5.0l Tbi (305") v8 - VIN E Chevrolet Camaro III рестайлинг

ENGINE IDENTIFICATION

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

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 CLEARANCE ADJUSTMENT

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 Arrangement

E-I-I-E-E-I-I-E (Both banks, Front-to-rear).

1. To adjust valves, rotate crankshaft to No. 1 firing position and adjust following valves: Intake No. 1, 2, 5 and 7. Exhaust No. 1, 3, 4 and 8.
2. Adjust valves by backing off adjusting nut until lash is felt at push rod, then tighten until lash is removed. Tighten adjusting nut an additional one full turn.
3. Rotate crankshaft to No. 6 firing position. Adjust following valves: Intake No. 3, 4, 6 and 8. Exhaust No. 2, 5, 6 and 7.
4. When adjustment is complete, install valve covers. Start engine and check timing.

REMOVAL & INSTALLATION

FUEL PRESSURE RELEASE

Disconnect negative battery cable. Loosen fuel filler cap. DO NOT tighten fuel filler cap until repair procedure is complete.

ENGINE

See appropriate ENGINE REMOVAL article.

Removal

1. Disconnect negative battery cable and drain cooling system. Remove air cleaner assembly. Disconnect computer control harness and set aside. Remove upper radiator hose at thermostat and heater hose at intake manifold.
2. Remove thermostat housing and gasket. Mark and remove necessary electrical connectors and vacuum hoses. Relieve fuel system pressure. See «FUEL PRESSURE RELEASE»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e__fuel-pressure-release) . Disconnect and cap fuel inlet and return lines.
3. Disconnect throttle and throttle valve cable. Disconnect cruise control cable (if equipped). Mark and remove spark plug wires at distributor cap. Remove EGR valve. Remove distributor cap.
4. Mark distributor position for installation reference and remove distributor. Remove ignition coil and coolant temperature switch. Remove intake manifold bolts and studs. Remove intake manifold and gaskets.

Installation

1. Clean mating surfaces. Install NEW gaskets on cylinder heads.
2. Apply 3/16" (5 mm) bead of RTV sealant along front and rear ridge of block. Place sealant around water passages and about 1/2" (13 mm) up each head to seal and retain manifold side gaskets.
3. Install manifold and bolts. Tighten bolts in sequence to specification. (Scheme 26) See «TORQUE SPECIFICATIONS»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e__torque-specifications). Reverse removal procedure to complete installation. Adjust timing and check for leaks.

Intake Manifold Bolt Tightening Sequence. Scheme 26

Removal (Left Side)

1. Disconnect negative battery cable. Label and disconnect spark plug wires. Disconnect air injection hoses. If equipped with A/C, remove A/C compressor and set aside without disconnecting hoses. Remove power steering pump and set aside without disconnecting hoses.
2. Loosen accessory brackets and move to side. Remove rear A/C and power steering adjusting bracket (if equipped). Remove lower power steering adjusting bracket. Raise and support vehicle. Remove exhaust pipe nuts at exhaust manifold and suspend exhaust pipe with wire. Lower vehicle. Remove exhaust manifold bolts and exhaust manifold.

Removal (Right Side)

Disconnect negative battery cable. Label and disconnect spark plug wires. Disconnect air injection hoses. Remove air management valve. Raise and support vehicle. Remove exhaust pipe nuts at exhaust manifold and suspend exhaust pipe with wire. Lower vehicle. Remove engine dipstick tube as necessary. Remove exhaust manifold bolts and exhaust manifold.

Clean mating surfaces of exhaust manifold and cylinder head. Position exhaust manifold and install bolts finger-tight. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Reverse removal procedure to complete installation.

CYLINDER HEAD

Note. Check compression before removal of cylinder head. Remove when cold. Check for warped gasket surface, nicks or damage. If cylinder head refinishing is needed, DO NOT machine more than .010" (.25 mm) from gasket surface. Replace head if cracked. Remove burrs or scratches with oil stone.

1. Remove intake manifold. See «INTAKE MANIFOLD»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e) . Remove exhaust manifold. See «EXHAUST MANIFOLD»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e) . Remove lower alternator mounting bolt and position alternator aside. NOTE: When removing valve covers, DO NOT distort sealing flange.
2. Remove valve covers and rocker arm assemblies. Drain coolant. Remove diverter valve, head bolts and cylinder heads. Remove gaskets.

