2.8l v6 - Vins [s,w,9] Chevrolet Camaro III рестайлинг

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Engine may be identified from the Vehicle Identification Number (VIN) stamped on metal tab located on top of instrument panel at lower left of windshield. The VIN number contains 17 characters. The 8th character identifies engine and 10th character establishes model year.

ENGINE IDENTIFICATION CODES

Valve Arrangement

E-I-I-E-I-E (Left bank, front-to-rear).

E-I-E-I-I-E (Right bank, front-to-rear).

Note. This procedure applies only to the VIN S, W & 9 engines with aluminum cylinder heads. The VIN W engines with cast iron cylinder heads are "zero lash" and not adjustable; just torque rocker arm nut to 18 Ft. Lbs. (25.2 N.m)

1. Rotate crankshaft to No. 1 firing position and adjust intake valves on No. 1, 5 and 6, and exhaust valves on No. 1, 2 and 3.
2. Adjust valves by backing off adjusting nut until lash is felt at push rod, then tighten until all lash is removed. Tighten adjusting nut an additional 1 1/2 turns. (Scheme 1)
3. Rotate crankshaft to No. 4 firing position and adjust intake valves on No. 2, 3 and 4, then exhaust valves on No. 4, 5 and 6.

Adjusting Valve Lash. Scheme 1

TROUBLE SHOOTING

Note. To trouble shoot engine mechanical components, see appropriate TROUBLE SHOOTING article in GENERAL INFORMATION.

ENGINE

See ENGINE REMOVAL article in this section.

Removal

Note. To relieve fuel system pressure, connect Fuel Gauge (J34730- to fuel pressure tap. To avoid spillage, wrap a shop towel around fitting while connecting. Install bleed hose into an approved gasoline container. Open valve to bleed down the fuel system pressure.

1. Disconnect negative battery cable. Drain cooling system. Remove air cleaner. Disconnect accelerator and throttle valve cable bracket at upper intake manifold. Disconnect EGR pipe at EGR valve.
2. Remove accessory drive belt. Disconnect heater pipe at power steering pump bracket and remove power steering pump bracket. Disconnect alternator electrical connectors and remove alternator. Remove upper intake manifold. Disconnect wires at cold start injector and port injectors.
3. Disconnect fuel lines at fuel rail and remove fuel rail. Remove spark plug wires at distributor. Mark position of distributor rotor, and remove distributor. Disconnect upper radiator hose and coolant sensor electrical connectors at thermostat housing.
4. Remove valve covers and thermostat at housing. Remove intermediate manifold bolts and intermediate manifold. Remove lower manifold bolts and lower manifold. Clean loose RTV sealer from front and rear ridges of cylinder block.

VINs "S" & "9" Intake Manifold Components. Scheme 2

VIN "W" Intake Manifold Components & Tightening Sequence. Scheme 3

Upper Intake Manifold Tightening Sequence (VINs S & 9). Scheme 4

Intermediate Intake Manifold Tightening Sequence (VINs S & 9). Scheme 5

Lower Intake Manifold Tightening Sequence (VINs S & 9). Scheme 6

Scheme 7

1. Clean sealing surfaces on cylinder head, valve covers and intake manifold. Apply bead of RTV sealer on front and rear ridges of cylinder block. Install new intake manifold gaskets on cylinder heads. Hold in place by extending bead of RTV sealer onto gasket ends. When applying sealer, keep out of bolt holes to prevent hydraulic lock of retaining bolts. NOTE: Intake manifold gaskets are marked Right Side and Left Side. Top of each gasket will have to be cut to install behind push rods. (Scheme 7) (Scheme 7): Installing Intake Manifold Gasket Gaskets are marked Right Side and Left Side.
2. Install intake manifold and check area between ridges and manifold for complete seal. Install bolts and nuts, and tighten in sequence. (Scheme 2)-6. To complete installation, reverse appropriate removal procedure.

Removal (Left Side)

1. Disconnect negative battery cable. Remove air cleaner. Remove air mass flow sensor and heat shield. Disconnect exhaust crossover pipe at manifold.
2. Raise vehicle on hoist and disconnect exhaust pipe. Lower vehicle, disconnect A.I.R management hoses and wires if equipped. Remove power steering bracket. Remove exhaust manifold bolts and remove manifold.

Removal (Right Side)

1. Disconnect negative battery cable. Remove air cleaner. Disconnect A.I.R. bracket at exhaust flange. Remove heat shield.
2. On MFI models, disconnect accelerator and throttle valve cable at throttle lever. Remove accelerator and throttle valve bracket from upper intake manifold. Disconnect power steering line at power steering pump. Remove EGR valve.
3. On all models, disconnect oxygen sensor, A.I.R. management hose and valve. Disconnect exhaust crossover pipe. Raise vehicle on hoist and disconnect exhaust pipe. Lower vehicle. Remove exhaust manifold bolts and exhaust manifold.

