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The deck height is shorter than the Series I, which reduced its weight and total engine package size. To make this change, GM engineers required that the piston connecting rods be shortened 1” (25 mm), and to redesign the crankshaft. A new intake manifold improved breathing, while a redesigned cylinder head featured larger valves and a higher compression ratio. The result was a 205 hp and 230 lb.-ft. Powerplant that had better fuel economy. To meet emissions standards of the ’90s, an EGR tube was placed in the intake manifold to reduce combustion temperatures.
This increased fuel mileage by a substantial margin and provided GM some engineering success. In fact, the 3800 Series II was on the Ward’s 10 Best Engines list 1995 through ’97. However, in April, 2009, GM issued a recall on 1.5 million vehicles with this engine due to an oil leak issue that could result in a fire. ( See the sidebar at the end of this article). Did You Know The Buick 3.8L has evolved from its humble beginnings as a cheap, easy-to-build, economy motor in 1962, into one of the best pushrod motors in the world. But did you know that the engine started its “life” as a Buick V8 that had two cylinders “missing”?
That was to allow GM to machine it on the same line as their V8 with common tooling. Unfortunately, that meant it had two cylinders missing in the firing order — making it a strange-sounding, rough-riding, odd-firing engine. While that was fine for the 1960s, it wasn’t good enough in the ’70s and in 1977, Buick split the crank pins to make it into an even-fire motor with smother performance. Unfortunately, the engine still had a severe primary imbalance because it was a 90° block with a 120° firing order. GM engineers realized that the 3800 would still need a balance shaft to make it suitable for the upscale FWD cars later on.
Buick 3800 Series 2 Specs
Buick 3800 Series 2 Intake Manifold Gasket
As the engine evolved into the Series I, a gerotor oil pump and roller lifters were added in ’86, on-center bores were added in ’88 along with the balance shaft, and a one-piece rear seal was introduced in ’90. The 3800 was completely updated in ’95 when it became the Series II motor that was lower, lighter, smoother and more powerful than any of its earlier variations.