Note. When servicing head, remove carbon deposits from combustion chamber with scraper and wire brush before removing valves. When disassembling, mark valve components for proper reassembly.

1. Clean cylinder block and head mating surfaces of gasket material, carbon and dirt. Ensure mating surfaces are free of nicks or scratches.
2. Clean bolt hole threads in cylinder block to ensure proper bolt torque. If steel gaskets are used, apply thin, even coat of sealer to both sides of gasket.
3. On composition steel asbestos gaskets, DO NOT use sealer. Install gaskets over dowel pins with "bead" side up. Install cylinder heads.
4. Apply sealing compound to head bolt threads. Install and tighten in sequence to specification. (Scheme 27) See «TORQUE SPECIFICATIONS»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e__torque-specifications). Reverse removal procedure to complete installation.

Cylinder Head Bolt Tightening Sequence. Scheme 27

Remove valve covers. See VALVE COVERS . Keep components in order to ensure installation to original location and position. Remove rocker arm nuts, balls, rocker arms and push rods. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Apply Prelube (3755008) to rocker arm and ball mating surface. Adjust valves as necessary. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

ROCKER ARM STUDS

Note. Cylinder heads use pressed-in rocker arm studs. Replace studs with damaged threads or loose fit in head. Studs are available in standard, .003" and .013" oversize.

Remove valve cover and rocker arm assembly for stud needing repair. Place Rocker Arm Stud Puller (J-5802-1) over stud. Install flat washer and nut. Tighten nut until stud is removed.

1. Using Reamer (J-5715 for .003" and J-6036 for .013" oversize studs), ream stud hole for oversize stud, as necessary. DO NOT install oversize stud without reaming stud hole, as damage to head may occur.
2. Coat press fit area of stud with hypoid gear oil. Drive stud into place using Stud Guide (J-6880) and hammer. When stud guide bottoms on head, stud is at correct height.

OIL PAN

See appropriate OIL PAN REMOVAL article.

PISTON & ROD ASSEMBLY

Note. When removing ridge at top of cylinder bore, never cut into ring travel area more than .03125" (.794 mm). Before removing piston and connecting rod, ensure rod caps are marked to their related rods for proper reassembly. DO NOT damage crankshaft journals or cylinder wall during removal.

1. With cylinder heads, oil pan, and oil pump 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. Remove ridge at top of cylinder bores (using ridge reamer) before removing pistons from block. Rotate crankshaft and inspect rods and caps for identification. Mark if necessary.
3. Remove rod cap and push each piston and rod assembly out top of cylinder bore. To protect crankshaft, place Connecting Rod Bolt Guide Set (J-5239) or 3/8" rubber hose over rod bolts. Remove bearing inserts from rod and cap. Inspect for size, wear and damage. Install rod caps on mating rods.

Note. Notch on piston top faces front of engine. Pistons are numbered from front-to-rear with No. 2-4-6-8 on right bank and No. 1-3-5-7 on left bank.

1. Check fit of new piston and/or rings in cylinder bore before assembling piston and pin to connecting rod. Install piston on connecting rod. Check piston pin for clearance, etching or wear. New pistons must be installed in cylinder for which they were fitted, used pistons in cylinders from which they were removed.
2. Measure cylinder bore diameter. Measure piston diameter (at skirt, across centerline of piston pin). Oil piston rings and cylinder walls. Ensure ring gaps are properly spaced. Install ring compressor on piston. Marked side of rings must be toward top of piston. Position piston with identification marks on rod and cap on same side.
3. Install rod bolt guide set or rubber sleeves before installing piston and rod assembly in bore. Tap gently with wooden handle to insert piston/rod assembly into cylinder bore.
4. After bearings have been inserted, oil journals and bearings. Ensure oil hole in bearing aligns with oil hole in rod. Turn crankshaft throw to bottom of stroke. Guide piston/rod assembly over crankshaft journal until rod bearing seats.
5. Remove rod bolt protectors. Match rod cap to rod and install. Tighten cap nuts in two steps. Repeat for each piston assembly. After piston/rod assembly is installed, check side clearance of rod on each crankshaft journal.

