PONTIAC FIERO 1988 Service Repair Manual

6A2-10 2.8 LITER V-6
5. Remove air management valve from A.I.R.
pump. 6. Remove alternator bracket.
7. Remove exhaust manifold bolts.
8. Disconnect air management hose.
9. Remove manifold.
Installation (Right)
1. Clean
mating surfaces on manifold and head,
then install manifold in position and install bolts.
2. Torque
manifold bolts to 34
N-m (25 ft. lbs.).
3. Attach air management hose.
4. Raise vehicle.
5. Install exhaust pipes.
6. Lower vehicle.
7. Install alternator bracket.
8. Install air management valve.
7. Connect battery.
Figure 6A2-9 Rocker Arm and Push Rods
ROCKER ARM AND PUSH ROD (FIGURE 6A2-9)
Removal
1. Remove
rocker arm cover as previously outlined.
2. Remove rocker arm nuts, rocker arm balls,
rocker arms and push rods. Place components in
a rack so they can be reinstalled in the same
location.
lnstallation and Adiustment
Whenever new rocker arms and/or rocker arm
balls are being installed, coat bearing surfaces of rocker
arms and rocker balls with a thin even coating of
"Molykote" or its equivalent.
1. Install push rods. Be sure push rods seat in lifter.
2. Install rocker arms, rocker arm balls and rocker
arm nuts. Tighten rocker arm nuts until all lash
is eliminated.
3. Adjust valves when lifter is on base circle of
camshaft lobe as follows:
a. Crank engine until mark on torsional
damper lines up with
"0" mark on the
timing tab. The engine should also be in the
# 1 firing position. This may be determined
Figure 6A2-10 Adjusting Valve Lash
by placing fingers on the # 1 rocker arms as
the mark on the damper comes near the
"0"
mark. If the valves are not moving, the
engine is in the
# 1 firing position. If the
valves move as the mark comes up to the
timing tab, the engine is in the
#4 firing
position and should be rotated one
revolution to reach the
# 1 position.
b. With the
engine in the
# 1 firing position,
the following valves may be adjusted.
Exhaust 1, 2, 3
Intake 1, 5,
6
c. Back
out adjusting nut until lash is felt at
the push rod, then turn in adjusting nut
until all lash is removed (Figure
6A2-10).
(This can be determined by rotating push
rod while turning adjusting nut). When lash
has been removed, turn adjusting nut in
1-1/2 additional turns (to center lifter
plunger).
d. Crank the
engine one revolution until the
timing tab
"0" mark and torsional damper
mark are again in alignment. This is the
#4
firing position. With the engine in this
position, the following valves may be
adjusted:
Exhaust 4, 5,
6
Intake 2, 3, 4
4.
Install rocker arm covers as previously outlined.
5. Start
engine and check timing and idle speed.
VALVE MECHANISM
Valve Stern Oil Seal and/or Valve Spring (Figure
6A2-12)
Removal
1. Remove rocker
arm cover as previously outlined.
2. Remove spark plug, rocker arm and push rod on
the
cylinder(s) to be serviced.
3. Install
air line adapter Tool J-23590 to spark plug
port and apply compressed air to hold the valves
in place.

2.8 LITER V-6 8A2-11
ENGAGE AT
Figure 6A2-1 1 Depressing Valve Spring
Figure
6A2-12 Valve Stem Seal
4. Using Tool J-5892 to compress the valve spring,
remove the valve locks, valve cap, oil shedder
(exhaust only) and valve spring and damper
(Figure
6A2- 1 1).
5. Remove the valve stem oil seal.
Installation
1. Set the valve spring and damper around the valve
guide boss.
2. Install a valve stem seal over the valve stem and
valve guide base inlet only. 3.
Drop an oil shedder and valve rotator over the
exhaust and a valve spring cap over the valve
spring.
4. Using Tool
5-5892, compress the valve spring.
5. Install the square cut "0" ring around the valve
stem in the lower groove, making sure it is not
twisted.
6. Insert valve stem key locks and release tool.
Figure 6A2-13 Oversize Lifter Marking
Valve Lifters (6A2-14)
Hydraulic valve lifters very seldom require
attention. The lifters are extremely simple in design,
readjustments are not necessary, and servicing of the
lifters requires only that care and cleanliness be
exercised in the handling of parts. Valve lifters should
be kept in order so they may be reinstalled in their
original position. Some engines will have both standard
and
.010" oversize valve lifters.
The cylinder case will be marked, where the O.S.
lifters are used, with a dab of white paint and
0.25
(mm) O.S. stamped on the lifter boss (Figure 6A2- 13).
If for any reason, the lifters are removed, it is
important that all lifters be reinstalled in their original
location. If replacement is necessary, lifters with a
narrow flat along the lower 3/4 of the length should be
used. This provides additional area to the cam lobe and
lifter surfaces.
Removal
1. Remove rocker arm covers and intake manifold
as previously outlined.
2. Remove rocker arm nuts, rocker arm balls,
rocker arms and push rods. Place components in
a rack so they can be reinstalled in the same
location.
3. Remove lifters.
Installation
1. Install valve lifters. Whenever new valve lifters
are being installed, coat foot of valve lifters with
"Molykote" or its equivalent. Make sure lifter
foot is convex.
Lifter foot is very slightly convex. It can be
detected by holding a good straight edge to the
surface and looking into a light source.
2. Install intake manifold as previously outlined.
3. Install and adjust valve mechanism as previously
outlined.

I Liher Body 6 Push Rod Seat Reta~ner 2 Push Rod Seal 7 Plunger 3 Mater~ng Valve 8 Check Ball Spr~ng 4 Check Ball 9 Plunger Spr~ng 5 Check Ball Rete~ner 10 Olllna Flat
Figure 6A2-14 Valve Lifter
Disassembly
1. Hold the plunger down with a push rod, and
using the blade of a small screw driver, remove
the push rod seat retainer.
2. Remove the push rod seat and metering valve.
3. Remove the plunger, ball check valve assembly
and the plunger spring.
4. Remove the ball check valve and spring by prying
the ball retainer loose from the plunger with the
blade of a small screw driver.
Cleaning and Inspection
Thoroughly clean all parts in cleaning solvent,
and inspect them carefully. If any parts are damaged
or worn, the entire lifter assembly should be replaced.
If the lifter body wall is scuffed or worn, inspect the
cylinder block lifter bore. If the bottom of the lifter is
scuffed or worn, inspect the camshaft lobe. If the push
rod seat is scuffed or worn, inspect the push rod. An
additive containing EP lube, such as EOS, should
always be added to crankcase oil for run-in when any
new camshaft or lifters are installed. All damaged or
worn lifters should be replaced. For proper lifter
rotation during engine operation, lifter foot must be
convex.
Assembly
1. Place
the check ball on small hole in bottom of
the plunger.
2. Insert
check ball spring on seat in ball retainer
and place retainer over ball so that spring rests on
the ball. Carefully press the retainer into position
in plunger with the blade of a small screw driver.
3. Place the plunger spring over the ball retainer and
slide the lifter body over the spring and plunger,
being careful to line up the oil feed holes in the
lifter body and plunger.
4. Fill the assembly with SAE 10 oil, then insert the
end of a
1/8" drift pin into the plunger and press
down solid. Do not attempt to force or pump the
plunger. At this point, oil holes in the lifter body
and plunger assembly will be aligned.
5. Insert a 1/16" drift pin through both oil holes to
hold the plunger down against the lifter spring
tension.
6. Remove
the
1/8" drift pin, refill assembly with
SAE 10 oil.
7. Install the metering valve and push rod seat.
8. Install the push rod seat retainer, press down on
the push rod seat and remove the 1/16" drift pin
from the oil holes. The lifter is now completely
assembled, filled with oil and ready for
installation. Before installing lifters, coat the
bottom of the lifter with "Molykote" or its
equivalent.
CYLINDER HEAD (FIGURE 6A2-15)
Removal (Left)
Remove intake manifold as previously outlined.
Raise vehicle.
Drain engine block.
Disconnect exhaust pipe.
Remove dipstick tube attachment.
Lower vehicle.
Remove serpentine belt.
Remove A/C compressor and lay aside.
Remove
P/S pump and lay aside.
