Buick Regal: Intake Manifold Installation

Special Tools

• EN-45059 Angle Meter
• EN-50790 HP Fuel Pump Installation Alignment Gauge

For equivalent regional tools, refer to Special Tools.

1.

Install a NEW gasket (1) on the intake manifold (3). Install the intake manifold and hand start the intake manifold bolts (2, 4).

2.

CAUTION: Refer to Fastener Caution.

Tighten the bolts and nuts in sequence twice to 12 N.m (106 lb in).

3.

Install the MAP sensor (1) and bolt (2). Tighten the bolt to 5 N.m (44 lb in).

4.

NOTE: The camshaft must be in the base circle position before the high pressure fuel pump is installed.

Use the EN-50790 alignment gauge (2) to ensure that the camshaft lobe is in the base circle position. At base circle position, the tool will be flush with the head (1).

5.

Lubricate the high pressure fuel pump cylinder head bore with clean, silicone-free 5W30 engine oil.

NOTE: Ensure that the high pressure fuel pump roller lifter is oriented properly, and the camshaft is at base circle.

6. Lubricate the high pressure fuel pump roller lifter (1) with 5W30 engine oil and install into the cylinder head bore.

7. Lubricate the NEW O-ring (3) with one drop of clean engine oil. Install the NEW fuel pump housing O-ring (3).

NOTE: Ensure the fuel pump housing gasket (2) is properly aligned with the tab upward at the 2 O'clock position.

8. Install the NEW fuel pump housing gasket (2).

9. Install the fuel pump assembly (4).

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.

11. Hand start the NEW fuel pump bolts evenly. Tighten the fuel pump bolts evenly to 8 N.m (71 lb in) plus 50 degrees using the EN-45059 meter.

12. Hand start both ends of the NEW fuel feed intermediate pipe (5).

1. Tighten the fitting nut to the fuel rail to 15 N.m (11 lb ft).
2. Tighten the fitting nut to the fuel pump to 15 N.m (11 lb ft).
3. Tighten the fitting nut to the fuel rail a final pass to 30 N.m (22 lb ft).
4. Tighten the fitting nut to the fuel pump a final pass to 30 N.m (22 lb ft).

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.

13. Install the fuel pump insulator (6).

14.

Install the fuel pump cover and bolts. Tighten the bolts to 10 N.m (89 lb in).

15.

Install a new throttle body gasket (3).

16. Install the throttle body (2).

17. Install the throttle body bolts (1) and tighten to 10 N.m (89 lb in).

18.

NOTE: Ensure the quick-connect is clean and free of debris. The latch should move freely prior to installation.

Install the EVAP canister valve (1) and connect the EVAP canister valve tube.

TURBOCHARGER INSTALLATION (1ST DESIGN TAMPER-PROOF PCV SYSTEM)

1.

NOTE: The exhaust pipe studs do not come installed on new turbochargers. If the turbocharger is being replaced, new studs will need to be installed.

Install the turbocharger oil feed pipe (2) and NEW washers (3) onto the turbocharger.

CAUTION: Refer to Fastener Caution.

2. Install the turbocharger oil feed pipe bolt (1) and tighten to 35 N.m (26 lb ft).

3. Install a NEW turbocharger oil return pipe gasket (4).

4. Install the turbocharger oil return pipe (5) onto the turbocharger.

5. Install the turbocharger oil return pipe bolts (6) and tighten to 10 N.m (89 lb in).

6.

Install a NEW turbocharger gasket (3) on the turbocharger.

7. Install NEW turbocharger oil feed and oil return pipe gaskets (4, 5).

8. Install the turbocharger (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.

9. Install NEW turbocharger nuts (2) finger tight.

10. Install the turbocharger oil feed and return pipe bolts (6) at the engine block. tighten the bolts to 10 N.m (89 lb in).

11.

NOTE: The PCV hose and fitting assembly connection is permanent. Reinstall these components as an assembly unless new components are being used.

NOTE: Always ensure the PCV hose fitting O-Ring seal is free of cuts or abrasions each time the fitting is attached to the turbocharger.

Inspect the PCV hose fitting O-Ring seal and replace if necessary.

12. Install the PCV hose and fitting assembly (1) to the turbocharger. Install the PCV hose fitting assembly bolt (2) and tighten to 8 N.m (71 lb in).

13.

Tighten the turbocharger nuts in sequence to 30 N.m (22 lb ft) plus 90 degrees.

14.

Install the turbocharger bypass valve solenoid (2).

15. Install the turbocharger bypass valve solenoid bolts (1) and tighten to 8 N.m (71 lb in).

16.

Install the turbocharger wastegate regulator solenoid valve (1).

17. Install the turbocharger wastegate regulator solenoid valve bracket bolt (2) and tighten to 8 N.m (71 lb in).

18. Connect the turbocharger wastegate regulator solenoid valve hoses to the turbocharger.

19.

Install the turbocharger coolant feed pipe (5) and NEW washers (2) on the turbocharger.

20. Install the turbocharger coolant feed pipe bolt (1) and tighten to 35 N.m (26 lb ft).

21. Install a NEW turbocharger coolant feed pipe gasket (4).

22. Install the turbocharger coolant feed pipe bolts (3) and tighten to 10 N.m (89 lb in).

23. Connect the turbocharger coolant feed pipe hose to the engine oil cooler.

24.

Install the turbocharger coolant return pipe (2) and NEW washers (4, 5) on the turbocharger.

25. Install the turbocharger coolant return pipe bolt (3) and tighten to 35 N.m (26 lb ft).

26. Connect the turbocharger coolant return pipe to the air bleed hose.

27. Install the camshaft cover heat shield bolt (1) that retains the turbocharger coolant return pipe (2) at the camshaft cover. Tighten the bolt to 10 N.m (89 lb in).

28.

Install the turbocharger wastegate actuator (2) and actuator bolts (1) and tighten to 8 N.m (71 lb in).

29. Install the turbocharger wastegate actuator arm retainer (3).

30.

Install the turbocharger heat shield (2).

31. Install the turbocharger heat shield bolts (1, 3) and tighten to 14 N.m (124 lb in).

READ NEXT: