Bolts Tightening Sequence

7.

CAUTION: Refer to Fastener Caution.

Tighten the fuel rail bolts in sequence to 25 N.m (18 lb ft).

8. Connect the electrical harness to the fuel rail harness connections.

9.

WARNING: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

Install the fuel injection fuel rail noise shield (1).

EXHAUST MANIFOLD INSTALLATION

1.

Install a NEW exhaust manifold gasket (2).

2. Install the exhaust manifold (1) to the cylinder head.

3. Hand start NEW exhaust manifold to cylinder head retaining bolts (3).

Fig. 15: Exhaust Manifold Bolts Tightening Sequence

CAUTION: Refer to Fastener Caution.

NOTE: Fasteners have adhesive patch and must be tightened to final torque within 5 minutes.

Tighten the NEW exhaust manifold to cylinder head bolts three passes in sequence to 20 N.m (15 lb ft).

5.

Install the exhaust manifold brace (2).

6. Install the exhaust manifold brace bolts (3) and tighten to 25 N.m (18 lb ft) 7. Install NEW exhaust manifold brace nuts (1) and tighten to 25 N.m (18 lb ft) 8.

Install the exhaust manifold heat shield (1).

9. Install the exhaust manifold heat shield bolts (2) and tighten to 14 N.m (124 lb in).

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