Installation

Clean RTV sealer from exhaust manifold and cylinder head mating surfaces. Position manifold to cylinder head. Install new bolts and tighten in sequence, from inside to outside. Reverse removal procedure to complete installation.

CYLINDER HEAD

Note. If cylinder head refinishing is needed, DO NOT machine more than .010" (.25 mm) from gasket surface.

1. Remove intake and exhaust manifolds as previously described. Remove alternator bracket. Remove A.I.R. management valve, pump, hose and brackets, if equipped. Remove dipstick tube and bracket.
2. Remove cruise control servo bracket, if equipped. Remove valve covers, loosen rocker arms and remove push rods. Note position of all components for proper reassembly. Remove head bolts, cylinder heads and gaskets.

Inspection

1. Place on wood blocks to prevent gasket surface damage. Check cylinder head and block gasket surface for flatness. Gasket surface flatness is .003" (.08 mm) in any 6" span and .006" (.152 mm) overall. Replace if either head or block must be machined more than .010" (.25 mm).
2. Check push rod straightness. If runout exceeds .015" (.38 mm), replace push rod. DO NOT attempt to straighten. Apply Molykote to rocker arm contact points and push rod ends during installation.

Scheme 8

1. Clean cylinder block and cylinder head mating surfaces. Ensure mating surfaces are free of any nicks or heavy scratches. Clean bolt hole threads in cylinder block to ensure proper bolt torque.
2. Install gaskets over dowel pins with note "This Side Up" showing. Install cylinder heads. Apply sealing compound to head bolt threads and tighten in sequence in 3 steps. (Scheme 8) NOTE: For VIN W engines, the cylinder head bolt should be tighten to 33 ft. lbs. (45 N.m.). Then, turn all head bolts an additional 90 degrees. The VIN S and 9 head bolt tightening torque is 65-90 ft. lbs. (88-122 N.m.) (Scheme 8): Cylinder Head Tightening Sequence Apply sealant to bolts and tighten in sequence in 2 steps.
3. Install push rods and rocker arms. On VIN W engines tighten rocker arm nuts to 15-20 ft. lbs. (20-27 N.m). On other engines adjust valves. Ensure lower ends of push rods are in lifter seats. Reverse removal procedure to complete installation.

Description

Powertrain mounts are nonadjustable hydraulic types and seldom require service. Broken or deteriorated mounts should be replaced immediately, because of added strain placed on other mounts and drive line components.

Checking

Raise engine to remove weight from mounts and to place a slight tension on rubber. Observe both mounts while raising engine. If a powertrain mount exhibits hard rubber surface covered with heat check cracks, rubber separated from metal plate of mount or rubber split through center, then replace mount.

If there is relative movement between a metal plate of mount and its attaching points, lower engine on mounts and tighten screws or nuts attaching mount of engine, frame or bracket.

Remove mount retaining nuts from below cradle mounting bracket. Raise engine to provide clearance. Remove mount to engine bracket nuts and mount.

Install mount and mount to engine bracket. Lower engine. Install mount retaining nuts. Tighten mount retaining nuts to 35 ft.lbs. (48 N.m).

Note. After engine mount installation, observe transaxle mounts for proper alignment. If window A in Fig. (Scheme 14) is not properly located, reposition it. If allowed to remain out of position, drive train component could fail.

Support transaxle. Remove crossmember to mount nuts, bracket to transaxle bolts, mount and bracket assembly, mount to bracket nut and mount.

Install mount on transaxle bracket, mount assembly to transaxle, mount to crossmember nuts and tighten. Install bracket to transaxle bolts and tighten.

Engine Strut. Scheme 9

Engine Mount. Scheme 10

Front & Rear Mount Assembly. Scheme 11

Transaxle Brackets (Rear). Scheme 12

Transaxle Brackets (Front). Scheme 13

Transaxle Mount Alignment. Scheme 14

Transaxle Mount Hole Location. Scheme 15

VALVES

Note. When reconditioning valves, ensure interference angles of valve and seat are not lapped out. Remove grooves and/or score marks from end of valve stem with oil stone. DO NOT remove more than .010" (.254 mm) from valve stem end.