VALVE & VALVE GUIDE SERVICING

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.

1. To check valve guide wear, insert valve with head positioned 1/16" above seat. Attach dial indicator to cylinder head. Position dial indicator stem against valve stem just above guide.
2. Move valve in guide and measure wear shown on indicator. If guide wear is excessive, ream to next oversize. Service valves are available in standard, .003", .015" and .030" oversize.
3. Clean valve guides. Reface valve seat if guide is reamed. If valve seat face is reground, check margin width dimension.
4. Check seats for proper angle and width. Measure valve seat runout. Runout should be within .002" (.05 mm) for intake and exhaust.
5. Use scraper to break (lightly chamfer or bevel) sharp top inside edge of guide. After guide repair, inspect valve stem end for wear. Valve stem end may be reconditioned by grinding to proper dimension at 90° angle.
6. Check valve head for warpage. DO NOT reface if knife edge will result. Knife edges lead to breakage, burning or pre-ignition due to heat localizing on edge. Replace if edge of valve head is less than .031" (.79 mm) thick after grinding.
7. When new valves are installed or after grinding, measure valve stem height. Ensure that there is at least .015" (.381 mm) minimum clearance between gauge surface and end of valve stem. Ensure that distance between gauge surface and spring retainer is .030" (.76 mm) minimum.
8. If gauge-to-stem clearance is less than specification, remove valve and grind tip of stem at 90° angle for clearance. Note that valve stem with less than .005" (.13 mm) above spring retainer is too short and must be replaced.

Removal (Cylinder Head Installed)

1. Rotate engine to TDC of compression stroke. Remove valve cover, spark plug, rocker arms and push rods on cylinder(s) to be serviced.
2. Install Air Line Adapter (J-23590) to spark plug port. Apply minimum of 140 psi (9.8 kg/cm 2 ) line pressure to hold valves in place. NOTE: If air pressure fails to hold valve closed, remove cylinder head for inspection.
3. Using Spring Compressor (J-5892), compress valve spring and remove valve locks, retainer cap (or rotator), spring and damper. Remove valve stem oil seal.

Removal (Cylinder Head Removed)

1. With rocker arm removed, compress valve spring using Spring Compressor (J-8062). Remove valve locks. Release compressor.
2. Remove valve retainer (or rotator), spring and damper, oil seals and shim(s). Keep components in order for installation in original location.

Inspection

1. Check valve spring for out of square with 90° straightedge. Out of square service limit is .0625" (1.588 mm) for intake and exhaust springs.
2. Check valve spring tension using Valve Spring Tester (J-8056). Springs must be within 10 lbs. of specified load at required height (without dampers). CAUTION: Install shims only if necessary. DO NOT use more than 2 shims.
3. Check valve springs for proper installed height of 1.688-1.750" (42.88-44.45 mm).
4. Measure from top of valve seat to top of valve spring or bottom of valve retainer. If height is excessive, install .0625" (1.587 mm) valve spring seat shim. Ensure spring height with shim does not result in installed height under minimum specification.

To install, reverse removal procedure.

Oil seals are installed on all valve stems and must be replaced when valve service is performed. To remove oil seals, see VALVE SPRINGS for disassembly procedure.

1. To reassemble, coat seals with oil. Install valve stem oil seal over stem and seat against cylinder head. Set shim, spring, damper, oil shedder and valve cap (or rotator) in place and compress spring.
2. Install oil seal on lower groove of stem. Ensure seal is flat and not twisted. Install retainer locks. Release valve spring compressor and remove air line adapter. After assembly, use Vacuum Applier (J-23994) to apply vacuum to valve cap. Ensure no air leaks past seal. To complete installation, reverse removal procedure.

HYDRAULIC VALVE LIFTER ASSEMBLY

Note. Before replacing lifter for noisy operation, ensure noise is not caused by improper collapsed lifter gap, worn rocker arms, push rods or valve tips. If lifter assembly is stuck in bore, use lifter puller or magnet.

Scheme 28

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 and, using Hydraulic Lifter Puller (BT-6407 or J-3049) or magnet, remove lifters.
2. Clean and inspect but DO NOT mix components or positions. Parts are select-fitted and not interchangeable. If lifter is sticking, disassemble and clean dirt, metal chips or varnish from components. If lifter check valve is not functional, obstructions may prevent it from closing when cam lobe is moving lifter or check valve spring may be broken. (Scheme 28) (Scheme 28): Exploded View of Hydraulic Lifter Assembly
3. Clean or replace components as necessary. 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: Camshaft lobes are ground, hardened and tapered with high side of lobe toward rear of engine. This causes lifters to rotate.
4. 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 any lobe is worn beyond specification.
5. Check lifter-to-bore clearance. Standard clearance is.0005-.0020" (.013-.051 mm). Standard diameter of lifter is.8422-.8427" (21.392-21.405 mm). Standard lifter bore diameter is.8435-.8445" (21.425-21.450 mm). NOTE: When performing leak-down test, lifters cannot be checked with engine oil, only test fluid. New lifters already contain test fluid. If new lifter is installed, remove sealer coating from inside and check leak-down rate. If old lifter is disassembled and cleaned, fill with test fluid before installing and testing.
6. Place lifter upright in Hydraulic Lifter Leak-Down Tester (J-5790). Check leak-down rate. Leak-down rate is 12-90 seconds measured at.0938" (2.38 mm) plunger travel, under 50 lb. (23 kg) load.
7. Coat lifter base with Molykote. When installing, ensure lifter is on base circle of camshaft. Tighten rocker arm bolt to specification. Coat gasket surfaces with RTV sealer. Install valve covers and intake manifold.

FITTING PISTONS

1. Inspect pistons. Replace any showing signs of excessive wear, wavy ring lands, or fractures. Replace if sponge-like or eroded surface is on edge of piston top (caused by detonation or pre-ignition).
2. If shiny surface on thrust side of piston is found, check for bent connecting rod. DO NOT straighten rod, replace as necessary. Inspect rods for signs of fracture and bearing bores for out-of-round and taper. If bore exceeds limits and/or rod is fractured, replace rod.
3. Check pistons for fractures at ring lands, skirts and pin bosses. Check for scuffed, rough or scored skirts. When measuring piston for side clearance or taper, measurement must be made at centerline of pin bore and 90° from piston pin hole.
4. Check piston-to-cylinder bore clearance by measuring piston and bore diameters. Ensure piston and cylinder bore are clean, dry and at room temperature 70°F (21°C) during measurement.
5. Measure diameter of cylinder bore at top, middle and bottom with gauge at right angle and parallel to centerline of engine. Inspect cylinder walls for scoring, roughness or wear. Check bore for out-of-round and taper. Standard bore out-of-round is .0010" (.025 mm). Maximum is .0020" (.051 mm).
6. Cylinder bore taper should not be more than .0005" (.013 mm) for thrust side and .0010" (.025 mm) for relief side. If cylinder wall is severely marred and/or worn, refinishing is needed.
7. Before cylinder refinishing, ensure main bearing caps are in place and tightened to specification to avoid distortion during refinishing operation. Pistons are available in standard, standard high limit and .010" oversize.

Scheme 29

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, check ring end gap at least.63" (16 mm) from bottom of bore. Install rings on pistons with end gaps staggered at proper intervals. Ensure ring gap is not in line with thrust face of pin bore. (Scheme 29) (Scheme 29): Piston Ring Gap Spacing (Notch On Piston Top Faces Front Of Engine)
4. Be sure manufacturer's marks face up when rings are installed. Install oil ring expander first, followed by lower side rail and upper side rail. DO NOT use ring expander on side rails; use only on middle and top rings.
5. If new piston rings are to be installed and no cross-hatch marks remain on cylinder walls, remove cylinder glaze using spring-type honing tool. After honing, clean bore and block with soap/water solution and oil cylinder walls.

PISTON PINS

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

1. Remove inserts from connecting rod and cap. Mark pistons, pins and inserts (if reusable) to assure assembly with same rod. Press pin from piston and rod using arbor press and Piston Pin Remover/Installer (J-24086-8 and 9).
2. Inspect and replace any piston pin showing signs of fracture, etching or wear. Check pin-to-rod bore fit. Check ID of rod pin bore. If pin bore in rod is larger than specification, replace rod.
3. Ensure proper fit by honing or reaming piston pin bore to light slip fit. If clearance exceeds .0010" (.025 mm), replace piston and pin assembly. Standard piston pin diameter is .9270-.9273" (23.54-23.55 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 rod. Ensure oil hole in rod aligns with oil hole in bearing, and arrow on top of piston is pointed toward front of engine.
2. Start piston pin in piston and 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. (2268 kg) pressure with press. Ensure piston floats during pin installation operation.

