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Buick Regal Workshop Service Repair Manual 1997-2004

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The Buick Regal, produced from 1997 to 2004, represents the Sixth Generation of this well-regarded mid-size sedan and coupe. Available with robust 3800 Series II V6 engines, including naturally aspirated...
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Buick Regal Workshop Service Repair Manual 1997-2004
The Buick Regal, produced from 1997 to 2004, represents the Sixth Generation of this well-regarded mid-size sedan and coupe. Available with robust 3800 Series II V6 engines, including naturally aspirated (L36) and supercharged (L67) variants, the Regal offered a compelling blend of comfort, refined driving dynamics, and strong performance, particularly in its supercharged iteration. Its engineering quality and reliability made it a competitive option against rivals like the Ford Taurus and Toyota Camry, offering a comfortable ride with capable handling that appealed to a broad range of drivers seeking dependable transportation. This comprehensive factory service repair manual provides in-depth technical information for the Buick Regal models from 1997-2004. It covers a vast array of maintenance procedures, from routine tasks like oil changes to critical scheduled services such as timing belt replacement. The manual details engine overhaul and rebuilding, transmission servicing and repair, brake system procedures, suspension work, and electrical system diagnostics, including complete wiring diagrams and trouble code interpretation. With over 8000 pages of factory-level detail, hundreds of illustrations, and searchable text, this manual is an indispensable resource for owners and technicians aiming to maintain, diagnose, and repair the vehicle effectively and efficiently.
🏷️ Basic Information
Identification
Make:
Buick
Model:
Regal
Model Year Range:
1997-2004
Vehicle Generation:
Sixth Generation (L36/L67 Supercharged)
👋 Introduction
Market Position
Vehicle Segment:
Mid-size Sedan/Coupe, known for comfort and a performance-oriented Grand Prix GTP-like option
Competitive Analysis
Key Competitors:
Ford Taurus, Chevrolet Lumina, Dodge Intrepid, Toyota Camry, Honda Accord
Key Features
Engine Options:
V6 3800 Series II naturally aspirated (L36) and supercharged (L67) variants, offering a balance of power and efficiency
Driving Experience:
Comfortable ride with capable handling, especially in supercharged models
Manual Value Proposition
Cost Savings:
Empowers owners to perform repairs, saving significant dealership labor costs
Repair Ease:
Simplifies repairs from basic maintenance to complex overhauls with step-by-step guidance and illustrations
Information Source:
Official factory data used by dealership technicians
📋 Manual Details
Coverage Areas
Engine Overhaul Rebuilding:
Comprehensive
Brakes System:
Complete Service Procedures
Sunroof System:
Repair and Servicing
Timing Belt Replacement:
Detailed Step-by-Step Instructions
Trouble Codes:
Diagnosis and Interpretation
Wiring Diagrams:
Complete Electrical Schematics
Troubleshooting Diagnostics:
In-depth Procedures
Computer Diagnostics:
Diagnostic Trouble Tree Charts
Engine Performance:
Tuning and Optimization
Front End Alignment:
Procedures and Specifications
Suspension System:
Repair and Servicing
Transmission Removal Installation:
Complete Procedures
Air Conditioning:
Service and Capacities
Transmission In Car Servicing:
Detailed Procedures
Firing Orders:
Provided for all engines
Factory Maintenance Schedules:
Complete Schedules and Charts
Serpentine Belt Routings:
Includes Diagrams
Driving Concerns:
Troubleshooting Guidance
Torque Specifications:
Complete Data
U Joint Cv Joint Service:
Detailed Procedures
Illustrations Diagrams:
Hundreds of Detailed Illustrations
Vacuum Diagrams:
Included
Page Count
Total Pages:
8000+
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Compatibility:
All Versions of Windows & Mac, APP ISO, iPhone, iPad, Android
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full Overhaul and Rebuilding Procedures, Specifications
Engine Performance:
Diagnosis, Tuning, and Specifications
Fuel System:
Diagnosis, Repair, and Component Specifications
Ignition System:
Diagnosis, Repair, and Specifications
Cooling System:
Service, Capacities, and Component Repair
Exhaust System:
Repair and Component Information
Transmission Automatic:
Removal, Installation, In-Car Servicing, Rebuilding
Transmission Manual:
Not explicitly mentioned, but implied coverage for all model/engine types
Drivetrain Axles:
U-Joint and CV-Joint Service Procedures
Suspension Front:
Repair Procedures, Alignment Specifications
Suspension Rear:
Repair Procedures and Component Information
Steering System:
Diagnosis, Repair, and Specifications
Brake System Front:
Disc Brake Service Procedures
Brake System Rear:
Drum/Disc Brake Service Procedures (model dependent)
Anti Lock Brakes ABS:
Diagnostic Codes and Troubleshooting
Electrical System Power:
Battery, Charging System, Starting System Service
Electrical System Lighting:
Headlights, Taillights, Interior Lighting Service
Electrical System Accessories:
Power Windows, Locks, Mirrors, Wiper Service
Body Interior:
Trim Removal, Component Replacement
Body Exterior:
Panel Repair, Door/Hood/Trunk Service
HVAC System:
Air Conditioning Service, Refrigerant Capacities
Restraint Systems:
Airbag System Diagnosis and Service (cautionary notes likely)