VALVE GUIDE SERVICING

1. With cylinder head removed and disassembled, check valve stem-to-guide clearance. If valve stem-to-guide clearance exceeds specifications, ream valve guide to next oversize, using Valve Guide Reamer (J-5330-1, 2 or 3 respectively). Valves are available with .0035", .0155" and .0305" oversize stems.
2. To check valve guide wear, insert valve with head positioned .059" (1.5 mm) away from valve seat. Attach dial gauge to cylinder head. Position gauge indicator against valve stem at right angle and just above guide. Move valve in guide and note guide wear shown on dial gauge.
3. Maximum dial gauge reading for intake valve-to-guide clearance is shown in specification table. Use Valve Guide Cleaner (J-8101) to clean guides. Use valve guide reamers in sequence to ream guides for installation of valves with oversize stems.
4. Reface valve seat after valve guide is reamed. If valve seat face is reground, check margin width dimension. Check valve seats for proper angle and seat width. Measure valve seat runout. Valve seat runout should be within .002" (.05 mm) for intake and exhaust.
5. Intake valve seat width is .049-.059" (1.25-1.50 mm). Exhaust valve seat width is .063-.075" (1.60-1.91 mm). Use scraper to break (lightly chamfer or bevel) sharp top inside edge of guide. After valve guide repair, inspect valve stem end for wear before installation. Valve stem end may be reconditioned by grinding.
6. Check valve head for warpage. Do not reface valve if knife edge will result. Knife edges lead to breakage, burning or pre-ignition due to heat localizing on edge. If edge of valve head is less than .031" (.8 mm) thick after grinding, replace valve.

VALVE STEM OIL SEALS

Note. An "O" ring seal is installed on lower groove of valve stem on all valves. A Teflon type oil seal is installed on intake valves only. Oil on stem will prevent twisting of "O" ring seal during installation. If oversized valves are used, install oversized valve stem oil seals.

1. If valve or valve seat has not been damaged, valve springs, seals, cup shields (exhaust valves only) and retainers may be replaced by holding affected valve against seat using air pressure.
2. Use Compressed Air Line Adapter (J-23590) installed in spark plug hole. A minimum of 140 psi (9.8 kg/cm 2 ) line pressure is required. If air pressure does not hold valve shut, valve is damaged or burned and cylinder head must be removed for service.
3. After removing rocker arm, reinstall rocker arm bolt. Insert slotted end of Valve Spring Compressor (J-5892) under rocker bolt head. Compress valve spring and remove valve retainer locks. Remove tool, retainer, cup shield (exhaust valves only), spring and oil seal.
4. With valve in head, install plastic seal protector cap over end of valve stem. Oil protector cap and start stem seal carefully over cap. Push seal down until seal jacket touches top of valve guide. Remove plastic seal protector cap. Using Valve Seal Installer (J-22330), bottom seal on valve guide.

Note. Use Valve Seal Tester (J-23994) to apply vacuum to valve cap to ensure no air leaks past new valve seal.

1. Remove valve cover, spark plug, rocker arm and push rod on cylinder(s) to be serviced. Be sure piston is at top of stroke with both valves closed. Install air line adapter to spark plug port and apply compressed air to hold valves in place.

Exploded View of Intake & Exhaust Valve Assembly Valve stem oil seals are on intake valves only. Scheme 16

1. Check valve spring for out of square with 90° straightedge. Valve spring out of square service limit is .0625" (1.588 mm) for intake and exhaust springs. Check valve spring compression pressure (without dampers) with valve spring tester. Springs should be replaced if not within 10 lbs. (4.5 kg) of specified load. Check valve spring free length. Standard free length is 1.91" (48.5 mm).
2. Position valve spring, damper, oil seal (intake only), oil shield (exhaust only) and valve retainer cap in place. Compress spring and install "O" ring type seals in lower groove of stems. Be sure seal is flat and not twisted. Lightly coat seal with oil, install valve locks and release compressor tool.
3. Ensure valve locks are properly seated in upper groove of valve stem. Remove air pressure and adapter and install spark plugs. Apply polyethylene grease to ends of push rods and tip of valve stems. Install rocker arms and tighten.

CHECKING VALVE SPRING INSTALLED HEIGHT

Installed height of valve spring should be 1.575" (40 mm). Measure from top of spring seat to top of oil shield (exhaust only) or retainer (intake only). If measurement exceeds specifications, install.030" (.75 mm) shim at spring seat. DO NOT install more than one shim. Ensure spring height with shim does not result in installed height under minimum specification. (Scheme 17)

Checking Valve Spring Installed Height. Scheme 17

ROCKER ARM STUDS REPLACEMENT

Cylinder heads use threaded rocker arm studs. Rocker arm studs having damaged threads should be replaced with new studs. If threads in head are damaged or stripped, head can be retapped and helical type insert installed. If helical insert is not available, replace cylinder head.

HYDRAULIC VALVE LIFTER ASSEMBLY REPLACEMENT

Note. Before replacing hydraulic lifter for noisy operation, be sure noise is not caused by improper collapsed lifter gap, worn rocker arms, pushrods or valve tips. If lifter assembly is stuck in bore, use Hydraulic Lifter Puller (J-3049) or magnet.