Loosen rocker arm until able to remove push rod.
Remove head bolts.
Remove head.
HEAD TORQUE SEQUENCE
/7 , 2 ing. Using a 12"
Figure 6A2-1'5 Cylinder Head Installation
Installation (Left)
The gasket surfaces on both head and cylinder
case deck must be clean of any foreign matter and free
of nicks of heavy scratches. Cylinder bolt threads in the
case and threads on the cylinder head bolts must be
clean. Dirt will affect bolt torque.
1. Place the gasket in position, over the dowel pins,
with the note "This Side Up" showing.
2. Install cylinder head.
3. Coat cylinder head bolt threads with sealer,
#1052080 or equivalent, and install bolts.

2.8 LITER V.6 6A2.13
Torque bolts as shown in Figure 6A2-15.
4. Install
push rods and loosely retain with rocker
arms. Make sure lower ends of
pushrods are in
lifter seats.
5. Install intake manifold.
6. Raise vehicle.
7. Install dipstick tube bracket.
8. Connect exhaust pipe
to exhaust manifold flange.
9. Lower vehicle.
10. Adjust
valve lash as previously outlined.
11. Continue
following intake manifold installation
for build up.
Removal (Right)
Remove intake manifold as previously outlined.
Raise vehicle.
Disconnect exhaust pipe.
Drain engine block.
Lower vehicle.
Loosen rocker arms until able to remove push
rod.
Remove serpentine belt.
Remove tensioner.
Remove A.I.R. bracket.
Remove generator bracket.
Remove head bolts.
Remove head.
Installation (Right)
The gasket surfaces on both the head and cylinder
case
deck must be clean of any foreign matter and free
of nicks of heavy scratches. Cylinder bolt threads in the
case and threads on the cylinder head bolts must be
clean. Dirt will affect bolt torque.
1. Place the gasket in position, over the dowel pins,
with the note "This Side Up" showing.
2. Install cylinder head.
3. Coat cylinder head bolt threads with sealer,
#lo52080 or equivalent, and install bolts.
Torque bolts as shown in (Figure
6A2-15).
Install push rods and loosely retain with rocker
arms. Make sure lower ends of push rods are in
lifter seats.
Install intake manifold.
Raise vehicle.
Install exhaust pipe to exhaust manifold flange.
Lower vehicle.
Adjust valve lash as previously outlined.
Install AIR bracket.
Install tensioner.
Install generator bracket.
Continue following intake manifold installation
for build up.
Disassembly
1. With cylinder head removed, remove rocker arm
nuts, balls and rocker arms (if not previously
done).
2. Using tool J-8062, compress the valve springs and
remove valve keys. Release the compressor tool and
remove spring caps, oil shedders, springs and
damper assemblies, then remove oil seals.
3. Remove valves from cylinder head and place
them in a rack so they can be installed in their
original positions.
Cleaning and Inspection
Clean all carbon from combustion chambers and
valve ports using 'tool
5-8089.
Thoroughly clean valve guides using 5-8 10 1.
Clean all carbon and sludge from push rods,
rocker arms and push rod guides.
Clean valve stems and heads on a buffing wheel.
Clean carbon deposits from head gasket mating
surface.
Inspect cylinder head for cracks in the exhaust
ports, combustion chambers, or external cracks
to the water jacket.
Inspect the valves for burned heads, cracked faces
or damaged stems.
NOTICE: Excessive valve stem to bore clearance
will cause high oil consumption and may cause
valve breakage. Insufficient clearance will result in
noise and sticky functioning of the valve and
disturb engine smoothness.
8. Measure valve stem clearance as follows:
a. Clamp
a dial indicator on one side of the
cylinder head. Locate the indicator so that
movement of the valve stem from side to
side (crosswise to the head) will cause direct
movement of the indicator stem. The
indicator stem must contact the side of the
valve stem just above the guide.
b. Drop
the valve head
1.5mm off the valve
seat.
c. Move
the stem of the valve from side to side,
using light pressure, to obtain a clearance
reading. If clearance exceeds specifications,
it will be necessary to ream valve guides for
oversize valves. Service valves are available
in std., 089,
.394 and .775mm O.S. sizes.