Note. Following procedures are with oil pan and cylinder heads 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". During production, .009" undersize bearings may have been installed for close tolerances on some journals.

CONNECTING ROD BEARING SERVICE

1. Remove connecting rod bearing caps and mark rods and caps for proper installation. Inspect each bearing for peeling, melting, seizure or improper contact. Replace defective bearings. Use Plastigage method for bearing clearance check.
2. Measure outside diameter of rod bearing journals to determine if out-of-round or tapered. Standard journal out-of-round is .0005" (.013 mm) and must not exceed .0010" (.025 mm). Standard journal taper is .0005" (.013 mm) and must not exceed .0010" (.025 mm). If journals are more than .0010" (.025 mm) out-of-round or tapered, crankshaft must be reconditioned or replaced.
3. When checking connecting rod clearances, do not support crankshaft. Instead, turn crankshaft until rod to be checked starts moving up, thus unloading lower bearing.
4. Cut Plastigage to same length as width of rod bearing. Place in bearing cap, parallel with crankshaft (not over oil hole or groove). Install rod bearings and cap and tighten. Always install caps with markings in original positions.
5. DO NOT turn crankshaft with Plastigage installed. Remove rod bearing cap from crankshaft and measure Plastigage at its widest part (using scale on Plastigage package). 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.
6. Selective fitting is required on each connecting rod. Service bearings are available in standard size, .001" and .002" undersize for new or used standard size crankshaft. Bearings of .010" and .020" undersize are for use with reconditioned crankshafts. After inspection and/or replacement, coat bearing surfaces with oil. Tighten connecting rod bearing caps in two steps. NOTE: Connecting rod bearing cap and rod identification numbers must remain on same side. Always replace the bearings in pairs. Never use new bearing in combination with used bearing. Never file or grind connecting rods or caps when fitting bearings.
7. Check for shiny surface on either side of piston pin boss, indicating bent connecting rod. Twisted rods will not create identifiable wear patterns, but will disturb the action of entire crankshaft assembly and may cause excessive oil consumption.
8. Check connecting rod side clearance with dial gauge indicator resting against rod cap. Pull cap toward front of engine and zero gauge. Push cap toward rear of engine and compare readings. If excessive, replace rod and cap.
9. Standard connecting rod side clearance is .006-.014" (.15-.36 mm). If side clearance is less than specification, remove rod and cap. Check for scratches, burrs, nicks or dirt between crankshaft and rod. Dress minor imperfections with oil stone.
10. 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 rod bolt heads are properly seated in rod.

MAIN BEARING SERVICE

Note. Selective fit main bearings are used. If a .009" undersize and a .010" undersize bearings were used for precision fitting during production, the main bearing cap is painted Light Green on each side of affected journal. The crankshaft throw will also be stamped with a "9" on one side of undersize journal, and have a large spot of Light Green paint.

1. Inspect each bearing for peeling, melting, seizure or improper contact. Replace defective bearings. If copper-lead bearing base is visible but is not showing in more than 20% of total area, bearing is not excessively worn. NOTE: DO NOT scrape gum or varnish deposits, clean inserts and caps in solvent. DO NOT file or lap caps to obtain proper bearing clearance. If main bearing caps are replaced, shimming may be needed. Laminated shims are available in various sizes.
2. Measure outside diameter of crankshaft main bearing journals in at least four places to determine if out-of-round or tapered. Standard journal out-of-round is .0002" (.005 mm) and must not exceed .0010" (.025 mm). Standard journal taper is .0002" (.005 mm) and must not exceed .0010" (.025 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 bearing clearance, shim adjacent main bearings to bearing being checked. Alternate method is to position jack under counterweight adjoining bearing being checked so weight of crankshaft will not compress Plastigage and provide incorrect reading.
4. DO NOT position jack under crankshaft pulley. Crankshaft post damage will result. With all bearing caps (other than one being checked) tight, check clearances using Plastigage method. DO NOT turn crankshaft with Plastigage installed. NOTE: New bearings are available in standard size and .0010", .0020", .0090", .010" and .020" undersize. Replace both upper and lower inserts together. 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 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. Remove and replace crankshaft sprocket as necessary. NOTE: Crankshaft sprocket removal will require Sprocket Remover (J-5825). Sprocket installation will require Sprocket Installer (J-5590).
6. If journals are remachined, ensure same journal shoulder radius is reproduced. Too small a radius results in fatigue failure of crankshaft. Too large a radius results in bearing failure due to radial ride of bearing.
7. 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 in solvent and blow out oil passages with compressed air.
8. When main bearings are installed, ensure oil 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.