Scheme 18

Scheme 19

1. Hydraulic lifter assemblies must be installed in original locations. Remove valve cover and intake manifold. Loosen rocker arm and rotate for clearance from push rod. Remove push rod. Using lifter remover tool or magnet, remove lifters.
2. Clean and inspect lifters, but do not mix components or positions. Parts are select-fitted and not interchangeable. (Scheme 18) (Scheme 18): Exploded View of Hydraulic Lifter Assembly Check lifter leakdown rate with test fluid in lifter.
3. If plunger is not free in body of lifter, replace entire assembly. Plunger should drop to bottom of body by its own weight when assembled dry. Assemble lifter and check free operation by pressing down on cap. NOTE: Check lifters with test fluid only. New lifters already contain test fluid. If new lifter is installed, remove sealer coating from inside of new lifter and check leak-down rate.
4. Place lifter upright in Hydraulic Lifter Leak-Down Tester (J-5790) and check leak-down rate. Leak-down rate is 12-90 seconds measured at.0938" (2.38 mm) plunger travel, under 50 lb. (22 kg) load.
5. Inspect lifter base-to-cam lobe contact area. Surface must have smooth and convex contact face. Replace any lifter with flat or concave surface. Inspect related cam lobe for proper lobe lift. Replace camshaft (and lifters if necessary) if any lobe is worn beyond specification. NOTE: Some engines have both standard and.010" oversize valve lifters. The cylinder block will be marked with White paint, where the oversize lifters are installed, and.010" O.S. will be stamped on lifter boss. (Scheme 19) (Scheme 19): Oversize Lifter Marking Cylinder block is marked where oversize lifter is installed.
6. Check lifter-to-bore clearance. Standard clearance is.0008-.0025" (.020-.064 mm). Standard diameter of lifter is.8420-.8427" (21.387-21.405 mm). Standard lifter bore diameter is.8435-.8445" (21.425-21.450 mm).
7. Coat lifter base with Molykote. When installing, ensure lifter is on base circle of camshaft. Tighten rocker arm bolt. Coat gasket surfaces with RTV sealer and install valve covers and intake manifold.

OIL PAN

See OIL PAN REMOVAL article in this section.

1. With cylinder head(s) and oil pan removed, inspect cylinder bores for ridges and/or deposits. Move piston to be removed to bottom of bore and cover with cloth to catch cuttings.
2. Before removing pistons from block, remove ridge at top of cylinder bores with ridge reamer. Rotate crankshaft and inspect connecting rods and rod caps for cylinder identification. Mark them if necessary.
3. Remove rod cap and push each piston and rod assembly out top of cylinder bore. To protect crankshaft, place rubber hose over rod bolts. Remove bearing inserts from rod and cap and inspect for size, wear and damage. Install rod caps on mating rods.

Note. Notch on top of piston faces front of engine. Pistons are numbered from front to rear with No. 2-4-6 on left bank and No. 1-3-5 on right bank.

1. Check fit of new piston and rings in cylinder bore before assembling piston and pin to connecting rod. Check piston pin for clearance, etching and wear. New pistons must be installed in the cylinder for which they were fitted. Install used pistons in the cylinder from which they were removed.
2. Measure cylinder bore diameter, then measure piston diameter (with rod and pin removed) at skirt across centerline of piston pin. Maximum fitted clearance is.002" (.05 mm) for new pistons and.0024" (.06 mm) for used pistons.
3. Oil piston rings and cylinder walls with light coat of oil. Ensure ring gaps are properly spaced and install Ring Compressor (J-8037 or J-8910) on piston. (Scheme 20) Marked side of compression rings must be toward top of piston. Position piston so that identification numbers on rod and cap are on same side.
4. Install rubber hose on connecting rod bolts before installing piston and rod assembly in bore. Tap gently with wooden handle to insert piston assembly into cylinder bore.
5. After bearings have been inserted, apply engine oil to journals and bearings. Ensure oil hole in bearing insert aligns with oil hole in connecting rod. Turn crankshaft throw to bottom of its stroke. Guide piston and rod assembly over crankshaft journal until rod bearing seats.
6. Remove rod bolt protectors. Match rod cap to rod and install. Tighten cap nuts in two steps. Repeat procedure for each piston assembly. After piston and rod assembly is installed, check side clearance of connecting rod on each crankshaft journal.