9. Check
valve spring tension with tool J-8056,
spring tester. Springs should be compressed to the
specified height and checked against the
specifications chart. Springs should be replaced if
not within 44
N (10 Ibs.) of the specified load
(without dampers).
10. Inspect
rocker arm studs for wear or damage.
ROCKER ARM STUDS
Cylinder heads use threaded rocker arm studs.
Rocker arm studs that have damaged threads should
be replaced with new studs. If, for some reason, the
threads in the head
are damaged or stripped, the head
can be retapped, and a helical type insert added. If such
an insert is not available, the head should be replaced.
VALVE GUIDES
Valves with oversize stems are available in .089,
,394 and ,775mm over sizes. To ream the valve guide

BA2-14 2.8 LITER V-6
bores for oversize valves use tool 5-5330-1, 2 or 3,
respectively.
VALVE SEATS
Reconditioning the valve seats is very important,
because the seating of the valves must be perfect for the
engine to deliver the power and performance designed
into it.
Another important factor is the cooling of the
valve heads. Good contact between each valve and its
seat in the head is imperative to insure that the heat in
the valve head will be properly carried away.
Several different types of equipment are available
for reseating valve seats. The recommendations of the
manufacturer of the equipment being used should be
carefully followed to attain proper results.
VALVES
Valves that are pitted can be refaced, to the
proper angle, insuring correct relation between the
head and stem, on a valve
refacing machine. Valve
stems which show excessive wear, or valves that are
warped excessively should be replaced. When a valve
head which is warped excessively is
refaced, a knife
edge will be ground on part or all of the valve head due
to the amount of metal that must be removed to
completely
reface the valve. Knife edges lead to
breakage, burning or preignition due to heat localizing
on this knife edge. If the edge of the valve head is less
than
.8mm thick after grinding, replace the valve.
Several different types of equipment are available
for
refacing valves. The recommendations of the
manufacturer of the equipment being used should be
carefully followed to attain the proper results.
Assembly
Insert a valve in the proper port.
Install a valve stem seal over the valve stem and
valve guide base inlet only.
Drop an oil shedder and valve rotator over the
exhaust and a valve spring cap over the valve
spring.
Using tool
5-8062 compress the valve spring.
Install the square cut
"0" ring around the valve
stem in the lower groove, making sure it is not
twisted.
Insert valve, stem key locks and release tool.
Install the valve locks and release the compressor
tool making sure that the locks seat properly in
the upper groove of the valve stem. Grease may
be used to hold the locks in place while releasing
the compressor tool.
Install the remaining valves.
Check each valve stem oil seal by placing valve
stem leak detector, tool J-23994, over the end of
the valve stem and against the cap. Operate the
vacuum pump and make sure no air leaks pass the
seal.
Check the installed height of the valve springs,
using
a narrow thin scale. Measure from the top
of the spring damper "feet" to the bottom inside
of the oil shedder exhaust and from the top of the
spring damper "feet" to the bottom of the valve
Figure 6A2-16 Checking Valve Spring Installed Height
cap for intake. If this is found to exceed the
specified height, install valve spring seat shim
approximately
.75mm thick. At no time should
the spring be shimmed to give an installed height
under the
minumum specified of 40mm.
TORSIONAL DAMPER
NOTICE: The inertial weight section of the
torsional damper is assembled to the hub with a
rubber sleeve. The removal and installation
procedures (with proper tools) must be followed or
movement of the inertia weight section the hub
will destroy the tuning of the torsional damper and
the engine timing reference.
Removal
1.
Disconnect battery negative cable at battery.
2. Remove serpentine drive belt.
3. Raise vehicle.
4. Remove drive pulley and remove damper
retaining bolt.
5. Install Tool J-23523 on damper and then turning
puller screw, remove damper.
Installation ,
1.
Coat front cover seal contact area (on damper)
with engine oil.
2. Place damper in position over key on crankshaft.
3. Pull damper onto crankshaft as follows:
a. Install
Tool J-29 1 13 into crankshaft so that
at least 6mm of thread engagement is
obtained.
b. Pull damper into position and remove tool
from damper.
4. Install drive pulley and damper retaining bolts.
Torque to specifications.
