GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Impala 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Engine Replacement

Removal Procedure
  1. Disconnect the battery ground (negative) 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. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  4. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  5. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  6. Carefully remove the throttle body air inlet duct.
  7. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
  8. Disconnect the AIR pipe, if equipped. Refer to Secondary Air Injection Combination Valve/Pipe Replacement in Engine Controls - 3.8L.

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

  9. Disconnect the fuel lines from the fuel rail. Reposition the fuel lines. Refer to Fuel Hose/Pipes Replacement - Filter to Engine in Engine Controls - 3.8L.

    10. 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.

  10. Disconnect the throttle and cruise cables with the mounting bracket from the throttle body. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.
  11. Remove the engine mount struts from the engine mount strut brackets. Refer to Engine Mount Strut Replacement .
  12. Remove the engine mount strut brackets from the upper radiator support. Refer to Engine Mount Strut Bracket Replacement .
  13. Remove the engine cooling fans. Refer to Fan Shroud Replacement in Engine Cooling.
  14. Remove the vacuum booster hose from the engine. Refer to Vacuum Brake Booster Hose Replacement in Hydraulic Brakes.
  15. Remove the power steering pump from the engine. Lay the power steering pump aside. Refer to Power Steering Pump Replacement in Power Steering System.
  16. Remove the electrical connections from the engine, as required.
  17. Disconnect the radiator inlet hose from the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  18. Disconnect the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  19. Disconnect the heater hoses from the engine. Refer to Heater Hoses Replacement in HVAC.
  20. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  21. Remove the A/C compressor from the engine. Do not discharge the system. Secure the compressor to the frame.
  22. Remove the torque converter cover. Refer to Catalytic Converter Replacement in Automatic Transaxle -- 4T65-E.
  23. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  24. Scribe the torque converter to the flywheel for installation.
  25. Remove the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle -- 4T65-E.
  26. Remove the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle -- 4T65-E.
  27. Remove the engine mount lower nuts. Refer to Engine Mount and Bracket Replacement .
  28. Disconnect the catalytic converter pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.

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

    33. Object Number: 160965 Size: SH
  33. Remove the upper transaxle-to-engine bolts (3, 4 and 5) and stud (2).
  34. Carefully remove the engine from the vehicle.

Installation Procedure
  1. Install the engine. Align the engine with the engine to transaxle dowel pins.

    2. 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.

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

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

  3. Remove the transaxle support.
  4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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

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

  6. Connect the catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  7. Install the engine mount lower nuts. Refer to Engine Mount and Bracket Replacement .
  8. Install the transaxle brace. Refer to Transmission Brace Replacement in Automatic Transaxle -- 4T65-E.
  9. Install the engine flywheel-to-torque converter bolts. Align the scribe marks. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle -- 4T65-E.
  10. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
  11. Install the torque converter cover. Refer to Catalytic Converter Replacement in Automatic Transaxle -- 4T65-E.
  12. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC.
  13. Remove the vehicle support.
  14. Lower the vehicle.
  15. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement in HVAC.
  16. Connect the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  17. Connect the radiator inlet hose to the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  18. Install the electrical connections to the engine.
  19. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
  20. Install the vacuum booster hose to the engine. Refer to Vacuum Brake Booster Hose Replacement in Hydraulic Brakes.
  21. Install the engine cooling fans. Refer to Fan Shroud Replacement in Engine Cooling.
  22. Install the engine mount strut brackets to the upper radiator support. Refer to Engine Mount Strut Bracket Replacement .
  23. Install the engine mount struts to the engine mount struts brackets. Refer to Engine Mount Strut Replacement .

    24. 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.

  24. Connect the throttle and cruise cables with the mounting bracket to the throttle body. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.
  25. Connect the fuel lines to the fuel rail. Refer to Fuel Hose/Pipes Replacement - Filter to Engine in Engine Controls - 3.8L.
  26. Connect the AIR pipe, if equipped. Refer to Secondary Air Injection Combination Valve/Pipe Replacement in Engine Controls - 3.8L.
  27. Carefully install the throttle body air inlet duct.
  28. Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
  29. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
  30. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  31. Fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement .
  32. Install the hood. Refer to Hood Replacement in Body Front End.
  33. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  34. Inspect all of the fluid levels.
  35. Inspect for leaks.
  36. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls - 3.8L.