FITTING PISTONS

1. Inspect piston for cracks, scoring, holes and worn ring grooves. Inspect rod bores for out-of-round and wear.
2. Measure piston clearances. Ensure piston and cylinder bore are clean, dry and at room temperature 70°F (21°C) during measurement. Measure diameter of cylinder bore at top, middle and bottom with gauge at right angle and parallel to centerline of engine.
3. Inspect cylinder walls for scoring, roughness or other signs of wear. Check bore for out-of-round and taper. Cylinder bore out-of-round should not be more than .0008" (.020 mm). Cylinder bore taper should not be more than .0008" (.020 mm).
4. Measure outer diameter of piston at centerline of pin bore and 90° to pin bore axis. If cylinder bore measurements differ by .0005" (.013 mm), bore cylinder block to next size oversize.
5. Before cylinder refinishing, ensure that main bearing caps are in place and tightened to avoid distortion during refinishing operation. Pistons are available in standard size and .020" and .040" oversizes. See Piston Size Code Chart. PISTON SIZE CODE CHART Code (1) Inches (mm) Standard S4 3.5039-3.5044 (89.001-89.014) S5 3.5044-3.5050 (89.014-89.027) Maximum Limit S6 3.5050-3.5055 (89.027-89.040) S7 3.5055-3.5060 (89.040-89.053) .020" (.50 mm) Oversize 1 3.5236-3.5241 (89.501-89.514) 2 3.5241-3.5246 (89.514-89.527) 3 3.5246-3.5251 (89.527-89.540) 4 3.5251-3.5257 (89.540-89.553) .040" (1.0 mm) Oversize 1 3.5433-3.5438 (90.001-90.014) 2 3.5438-3.5443 (90.014-90.027) 3 3.5443-3.5448 (90.027-90.040) 4 3.5448-3.5453 (90.040-90.053) (1) Coded numbers are for piston Identification purposes. Number is stamped on, or attached to piston.
6. Measure new piston and bore and/or hone cylinder to correct clearance. After refinishing operation, allow bore to cool, then clean bore with soap and water solution and oil cylinder walls.

Scheme 20

1. Clean ring grooves with ring groove cleaner or piece of broken ring. Ensure oil holes (or slots) in piston are clean. Measure piston ring side and end gap clearance for all pistons.
2. Ring side clearance should be checked with feeler gauge between ring and piston lower ring land. Gauge should slide freely around entire circumference without binding. If step has formed around inner portion of lower ring land, piston must be replaced.
3. Using piston to position ring in cylinder bore, position ring.236" (6 mm) from top of bore and check ring end gap. Install rings on pistons with end gaps staggered at proper intervals. Ensure ring gap is not in line with thrust face of pin bore.
4. Be sure manufacturer's marks face up when rings are installed. Install oil ring expander first, followed by lower side rail. Do not use ring expander on side rails. When installing lower side rail, place one end between piston ring groove and expander.
5. Hold end firmly and press down portion to be installed until side rail is in position. Install upper side rail. Using ring expander, install intermediate and upper rings. Check that all components are within specifications. (Scheme 20): Piston Ring Gap Spacing
6. If new piston rings are to be installed and no visible cross-hatch marks remain on cylinder walls, remove cylinder wall glaze using spring-type honing tool. After honing, clean bore and block with soap and water solution and oil cylinder walls.

FITTING PISTON PINS

Note. When removing or installing piston pin, connecting rod should be in firm contact with body of pin setting tool.

1. Remove bearing inserts from connecting rod and cap. Mark pistons, pins and inserts (if reusable) to assure assembly with same rod. Press piston pin from piston and connecting rod using Piston Support (J-24086-20).
2. Inspect and replace any piston pin showing signs of fracture, etching or wear. Check piston pin-to-rod bore fit and piston pin-to-piston fit. If pin bore in rod or piston is larger than specification, replace connecting rod or piston.
3. Ensure proper fit by honing or reaming piston pin bore to light slip fit. Check table for proper specification. Standard piston pin diameter is .9052-.9055" (22.993-23.002 mm). Lubricate pin and small end of rod bore with engine oil.

1. Check piston to cylinder bore clearance before assembling piston and pin to connecting rod. Ensure oil hole in connecting rod aligns with oil hole in bearing and arrow or notch on top of piston is pointed toward front of engine.
2. Start piston pin in piston and connecting rod. Using guide bar and push rod, press pin through both piston and rod until pilot hub bottoms on support fixture and/or pin is centered in piston. After pilot hub bottoms, DO NOT exceed 5000 lbs. (2275 kg) pressure with press. Remove piston assembly from tool and check piston pin for freedom of movement.

CONNECTING ROD BEARINGS

Note. Following procedures are with oil pan and cylinder head(s) removed. Main and rod bearing size is indicated by letter stamped into bearing tang or actual bearing size stamped opposite of tang. Bearing marks are as follows: A = .0005", B = .0010", and C = .0015".