5. Lower vehicle.
6. Install serpentine belt.
7. Connect battery negative cable.

2.8 LITER V.6 6A2-15
18-30 N.m (13-22 FT. LBS.)
I 11 47-48 N.m (20-35 FT. LBS.) I
Figure 6A2-17 Water Pump/Front Cover Orientation
CRANKCASE FRONT COVER
Removal
1. Raise engine.
2. Remove oil pan.
3. Lower vehicle.
4. Remove water pump as outlined in Section 6B.
5. If A/C equipped, remove compressor from
mounting bracket and lay aside. Then remove
compressor mounting bracket.
6. Remove torsional damper as previously outlined.
7. Disconnect lower radiator hose at front cover and
heater hose at water pump.
8. Remove remaining front cover bolts and remove
cover.
Installation
1. Install new gasket. When installing new gasket,
be sure sealing surfaces are clean. Care should be
taken not to damage sealing surfaces.
2. Place front cover on the engine, install stud bolt
and bolts, install water pump as outlined in
Section 6B, install retaining bolts and nut and
torque to specifications.
3. Connect lower radiator hose to front cover.
Torque clamps to
3.5 N-m (30 lb. in.).
4. Install torsional damper as previously outlined.
5. Install water pump as outlined in Section 6B.
6. If A/C equipped, install compressor mounting
bracket and install compressor.
7. Raise vehicle.
8. Inspect oil pan gasket replace if necessary.
9. Install oil pan.
10. Lower vehicle.
11. Install serpentine belt.
12. Fill cooling system. Leave radiator cap off.
13. Connect battery negative cable and start engine.
14. Run engine until upper radiator hose becomes
hot (thermostat open).
15. Check coolant level and add as necessary.
16. Install radiator cap, making sure arrows on cap
line up with overflow tube.
OIL SEAL (FRONT COVER)
Replacement
With Cover Removed
1. With cover removed, pry oil seal out of cover
from the front with a large screw driver.
2. Install new seal so that open end of the seal is
toward the inside of cover and drive it into
position with Tool
5-23042. Support cover at seal
area. Pre-lube seal with engine oil prior to
installation of torsional damper.
With Cover Installed
1. With torsional damper removed, pry seal out of
cover from the front with a large screw driver,
being careful not to damage the surface on the
crankshaft.
2. Install new seal so that open end of seal is toward
the inside of cover and drive it into position with
To01 5-23042.
Figure 6A2-18 Timing Chain and Sprockets
TIMING CHAIN AND SPROCKET
Removal
1. Remove crankcase front cover as previously
outlined.
2. Place #1 piston at top dead center with the
marks on the camshaft and crankshaft sprockets
aligned (#4 firing).
3. Remove camshaft sprocket bolts and remove
camshaft sprocket and chain (Figure
6A2- 18).
Sprocket is a light fit on camshaft.
If sprocket
does not come off easily, a light blow on the lower
edge of the sprocket (with a plastic mallet) should
dislodge the sprocket.
Installation
1. Install timing chain on camshaft sprocket, lube
thrust surface with Molykote or its equivalent.
Hold the sprocket vertically with the chain
hanging down and align the marks on the
camshaft and crankshaft sprockets. (Refer to
Figure
6A2- 19).

6A2-16 2.8 LITER V-6
Figure 6A2-19 Camshaft Timing
2. Align dowel in camshaft with dowel hole in
camshaft sprocket, then install sprocket on
camshaft.
3. Draw the camshaft sprocket onto camshaft using
the mounting bolts. Torque to specifications.
4. Lubricate timing chain with engine oil.
5. Install crankcase front cover as previously
outlined.
Figure 6A2-20 Measuring Camshaft Lobe Lift
CAMSHAFT
Measuring Lobe Lift Procedure is similar to that
used for checking valve timing. If improper valve
operation is indicated, measure the lift of each push rod
in consecutive order and record the readings.
1. Remove the valve mechanism, as previously
outlined.
2. Position
indicator with ball socket adapater (Tool
5-8520) on push rod. Make sure push rod is in the
lifter socket.
3. Rotate the crankshaft slowly in the direction of
rotation until the lifter is on the heel of the cam lobe.