Note. Some production engines may have rear main bearings that the distance between thrust faces is .008" wider than standard. Crankshaft will have .008" stamped on rear counterweight. Ensure proper distance between thrust faces is maintained if rear main bearings are replaced.

THRUST BEARING ALIGNMENT

1. Tighten main bearing cap bolts (except rear main) to specification. Tighten rear main bolts to 11 ft. lbs. (15 N.m). Tap end of crankshaft rearward and forward to line up main bearing thrust surfaces with crankshaft thrust face.
2. Tighten all main bearing cap bolts to specification. Rotate crankshaft to ensure there is no excessive drag. Measure end play at front end of rear main bearing using feeler gauge. Standard end play is .002-.006" (.05-.15 mm).

1. Remove oil pan bolts and lower oil pan. Remove transmission.
2. Remove retainer and seal assembly. Remove gasket.

Note. Whenever the retainer is removed, a new retainer gasket and rear main seal must be installed.

1. Clean mating surfaces of case and retainer assembly. Install new gasket on studs in engine case. It is not necessary to use any type of sealant to retain gasket in place.
2. Install retainer to case bolts, torque bolts to 90-120 INCH lbs. (10-13 N.m). Install transmission. Inspect oil pan gasket for damage. Replace gasket if necessary. Apply a small amount of 1052751 or equivalent to front and rear corners of oil pan. NOTE: Only a small amount of sealant is required. Excessive amounts of sealant may cause a problem with proper sealing of oil pan.
3. Install oil pan bolts. Install rear main seal using tool J-35621 as previously outlined. (Scheme 30)

Installing Crankshaft Rear Oil Seal. Scheme 30

TORSIONAL DAMPER

Note. The inertia weight section of torsional damper is assembled to hub with rubber sleeve. Removal and installation procedures (using proper tools) must be followed, or movement of inertia weight section on hub will destroy tuning of damper and engine timing reference.

Disconnect negative battery cable. Remove accessory drive belt(s). Raise vehicle, if necessary, and remove crankshaft pulley and damper retaining bolt. Install puller/installer. Turn puller bolt and remove damper.

1. Coat front cover seal contact area on damper with oil. Place damper in position over key on crankshaft. Using hub puller/installer, position threaded end of tool on crankshaft, ensuring .50" (13 mm) of thread engagement.
2. Install remaining tool components and pull damper into position. Remove installer tool. Install crankshaft pulley. Install and tighten damper retaining bolts. Install accessory drive belt(s) and related components. Tighten belts, nuts and bolts.

1. Drain cooling system. Remove fan shroud or radiator upper support, as applicable. Remove fan and pulley from water pump hub. Remove torsional damper. See «TORSIONAL DAMPER»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e__torsional-damper) .
2. Remove alternator upper and lower brackets, air brace and bracket, and power steering pump lower bracket (if equipped) from water pump and swing aside.
3. Remove radiator lower hose and heater hose from water pump. Remove water pump-to-block attaching bolts. Remove water pump. Remove front cover attaching screws, front cover, and gasket. Discard gasket.