1. Remove connecting rod bearing caps and mark rods and caps for proper installation. Replace defective bearings. Use Plastigage method for checking bearing clearance.
2. Measure outside diameter of crankshaft connecting rod bearing journals to determine if out-of-round or tapered. Journal out-of-round must not exceed .0002" (.005 mm) in a half turn. Journal runout (one turn) must not exceed .0002" (.005 mm). Journal taper must not exceed .0002" (.005 mm).
3. When checking connecting rod clearances, crankshaft does not have to be supported. Instead, turn crankshaft until connecting rod to be checked starts moving toward top of engine, thus unloading lower bearing.
4. Using Plastigage method check connecting rod bearing clearance. If clearance exceeds specifications, replace bearing. NOTE: If clearance cannot be brought within specifications with service bearings, grind crankshaft to next undersize. If already ground to maximum undersize, replace crankshaft.
5. Selective fitting is required on each connecting rod. After inspection and/or replacement, coat bearing surfaces with engine oil. Tighten connecting rod bearing caps in two steps. NOTE: Connecting rod bearing cap and rod identification numbers must remain on same side. Never file or grind connecting rods or caps when fitting bearings.
6. Tap each connecting rod lightly (parallel to crankshaft) to ensure clearance. Check connecting rod side clearance between connecting rod cap and crankshaft throw with feeler gauge. Compare reading to specifications, if clearance is excessive replace connecting rod and cap.
7. During assembly, ensure oil hole in bearing aligns with oil hole in connecting rod. Check bearing tangs are seated in appropriate slots in rod and cap. Ensure connecting rod bolt heads are properly seated in connecting rod.

MAIN BEARING CHECKING

Note. Following procedures are with oil pan and cylinder head(s) removed. Main and rod bearing size is indicated by letter stamped into bearing tang or actual bearing size stamped opposite of tang. Bearing marks are as follows: A = .0005", B = .0010", and C = .0015".

1. Inspect each bearing for wear and replace defective bearings. Measure outside diameter of crankshaft main bearing journals in at least four places to determine if out-of-round or tapered.
2. Journal out-of-round must not exceed .0002" (.005 mm) in a half turn. Journal runout (one turn) must not exceed .0002" (.005 mm). Journal taper must not exceed .0002" (.005 mm). NOTE: Observe location of high spots on main bearings. If high spots are not in line, crankshaft may be bent and should be checked.
3. To check main bearings with engine in vehicle, crankshaft should be supported front and rear to remove clearance from upper bearing. DO NOT support under crankshaft pulley, crankshaft post damage will result. With all bearing caps (other than one being checked) tight, check clearances using Plastigage method. When checking No. 1 main bearing, loosen accessory drive belts to prevent false reading.
4. If engine is out of vehicle and upside down, crankshaft will rest on upper bearings and clearance can be checked between lower bearing and journal using Plastigage method. NOTE: New bearings are available in standard, .0005" and .001" undersize for use with standard size crankshaft. Replace upper and lower inserts as a unit. If undersize bearings are used on more than one journal, position in cylinder block rather than bearing cap.
5. If standard and undersize bearing combination do not bring bearing clearance within specified limits, crankshaft will have to be refinished and undersized bearings installed. If journal will not clean up to maximum undersize bearing, replace crankshaft.
6. When journals are refinished, chamfer oil holes and polish journals with No. 320 grit polishing cloth and engine oil. After chamfer and polish operations, clean crankshaft thoroughly in solvent and blow out oil passages with compressed air.
7. When crankshaft main bearings are installed, ensure oil distributing grooves on bearings are installed on same side. Oil new upper bearing and insert plain (unnotched) end between crankshaft and notched side of block. Rotate bearing into place. Ensure main bearing caps are installed with arrows pointing toward front of engine. Install main cap bolts and tighten.

THRUST BEARING ALIGNMENT

1. Check crankshaft end play with crankshaft bearing caps installed. Mount dial indicator to front of engine and locate probe on nose of crankshaft. Move crankshaft to rear of its travel. Zero dial indicator.
2. Move crankshaft forward and read end play on gauge. Replace No. 3 main thrust bearing (upper and lower) if not to specification. Standard crankshaft end play is .0024-.0083" (.06-.21 mm). Rotate crankshaft to ensure there is no excessive drag.

Remove transaxle/transmission and flywheel. Remove old seal by inserting screwdriver through the dust lip at an angle and prying out. Care must be used not to damage the surface of the crankshaft. Check seal bore and crankshaft for nicks and burrs.

1. Apply light coat of engine oil to new seal. Place seal on Seal Installer (J-34686) until dust lip bottoms against collar of tool. Align dowel pin of tool with dowel pin hole in crankshaft. Attach tool to crankshaft by hand or tighten attaching screws to 2-5 ft. lbs.
2. Turn "T" handle of tool so that collar pushes seal into bore. Turn handle until collar is tight against engine block. Loosen "T" handle, remove attaching screws and installing tool.
3. Check to ensure that seal is seated squarely into bore. Install flywheel. Install transaxle/transmission.

TORSIONAL DAMPER

Note. The inertia weight section of torsional damper is assembled to hub with rubber sleeve. Use proper tools for removal and installation or hub will be ruined.

Disconnect negative battery cable. Remove accessory drive belts. Raise vehicle. Remove inner fender splash shield. Remove accessory drive pulley and damper retaining bolt. Install Hub Puller (J-23523). Turn puller bolt and remove damper.