At this point, the push rod is in its lowest
position.
4. Set the dial indicator on zero, then rotate the
crankshaft slowly, or attach an auxiliary starter
switch and "bump" the engine over, until the
push rod is in the fully raised position (Figure
6A2-20).
CAUTION: Whenever the engine is
cranked remotely at the starter, with
a special jumper cable or other means,
the distributor primary lead must be
disconnected from the coil to prevent
electrical shock.
5. Compare the total lift recorded from the dial
indicator with the specifications.
6. If camshaft readings for all lobes are within
specifications, remove dial indicator assembly.
7. Install and adjust valve mechanism, as previously
outlined.
Removal
1. Remove valve lifters as previously outlined.
2. Remove crankcase front cover as previously
outlined.
3. Remove fuel pump and push rod.
4. Remove timing chain and sprocket as previously
outlined.
5. Remove camshaft.
NOTICE: All camshaft journals are the same
diameter and care must be exercised in removing
camshaft to avoid damage to bearings.
Inspection
The camshaft bearing journals should be
measured with a micrometer for an out-of-round
condition. If the journals exceed
.025mm out-of-round,
the camshaft should be replaced.
Installation
Whenever a new camshaft is installed, coat
camshaft lobes with
GM E.O.S, or equivalent.
Whenever a new camshaft is installed, install new
oil, new filter and replacement of all valve lifters is
recommended to insure durability of the camshaft
lobes and lifter feet.
1. Lubricate camshaft journals with engine oil and
install camshaft.
2. Install timing chain, as previously outlined.
3. Install fuel pump push rod and fuel pump.
4. Install crankcase cover, as previously outlined.
5. Install
lifters, as previously outlined.
6. Complete build up of engine.
CAMSHAFT BEARINGS
Removal
Camshaft bearings can be replaced while engine
is disassembled for overhaul or without complete
disassembly of the engine. To replace bearings without
complete disassembly remove the camshaft and
crankshaft leaving cylinder heads attached and pistons
in place. Before removing crankshaft, tape threads of

2.8 LITER V-6 6A2-17
Figure 6A2-2 1 Camshaft Rear Cover
connecting rod bolts to prevent damage to crankshaft.
Fasten connecting rods against sides of engine so they
will not be in the way while replacing camshaft
bearings.
1. With camshaft and crankshaft removed, remove
camshaft rear cover from cylinder block (Figure
6A2-2 1).
2. Using Tool J-6098, with nut and thrust washer
installed to end of threads, index pilot in camshaft
front bearing and install puller screw through
pilot.
3. Install remover and installer tool with shoulder
toward bearing, making sure a sufficient amount
of threads are engaged.
4. Using two wrenches, hold puller screw while
turning nut. When bearing has been pulled from
bore, remove remover and installer tool and
bearing from puller screw.
5. Remove remaining bearings (except front and
rear) in the same manner. It will be necessary to
index pilot in camshaft rear bearing to remove the
rear intermediate bearing.
6. Assemble remover and installer tool on driver
handle and remove camshaft front and rear
bearings by driving towards center of cylinder
block.
Installation
1. Assemble remover and installer tool on driver
handle and install camshaft bearings.
2. Using Tool Set J-6098, with nut then thrust
washer installed to end of threads, index pilot in
camshaft bearing and install puller screw through
pilot.
3. Index camshaft bearing in bore with oil hole
aligned at
2:30 o'clock on rear and intermediate
bearing. Front bearing has oil holes at
1:00
o'clock and 230.
4. Using two wrenches, hold puller screw while
turning nut. After bearing has been pulled into
bore, remove the remover and installer tool from
puller screw and check alignment of oil hole in
camshaft bearing.
5. Install remaining bearings in the same manner.
6. Install the camshaft rear cover after applying a
fresh 3mm diameter
(1/8") bead of RTV,
#I052917 .or equivalent. Apply RTV or
equivalent on engine block in machined groove.
Sealant must be wet to touch when bolts are
torqued.
NOTICE: Prior to rear cover installation check
that the sealing surfaces on the cover and block are
clean or free of oil. Be sure that all loose RTV is
removed. Make sure that old RTV is removed
from block groove and blind attaching holes.