1. Clean gasket surfaces. Apply gasket sealer to new gasket. Apply RTV sealer to joint formed where oil pan meets cylinder block (trim excess gasket material that protrudes at junction). Place gasket on cover. Install cover-to-oil pan seal. Place light coat of engine oil on bottom of seal.
2. Place cover over end of crankshaft and loosely install upper cover-to-block bolts. Tighten bolts alternately while pressing down on cover so dowels are aligned with holes in cover. DO NOT force cover over dowels, or hole distortion will result.
3. Install remaining bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e__torque-specifications) . Install torsional damper, pulley, fan, belts and water pump. To complete installation, reverse removal procedure. Refill cooling system. Start engine and check for leaks.

The oil seal may be replaced without removing cover. Remove torsional damper. Pry old seal out with large screwdriver. Be careful not to damage sealing surface of crankshaft or block.

Install new seal with open end toward inside of cover. Drive seal into position using Oil Seal Installer (J-23042). To complete installation, reverse the removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Remove front engine cover. See FRONT ENGINE COVER . Using torsional damper retaining bolt to rotate crankshaft, align timing marks. Remove camshaft sprocket bolts. Use 2 large screwdrivers to alternately pry camshaft sprocket forward until free.

Scheme 31

1. With camshaft installed, place timing chain over camshaft sprocket so that it hangs below sprocket. Align marks on camshaft and crankshaft sprockets. (Scheme 31) (Scheme 31): Timing Chain Sprocket Alignment
2. Align dowel in camshaft with dowel hole in camshaft sprocket and install sprocket. Use mounting bolts to draw sprocket onto camshaft. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e__torque-specifications). Check sprocket alignment, lubricate chain and install remaining components.

1. Disconnect battery. Drain cooling system. Remove fan shroud or upper radiator support, if necessary. Remove drive belt(s). Remove fan and pulley. Remove upper and lower alternator brackets and power steering pump lower bracket from water pump (if equipped) and swing aside.
2. Remove lower radiator hose and heater hose from water pump. Remove water pump-to-block attaching bolts and pump.

To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . If using a new pump, transfer pulley and heater hose fitting from old pump. Use new gasket.

Note. For information on cooling system capacities and other cooling system components, see appropriate ENGINE COOLING article.

1. Disconnect negative battery cable. Mark and disconnect spark plug wires at spark plugs. Remove necessary AIR hoses. Mark and remove necessary electrical connectors.
2. Remove necessary accessories and brackets. Remove bolts retaining valve covers. Use a block of wood and rubber mallet to loosen valve cover (if necessary). Remove valve cover and gasket. To install, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e__torque-specifications) .

1. Remove intake manifold. See «INTAKE MANIFOLD»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e) . Remove valve covers. See «VALVE COVERS»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e) . Loosen rocker arms and remove pushrods. See «ROCKER ARMS & PUSH RODS»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e) . Remove lifters.
2. Disconnect upper and lower transmission cooler lines at radiator, if equipped. Remove cooling fan and fan shroud. Remove radiator. Remove water pump and front engine cover. See «FRONT ENGINE COVER»(/chevrolet/camaro/iii-1985-1992/remont/mechanical/#50l-tbi-305-v8-vin-e) .
3. Rotate crankshaft and align timing marks. Remove camshaft sprocket bolts, camshaft sprocket and timing chain. Install two 5/16"-18 x 4" bolts in camshaft bolt holes and carefully remove camshaft.

Note. All camshaft journals are same diameter. Use care when removing camshaft to prevent damage to lobes or journals.

1. Check camshaft journals for out-of-round condition. If journals exceed .001" (.025 mm) out-of-round, replace camshaft and lifters. Check camshaft end play. Standard end play is .0040-.0012" (.038-.127 mm). If not to specification, check camshaft end cover for grooves or wear. Replace as necessary.
2. Check camshaft lobe lift. Attach dial indicator with a ball/socket attachment to camshaft carrier or "V" block. Measure lobe lift. If lobe lift loss is more than .002" (.05 mm), replace camshaft. Check camshaft journal-to-bearing clearance. Standard clearance is .0010-.0040" (.025-.101 mm).

Note. Camshaft lobes are ground, hardened and tapered with high side of lobe toward rear of engine. This causes valve lifters to rotate.

Lubricate journals with engine oil and, on new camshafts, apply Molykote to camshaft lobes. Carefully install camshaft. Complete installation by reversing removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

1. With crankshaft and camshaft removed, fasten rods against side of engine, out of work way. Drive rear camshaft plug out of block. Using Camshaft Bearing Remover (J-6098), index pilot in front bearing and install puller screw through pilot.
2. Install tool with shoulder toward No. 2 bearing. Ensure enough threads are engaged. With two wrenches, hold puller screw while turning nut. With bearing pulled from bore, remove tool and bearing from screw. Remove No. 3 bearing in same manner.
3. Index pilot in rear bearing to pull rear intermediate (No. 4) bearing. Assemble remover on driver handle, and remove front and rear bearings by driving toward center of block.

1. Install front and rear bearings first. These bearings act as guides for pilot and center remaining bearings being pulled into place. Assemble tool on driver handle. Align oil holes. Install camshaft front and rear bearings by driving toward center of block. NOTE: No. 1 bearing should be installed so oil holes are an equal distant from 6 o'clock position; No. 2 through No. 4 bearings should be installed with oil holes at 5 o'clock position; and No. 5 at 12 o'clock position.
2. Using camshaft bearing remover, install two center bearings with oil holes aligned with holes in block. Coat camshaft plug with sealer. Plug should be installed flush to 1/32" (.79 mm) deep and parallel with block surface. Reverse removal procedure to complete installation.

CRANKCASE CAPACITY

On all V8 engines, crankcase capacity without filter change is 4 quarts (3.8L). With filter change, 5.0 quarts (4.7L).

NORMAL OIL PRESSURE

On all engines, oil pressure is 50-65 psi (3.5-4.6 kg/cm 2 ) @ 2000 RPM.

PRESSURE REGULATOR VALVE

Pressure regulator valve is located in oil pump body and is nonadjustable.

ENGINE OILING SYSTEM

Oil is supplied under pressure by gear-type pump, driven by distributor, which in turn is driven by helical gear on camshaft. The main oil gallery (down center of block above camshaft) feeds oil through drilled passages to camshaft and crankshaft to lubricate bearings. The valve lifter oil gallery feeds lifters which, through hollow push rods, feed rocker arms. All other components are lubricated by splash or nozzle.

Remove oil pan. Remove oil pump-to-rear main bearing cap bolt. Remove oil pump and extension shaft.

Scheme 32

1. Remove pump cover and mark gear teeth so they may be reassembled with same teeth indexing. Remove idler gear, drive gear and shaft from pump body. Remove pressure regulator valve retaining pin, valve and related parts. (Scheme 32) (Scheme 32): Exploded View of Oil Pump Assembly
2. If replacement is necessary, mount pump in soft-jawed vise and pull pick-up screen and pipe assembly from pump body. DO NOT disturb pick-up screen on pipe. This is serviced as an assembly.

1. Check oil pump body for cracks or wear. Inspect pump gears for cracks, wear or damage. Check shaft for looseness in housing. Replace pump as a unit if any parts are not to specification.
2. Check inside of cover for wear that would permit oil to leak past ends of gears. Check oil pick-up screen for damage to screen or relief grommet. Remove debris from surface of screen.
3. When assembling oil pump, fill cavities with petroleum jelly to ensure immediate oil pressure. Install cover, tighten bolts and ensure shaft turns freely. Install regulator valve plunger, spring, retainer and pin.

Reassembly

1. If pick-up screen and pipe assembly was removed, replacement with new part is necessary. Loss of press fit could result in air leak and loss of oil pressure. NOTE: When installing new oil pump pipe assembly, be careful of twisting, shearing or collapsing pipe.
2. Apply sealer to end of replacement pick-up tube. Using Oil Pump Pipe Installer (J-8369), tap tube in place with plastic hammer. Install pressure regulator valve and related parts.
3. Install drive gear and shaft in pump body. Install idler gear in pump body with smooth side of gear toward opening. Install pump cover. Turn drive shaft to ensure smooth operation.

Install pump and extension shaft to rear main bearing cap. Align slot on top end of extension shaft with drive tang on lower end of distributor drive shaft. Install pump to rear main bearing cap bolt and tighten.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

VALVE SPRING SPECIFICATIONS

VALVE SPRING SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• FUEL PRESSURE RELEASE
• TORQUE SPECIFICATIONS
• INTAKE MANIFOLD
• VALVE CLEARANCE ADJUSTMENT
• TORSIONAL DAMPER