Note. The torsional damper has three timing notches on inertia ring. No. 1 cylinder timing reference is shown by White paint (in production). If new damper assembly is installed, mark in same location for reference. No. 1 cylinder reference is first clockwise mark from keyway when viewed from front of engine.

1. Coat front cover seal contact area on damper with oil. Clean and apply sealant to key and keyway. Place damper in position over key on crankshaft. Using Hub Installer (J-29113), pull damper in position on hub leaving .24" (6 mm) of thread engagement. Remove installation tool.
2. Install accessory drive pulley and damper retaining bolts and tighten. Install inner fender splash shield. Lower vehicle. Install belts. Tighten belts, nuts and bolts. Connect battery cable.

1. Disconnect negative battery cable. Remove accessory drive belts and drain cooling system. Remove A/C compressor, A.I.R. pump and bracket if equipped.
2. Disconnect lower radiator hose at front cover and heater hose at water pump connection. Remove water pump. Raise vehicle. Remove torsional damper. Remove oil pan-to-front cover bolts.
3. Lower vehicle. Remove remaining front cover retaining bolts, front cover and gasket. Clean all gasket sealing surfaces of sealer and check for nicks, cracks or damage to components. (Scheme 21)

Water Pump and Front Cover (2.8L VIN S). Scheme 21

Water Pump and Front Cover (2.8L VIN W). Scheme 22

Scheme 23

1. Apply continuous bead of anaerobic sealant to front cover sealing surface. (Scheme 23) Apply continuous bead of RTV sealer to oil pan surface of front cover. Install components within 5 minutes of sealant application. (Scheme 23): Front Cover Sealant Placement
2. Place front cover on engine and install stud bolt and remaining attaching bolts. Install water pump. Install water pump retaining bolts and tighten. Reverse removal procedure to complete installation. Run engine until thermostat opens. Check for leaks at all gasket junctions. Check coolant level and add coolant as necessary.

The oil seal may be replaced without removing front cover. Remove drive belts and related components. Raise vehicle. Remove torsional damper. Using large screwdriver, carefully wedge between crankshaft and seal. Pry seal out of cover from front. Use caution when removing seal to insure crankshaft is not damaged.

Install new seal with open end of seal facing inside of front cover. Using Seal Aligner (J-23042), drive seal into position. To complete installation, reverse removal procedure.

Scheme 24

1. Remove front engine cover and rotate No. 1 piston to TDC. Align timing marks on crankshaft and camshaft sprockets (No. 4 firing position). Remove camshaft sprocket-to-camshaft bolts. Remove sprocket and chain. (Scheme 24) (Scheme 24): Timing Chain Sprocket Alignment Remove sprocket by tapping lower edge with plastic mallet.
2. Sprocket is a light press fit on camshaft. If sprocket does not come off easily, dislodge by tapping lightly on lower edge of sprocket with plastic mallet.

1. Install timing chain over camshaft sprocket. Lube thrust surface with Molykote. Hold sprocket vertically with chain hanging down. Align marks on camshaft and crankshaft sprockets. (Scheme 24)
2. Align dowel on camshaft with dowel hole in camshaft sprocket. Install chain and sprocket on camshaft. Use mounting bolts to draw sprocket onto camshaft and tighten bolts.
3. Check sprocket alignment. Lubricate timing chain with engine oil. To complete installation, install front engine cover (with new seal) and reverse removal procedure.

1. With engine removed from vehicle, remove front engine cover. Remove intake manifold, rocker arm assemblies, push rods and valve lifters. If equipped, remove mechanical fuel pump and fuel pump push rod. Keep all components separate and in order of removal for proper installation.
2. Rotate No. 1 piston to TDC. Align timing marks on crankshaft and camshaft sprockets (No. 4 firing position). Remove camshaft sprocket retaining bolts. Remove timing chain and sprocket from end of camshaft. Remove camshaft.

Note. All camshaft journals are the same diameter. Use care during removal to avoid damage to camshaft bearings.

Lubricate journals with engine oil and apply Molykote to camshaft lobes. If new camshaft is installed, ensure new lifters, oil filter and oil are also installed. Carefully install camshaft, making sure not to nick or damage camshaft lobes or journals. Reverse removal procedure to complete installation.

1. With engine removed from of vehicle, remove crankshaft and camshaft. Leave piston assemblies installed but move pistons up into bores and fasten connecting rods against sides of engine. Remove camshaft rear cover from cylinder block.
2. Use Camshaft Bearing Remover (J-6098) with nut and thrust washer installed to end of threads. Index pilot in camshaft front bearing and install puller bolt through pilot.
3. Install tool with shoulder toward bearing and ensure sufficient amount of threads engage. Using two wrenches, hold puller bolt while turning nut. When bearing is out of block, remove tool components and bearing.
4. Remove front intermediate bearing, with remover indexed on front bearing. Remove rear intermediate bearing, with tool indexed on rear bearing. Assemble bearing remover on driver handle and remove front and rear bearings by driving them toward center of cylinder block.

