Engine Block Plug Installation. Buick Roadmaster 1996

For 1990-2009 cars

#### Tools Required

J 41712 Oil Pressure Switch Socket

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.

1. Install the NEW fuel pump opening cover gasket, fuel pump opening cover and bolts.

Tighten

• | Tighten the fuel pump opening cover upper bolts to 12 N·m (106 lb in).

• | Tighten the fuel pump opening cover lower bolts to 40 N·m (30 lb ft).

2. Install the transmission locator pins (if required).

A properly installed transmission locator pin will protrude 12.7 mm (0.5 in) from the rear face of the engine block.

3. Install the dowel pins (cylinder head locator) (if required).

A properly installed dowel pin will protrude 6.4 mm (0.25 in) from the cylinder head deck surface of the engine block.

4. Apply sealant GM P/N 12346004 or equivalent to the outside diameter of the expansion cup plug (camshaft rear bearing hole).
5. Install the expansion cup plug (camshaft rear bearing hole).

A properly installed expansion cup plug will be installed 8.8 mm (0.348 in) into the rear of the engine block.

6. Apply sealant GM P/N 12346004 or equivalent to the threads of the left side rear and left rear top engine oil gallery plugs.
7. Install the left side rear and left rear top oil engine gallery plugs.

Tighten
Tighten the left side rear and left rear top engine oil gallery plugs to 20 N·m (15 lb ft).

8. Apply sealant GM P/N 12346004 or equivalent to the threads of the square socket plugs (engine block oil gallery).
9. Install the rear oil gallery plugs.

Tighten
Tighten the square socket plugs to 20 N·m (15 lb ft).

10. Apply sealant GM P/N 12346004 or equivalent to the outside diameter of the engine oil gallery plugs.
11. Install the NEW engine block oil gallery plugs.

A properly installed engine oil gallery plug must be installed below flush with the front face of the engine block.

12. Apply sealant GM P/N 12346004 or equivalent to the threads of the engine block coolant drain hole plug.
13. Install the engine block coolant drain hole plug.

Tighten
Tighten the engine block coolant hole plug to 18 N·m (13 lb ft).

14. Apply sealant GM P/N 12346004 or equivalent to the threads of the engine oil pressure sensor fitting.
15. Install the engine oil pressure sensor fitting.

Tighten
Tighten the engine oil pressure sensor fitting to 15 N·m (11 lb ft).

16. Rotate the engine oil pressure sensor fitting clockwise to the proper position (1), 50 degrees from the centerline (2).
17. Apply sealant GM P/N 12346004 or equivalent to the threads of the fuel pump switch & engine oil pressure gauge sensor.
18. Install the fuel pump switch & engine oil pressure gauge sensor using the J 41712 .

Tighten
Tighten the fuel pump switch & engine oil pressure gauge sensor to 30 N·m (22 lb ft).

19. Apply sealant GM P/N 12346004 or equivalent to the threads of the knock sensor.
20. Install the knock sensor.

Tighten
Tighten the knock sensor to 19 N·m (14 lb ft).