&'p-x&F--
1 20-30 N~rn (14-22 FT. LBS.)
Figure 6A2-22 Oil Pan
OIL PAN (FIGURE 6A2-22)
Removal
1. Disconnect battery negative cable.
2. Remove air cleaner.
3. Remove distributor cap and lay aside.
4. Remove upper half of fan shroud.
5. Raise vehicle.
6. Drain engine oil.
7. Remove converter dust cover.
8. Remove exhaust
pipe at manifolds.
9. Remove starter bolts and lay starter aside.
10. Remove
motor mount through bolts.
1 1. Remove oil pan bolts.
12. Install jack and raise engine.
13. Remove oil pan.

6A2-18 2.8 LITER V-6
Installation
Clean sealing surfaces on cylinder case and oil
pan.
Install gasket and attach retaining bolts.
Remove jack and lower engine.
Install motor mount through bolts.
Install starter.
Install exhaust pipes.
Install converter dust cover.
Lower vehicle.
Install fan shroud.
Install distributor cap.
Refill crankcase.
Install air cleaner.
Connect battery.
Start engine, check for leaks.
OIL PUMP (FIGURE 6A2-22)
Removal
1. Remove oil pan as previously outlined.
2. Remove pump to rear main bearing cap bolt and
remove pump and extension shaft.
Disassembly
1. Remove
the pump cover attaching bolts and the
pump cover. Mark gear teeth so they may be
reassembled with the same teeth indexing.
2. Remove the idler gear and the drive gear and
shaft from the pump body.
3. Remove the pressure regulator valve retaining
pin pressure regulator spring and valve.
4. If the pickup screen and pipe assembly need
replacing, mount the pump in a soft-jawed vise
and extract pipe from pump cover. Do not disturb
the pickup screen on the pipe. This is serviced as
an assembly.
Cleaning and lnspection
1. Wash all parts in cleaning solvent and dry with
compressed air.
2. Inspect the pump body and cover for cracks or
excessive wear.
3. Inspect pump gears for damage or excessive wear.
The pump gears and body are not serviced
separately. If the pump gears or body are
damaged or worn, replacement of the entire oil
pump assembly is necessary.
4. Check the drive gear shaft for looseness in the
pump body.
5. Inspect inside of pump cover for wear that would
permit oil to leak past the ends of the gears.
6. Inspect the pickup screen and pipe assembly for
damage to screen or pipe.
7. Check the pressure regulator valve for fit.
Assembly
1. If the pickup screen and pipe assembly was
removed, it should be replaced with a new part.
Loss of press fit condition could result in an air
leak and loss of oil pressure. Mount the pump in
a soft-jawed vise, apply sealer to outside diameter of
swaged end of pipe, and using Tool
J-8369 tap
the pipe in place with a plastic hammer.
NOTICE: Be careful of twisting, shearing or
collapsing pipe while installing in pump.
2. Install the pressure regulator valve and related
parts.
3. Install the drive gear and shaft in the pump body.
4. Install the idler gear in the pump body in the
original orientation.
5. Install cover gasket.
6. Install the pump cover and torque attaching
screws to specifications.
7. Turn drive shaft by hand to check for smooth
operation.
Installation
1. Assemble pump and extension shaft with retainer
to rear main bearing cap, aligning top end of
hexagon extension shaft with hexagon socket
lower end of distributor drive gear.
2. Install pump to rear bearing cap bolt and torque
to specifications.
3. Install oil pan as previously outlined.
ROD CAP AND
Figure 6A2-23 Measuring Connecting Rod Side
Clearance
CONNECTING ROD BEARINGS
Connecting rod bearings are of the precision
insert type and do not utilize shims for adjustment. DO
NOT FILE RODS OR ROD CAPS. If clearances are
found to be excessive, a new bearing will be required.
Service bearings are available in standard size and
.013mm and .026mm undersize for use with new and
used standard size crankshafts.
lnspection and Replacement
1. With oil pan and oil pump removed, remove the
connecting rod cap and bearing.
2. Inspect the bearing for evidence of wear or
damage. (Bearings showing the above should not
be reinstalled.)
3. Wipe both upper and lower bearing shells and
crankpin clean of oil.

2.8 LITER V-6 6A2-19
4. Measure the crankpin for out-of-round or taper
with a micrometer. If not within specifications,
replace or recondition the crankshaft. If within
specifications and a new bearing is to be installed,
measure the maximum diameter of the crankpin,
to determine new bearing size required.
5. If within specifications, measure new or used
bearing clearance with Plastigage or its
equivalent.
NOTICE: If a bearing is being fitted to an
out-of-round crankpin, be sure to fit to the
maximum diameter of the crankpin. If the bearing
is fitted to the minimum diameter and the
crankpin is out-of-round .025mm interference
between the bearing and
crankpin will result in a
rapid bearing failure.
a.
Place a piece of gaging plastic the full width
of the
crankpin as contacted by the bearing
(parallel to the crankshaft).
b. Install
the bearing in the connecting rod and
cap.
c. Install
the rod cap and evenly torque nuts
to specifications. Do not turn the crankshaft
with gaging plastic installed.
d. Remove
the rod cap and using the scale on
the gaging plastic envelope, measure the
gaging plastic width at the widest point.
6. If
the clearance exceeds specifications, select a
new, correct size, bearing and remeasure the
clearance.
If clearance cannot be brought to within
specifications, the
crankpin will have to be
ground undersize. If the
crankpin is already
at maximum undersize, replace crankshaft.
7. Coat the
bearing surface with oil, install the rod
cap and torque nuts to 50
N-m (37 lb. ft.).
8. When all connecting rod bearings have been
installed tap each rod lightly (parallel to the
crankpin) to make sure they have clearance.
9. Measure all connecting rod side clearances (see
specifications) between the rod cap and
crankshaft throw (Figure 6A2-23).
MAIN BEARINGS (FIGURE 6A2-24)
Main bearings are of the precision insert type and
do not utilize shims for adjustment. If clearances are
found to be excessive, a new bearing, both upper and
lower halves, will be required. Service bearings are
available in standard size and undersize.
Selective fitting of both rod and main bearing
inserts is necessary in production in order to obtain
close tolerances. For this reason you may find one half
of a standard insert with one half of a
.016mm
undersize insert which will decrease the clearance
.008mm from using a full standard bearing.
Inspection
In general, the lower half of the bearing (except
# 1 bearing) shows a greater wear and the most distress
from fatigue. If upon inspection, the lower half is
suitable for use, it can be assumed that the upper half
APPLY OIL TO ALL MAlN BEARINGS
E WITH ARROW ON CAP
FRONT OF ENGINE.
(1, 2 8, 3 ONLY).
Figure 6A2-24 Main Bearings
is also satisfactory. Of the lower half shows evidence
of wear or damage, both upper and lower halves should
be replaced. Never replace one half without replacing
the other half.
Checking Clearance
To obtain the most accurate results with
"Plastigage", (or its equivalent), a wax-like plastic
material which will compress evenly between the
bearing and journal surfaces without damaging either
surface, certain precautions should be observed.
If the engine is out of the vehicle and upside
down, the crankshaft will rest on the upper bearings
and the total clearance can be measured between the
lower bearing and journal. If the engine is to remain in
the vehicle, the crankshaft should be supported both
front and rear to remove the clearance from the upper
bearing. The toal clearance can then be measured
between the lower bearing and journal. When checking
# 1 main bearing, loosen accessory drive belts so as to
prevent tapered reading with plastic gage.
NOTICE: To assure the proper seating of the
crankshaft, all bearing cap bolts should be at their
specified torque. In addition, prior to checking the
bearing fit, the surface of the crankshaft journal
and bearing should be wiped clean of oil.
1. With the oil pan and oil pump removed, and
starting with the rear main bearing, remove
bearing cap and wipe oil from journal and bearing
cap.
2. Place a piece of gaging plastic the full width of the
bearing (parallel to the crankshaft) on the
journal. Do not rotate the crankshaft while the
gaging plastic is between the bearing and journal.
3. Install
the bearing cap and evenly torque the
retaining bolts to 95
N.m (70 lb. ft.). Bearing cap
MUST be torqued to specification in order to
assure proper reading. Variations in torque affect
the compression of the plastic gage.