Body Control Module:
Diagnostic Codes and Troubleshooting
Procedures Included
Routine Maintenance:
Oil Changes, Filter Replacements, Fluid Checks
Scheduled Maintenance:
Timing Belt Replacement, Spark Plug Replacement Intervals
Diagnostic Troubleshooting:
Step-by-step guides for various fault conditions
Component Removal Installation:
Detailed instructions for all major and minor components
Engine Rebuilding:
Complete overhaul procedures, including piston, ring, bearing, and valve servicing
Transmission Rebuilding:
Overhaul and rebuilding procedures for automatic transmissions
Brake System Repair:
Pad and Rotor Replacement, Caliper Servicing
Suspension Repair:
Shock/Strut Replacement, Bushing Replacement
Electrical Troubleshooting:
Using wiring diagrams to diagnose electrical faults
Technical Depth
Depth:
Factory-level detail, suitable for both DIY enthusiasts and professional technicians
Diagnostic Tools:
Information on using OBD-II scanners and specific diagnostic procedures
Rebuild Specifications:
Detailed tolerances, clearances, and torque values for engine and transmission components
📊 Manual Specifications
File Format
Indexing:
Fully Indexed and Bookmarked by Topic
Searchability:
Searchable text within the PDF for quick information retrieval
Print Quality
Document Origin:
Original Adobe Document
Print Ability:
Print Entire Manual or Select Pages
Zoom Capability:
Zoom in on Diagrams and Pictures for Clarity
Binding Type
Binding:
Digital Download (PDF)
Paper Type
Paper Quality Equivalent:
Perfect Quality and Perfect Printing (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
3800 Series II V6 (L36)
Engine Displacement 1:
3.8 Liters (231 cubic inches)
Engine Configuration 1:
Overhead Valve (OHV), V6
Horsepower L36:
Approx. 200-205 hp (varies slightly by year)
Torque L36:
Approx. 225-230 lb-ft (varies slightly by year)
Optional Engine
Engine Code 2:
3800 Series II Supercharged V6 (L67)
Engine Displacement 2:
3.8 Liters (231 cubic inches)
Engine Configuration 2:
Overhead Valve (OHV), V6 with Supercharger
Horsepower L67:
Approx. 240 hp
Torque L67:
Approx. 280-285 lb-ft
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MFI)
Fuel Type:
Unleaded Gasoline (87 octane recommended for L36, 89 or higher recommended for L67)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (4T65-E)
Optional
Transmission Type Supercharged:
Heavy-duty 4-Speed Automatic (4T65E-HD) on Supercharged models
Features
Transmission Control:
Electronic Control Unit (ECU) controlled for shift points and performance
📐 Dimensions
Exterior
Wheelbase:
Approx. 109.5 inches
Length:
Approx. 199.7 inches
Width:
Approx. 71.4 inches
Height:
Approx. 55.0 inches
Weights
Curb Weight Approx:
3400-3700 lbs (varies by trim and engine)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for comparable models of the era)
NHTSA Front Impact Passenger:
Good (for comparable models of the era)
Active Features
ABS:
Standard on most models
Traction Control:
Available, particularly on supercharged models
Passive Features
Airbags:
Driver and Passenger airbags standard
Seat Belts:
Front and rear seat belts
💡 Technology Features
Infotainment
Radio Options:
AM/FM Stereo with CD player, Cassette, and premium sound system options
Climate Control:
Manual and automatic climate control systems
Driver Assistance
Cruise Control:
Standard cruise control
Keyless Entry:
Available keyless entry system
Connectivity
Onboard Diagnostics:
OBD-II compliant system for diagnostic code retrieval
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for exact recommendations)
Timing Belt Replacement Interval:
Typically around 90,000-100,000 miles for the 3800 V6 engines (crucial for preventing catastrophic engine damage)
Spark Plug Replacement Interval:
Approximately every 100,000 miles (often using iridium or platinum plugs)
Fluid Specifications
Engine Oil Type L36:
API Certified SAE 5W-30 Synthetic Blend or Full Synthetic
Engine Oil Type L67:
API Certified SAE 5W-30 Full Synthetic recommended due to supercharger heat
Transmission Fluid Type:
Dexron III or Dexron VI compatible automatic transmission fluid (ATF)
Coolant Type:
GM P/N 12346290 (Orange) or equivalent silicate-free, extended-life coolant (50/50 mix with distilled water)
Known Issues
Intake Manifold Gaskets:
Leaking intake manifold gaskets (especially on earlier 3800 engines) causing coolant leaks or misfires
Supercharger Pulley Bearing:
Failure of the supercharger pulley bearing on L67 models, leading to noise and potential belt failure
Window Regulators:
Common failure of power window regulators
Rear Main Seal:
Potential leaks from the rear main engine seal
Transmission Solenoids:
Occasional failure of transmission shift solenoids in the 4T65-E
📚 Vehicle History
Brand Heritage
Brand Legacy:
Buick is a historical American luxury automobile brand, known for comfort and smooth rides.
Model Evolution
Previous Generations:
The Regal nameplate has a long history in Buick's lineup, evolving through various iterations and market segments.
Production
Manufacturing Location:
Oshawa, Ontario, Canada (General Motors Canada Assembly Plant)
Key Updates During Range:
Introduction of the supercharged L67 engine, enhanced interior features, and minor styling revisions throughout the 1997-2004 period.
🏆 Awards & Recognition
Recognitions
Engine Awards:
The GM 3800 Series II V6 engine was a Ward's 10 Best Engines winner in the past, recognized for its refinement and durability.
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