1. Assemble remover/installer tool on driver handle and install camshaft bearings. Install front and rear bearings first. These act as guides for the pilot and center the remaining bearings which are being pulled into place. Install front and rear bearings by driving toward the center of the block.
2. During installation, position bearings so that oil holes line up with oil gallery holes in the block. Front bearing has oil holes at 1:00 and 2:30 positions. Rear and intermediate bearings have oil hole between 2 and 3 o'clock positions.
3. Install each center bearing using same index location used in removal. Pull bearings into bearing saddle from the center. With bearings installed, check alignment of oil holes in block and bearing.
4. Apply RTV sealer to camshaft end cover and install. Apply RTV sealer onto engine block in machined groove. Sealant must be wet when installing. Tighten bolts. Reverse removal procedure to complete operation.

Disconnect battery ground cable, then drain cooling system. Disconnect heater hose at water pump, then remove drive belts and water pump pulley. Using the existing tapped hole in the cylinder head, install tool No. J-29167 and torque mounting bolt to 10 ft. lbs. Remove water pump attaching bolts, then remove pump assembly from engine.

Clean mating surfaces of water pump and cylinder block, then apply a bead of sealant or equivalent to water pump mating surface. Apply sealant to pump attaching bolt threads, then install water pump assembly. Torque to specification. Remove tool J-29176, then install water pump pulley and drive belts and connect heater hose to pump. Fill cooling system and connect battery ground cable, then start engine and check for leaks.

Note. For further information on cooling system capacities and other cooling system components, see ENGINE COOLING SYSTEMS article in the ENGINE COOLING section.

CRANKCASE CAPACITY

Four quarts (3.8 liters) with or without filter change.

NORMAL OIL PRESSURE

Normal oil pressure is 50-65 psi (3.5-4.5 kg/cm 2 ) @ 1200 RPM.

PRESSURE REGULATOR VALVE

Pressure regulator valve in oil pump body is not adjustable.

Oil is supplied under pressure by gear type pump, driven by distributor, which in turn is driven by helical gear on camshaft. The left main oil gallery (along upper left side of camshaft) supplies oil to left side hydraulic lifters. The left gallery also supplies oil to the camshaft bearings, crankshaft and right gallery.

The right oil gallery supplies oil to right side hydraulic lifters. The oil supplied to lifters lubricate rocker arms through hollow push rods. All other components are lubricated by splash or nozzle.

Disconnect negative battery cable and drain crankcase. Raise vehicle. Remove starter. Remove flywheel dustcover. Disconnect exhaust pipe at manifold. Support engine and remove engine mount bracket. Remove oil pan bolts and remove oil pan. Clean gasket surfaces and bolt holes of old RTV sealer. Remove bolt attaching oil pump to rear main bearing cap. Remove pump and extension shaft.

Exploded View of Oil Pump. Scheme 25

Disassembly

1. Remove pump cover attaching bolts and pump cover. Mark teeth on both gears for reassembly with same teeth indexing. Remove idler gear, drive gear and shaft from pump body.
2. Remove pressure regulator valve retaining pin, valve and spring. If pickup screen and pipe assembly need replacement, mount pump in soft-jawed vise and remove pipe from pump cover. DO NOT disturb pickup screen on pipe. This is serviced as an assembly.

Note. If pump gears or body are damaged or worn, replace pump. Do not disturb pickup screen on pipe, screen is serviced as an assembly only. If removed, replace with new part. Be careful of twisting, shearing or collapsing pipe while installing in pump.

1. Check oil pump body for cracks or excessive wear. Inspect pump gears for cracks, excessive wear or damage. Check shaft for looseness in housing. Replace pump as a unit if necessary.
2. Check inside of cover for wear that would permit oil to leak past ends of gears. Check oil pickup screen for damage to screen or relief grommet. Remove any debris from surface of screen.

OIL PUMP SPECIFICATIONS

Reassembly

1. When assembling oil pump, fill pump cavities with petroleum jelly to ensure immediate oil pressure. If oil pickup tube and screen were replaced, apply sealer to outside of swaged end of pipe. Using Installer Tool (J-8369), tap pipe into place with plastic mallet.
2. Install pressure regulator valve, spring and retaining pin. Install idler gear, drive gear and shaft into pump body. Install pump cover and check drive shaft for free operation.

Install oil pump in engine with top end of hexagon extension shaft aligned with hexagon socket in lower end of distributor drive gear. To complete installation, reverse removal procedures.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS (VIN W)

GENERAL ENGINE SPECIFICATIONS (VIN S)

GENERAL ENGINE SPECIFICATIONS (VIN 9)

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTONS, PINS, RINGS SPECIFICATIONS

PISTONS, PINS, RINGS SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

VALVE SPRINGS SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION