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 by the eighth character of Vehicle Identification Number (VIN) located on top of instrument panel near lower left corner of windshield.
Partial VIN number and engine code or identification number is stamped on cylinder block. The first character indicates manufacturer, and second character indicates the year. (Scheme 10)
| Application | Engine Code | VIN Code | |
|---|---|---|---|
| 2.8L V6 | |||
| RWD | LB8 | S | |
| FWD | LB6 | W | |
ENGINE IDENTIFICATION CODES
Scheme 10
Valve Arrangement
E-I-I-E-I-E (Left bank, front-to-rear).
E-I-E-I-I-E (Right bank, front-to-rear).
2.8L VIN S
- Remove valve cover. Rotate crankshaft until No. 1 cylinder is at TDC of compression stroke and vibration damper reference mark aligns with "0" mark on timing tab of front timing case cover.
- Adjust intake valves on cylinders No. 1, 5, and 6, and exhaust valves on cylinders No. 1, 2, and 3. To adjust valves, back off adjusting nut until lash is felt at push rod.
- Tighten adjusting nut until all lash is removed. This can be determined by rotating the push rod. Tighten adjusting nut an additional 1 1/2 turns.
- Rotate crankshaft one revolution and realign timing marks. This is the No. 4 cylinder firing position. Adjust intake valves on cylinders No. 2, 3 and 4 and exhaust valves on cylinders No. 4, 5 and 6. Install valve cover and gasket.
TROUBLE SHOOTING
Note. To trouble shoot engine mechanical components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.
ENGINE (2.8L VIN W)
Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.
| CAUTION | Relieve fuel pressure. Install Fuel Pressure Gauge (J-34730-1) to fuel rail service valve. Place bleed hose into approved container and bleed fuel system. |
- Disconnect battery cables. Remove air cleaner. Drain cooling system. Remove engine strut bracket from radiator support and position to rear. Remove A/C compressor from mounting bracket and lay aside (if equipped).
- Disconnect vacuum hoses. Disconnect accelerator cable and TV cable. Disconnect engine harness from ECM and pull connector through front of dash. Disconnect engine harness from junction block at left side of dash panel.
- Disconnect radiator and heater hoses from engine. Remove power steering pump and bracket from engine and lay aside (if equipped). Disconnect fuel lines at rubber hose connections on left side of engine compartment.
- Raise and support vehicle. Remove engine front mount-to-cradle retaining nuts on right side of vehicle. Disconnect battery cables from engine. Remove starter.
- Remove transaxle inspection cover. On automatic transaxle equipped vehicles, disconnect torque converter from drive plate. On all vehicles, remove crankshaft pulley and all belts. Disconnect exhaust pipe.
- Remove lower transaxle-to-engine bolt from rear of engine. Disconnect power steering cut-off switch (if equipped).
- Lower vehicle. Remove exhaust crossover pipe. Remove remaining transaxle-to-engine bolts. Make note of battery ground cable stud location for reassembly.
- Place support under transaxle rear extension. Attach engine lift and remove engine. To install, reverse removal procedure.
ENGINE (2.8L VIN S)
| CAUTION | Relieve fuel pressure. Install Fuel Pressure Gauge (J-34730-1) to fuel rail service valve. Place bleed hose into approved container and bleed fuel system. |
- Disconnect battery cables. Remove air cleaner. Mark hinges for installation and remove hood. Drain cooling system. Remove lower radiator hose. Remove upper fan shroud. Remove upper radiator hose and coolant recovery hose.
- Disconnect transmission cooler lines at radiator. Remove radiator. Remove fan assembly. Remove heater hoses.
- Disconnect throttle and cruise control detent linkages from throttle valve. Disconnect all vacuum lines and wiring to engine. Remove distributor cap.
- Remove power steering pump and position aside with hoses connected. Raise and support vehicle. Remove exhaust pipes at manifolds. Remove transmission torque converter cover. Match mark and remove drive plate-to-converter bolts. Disconnect starter wires.
- Remove transmission-to-engine bolts. Remove motor mount through bolts. Lower vehicle. Remove bracket holding air injection-to-converter pipes. Support transmission with jack. Install engine lift. Remove engine, disconnecting wire from bracket at left rear of engine. To install, reverse removal procedure.
INTAKE MANIFOLD (2.8L VIN S)
| CAUTION | Fuel system is under pressure. Fuel pressure must be released prior to disconnecting or servicing fuel system components. |
Removal (2.8L VIN S)
- Disconnect negative battery cable. Fuel pressure must be released. To release fuel pressure, loosen fuel tank cap and connect Fuel Gauge (J-34730-1) to fuel pressure tap on fuel rail.
- Wrap shop towel around pressure tap during gauge installation to prevent spillage. Place bleed hose into container and open valve to bleed system pressure.
- Drain cooling system. Disconnect spark plug wires and remove distributor cap. Mark distributor position and remove hold-down and distributor.
- Disconnect vacuum hoses, coolant hoses, control cable and air inlet duct at throttle body. Remove throttle body and gasket. Remove EGR pipe-to-manifold bolts. Remove EGR tube and gasket.
- Remove A/C compressor bracket at upper intake manifold. Remove upper intake manifold bolts, manifold and gaskets. (Scheme 11) Disconnect cold start tube at fuel rail. Disconnect fuel lines, electrical connections and vacuum hoses at fuel rail.
- Remove fuel rail bolts and fuel rail. Use care not to damage fuel injectors. Remove air management hose and bracket (M/T only). Disconnect emission canister hoses.
- Remove valve covers. Loosen rocker arms and remove push rods. Mark push rod location for reassembly reference. CAUTION: Push rod location must be marked for reassembly reference. Components must be installed in original location.
- Disconnect upper radiator hose and electrical connectors at thermostat housing. Remove intermediate manifold and gasket. (Scheme 11) Remove lower manifold bolts, manifold and gaskets.
Scheme 11
Installation
- Ensure all sealing surfaces are clean. Apply 3/16" bead of RTV sealant on sealing surfaces of cylinder block. Install new intake manifold gaskets on cylinder heads. Ensure all holes are aligned. Extend RTV sealant bead 1/4" upward on ends of each gasket. CAUTION: Ensure gaskets are properly installed. Gaskets may be marked for proper direction of installation.
- Install lower intake manifold. Tighten bolts to specification in proper sequence. (Scheme 12) To install remaining components, reverse removal procedure using new gaskets and "O" rings. Coat fuel injector "O" rings with engine oil prior to installation. Tighten intermediate and upper intake manifold bolts to specification using proper sequence. (Scheme 12)
- Install push rods in original location. Coat rocker arms and pivot balls with Molykote. Install rocker arms and adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS in this article. Install remaining components. Fill cooling system.
Scheme 12
INTAKE MANIFOLD (2.8L VIN W)
| CAUTION | Fuel system is under pressure. Fuel pressure must be released prior to disconnecting or servicing fuel system components. |
Removal
- Disconnect negative battery cable. Fuel pressure must be released. To release fuel pressure, loosen fuel tank cap and connect Fuel Gauge (J-34730-1) to fuel pressure tap on fuel rail.
- Wrap shop towel around pressure tap during gauge installation to prevent spillage. Place bleed hose into container and open valve to bleed system pressure.
- Drain cooling system. Disconnect vacuum hoses, coolant hoses, control cable and air inlet duct at throttle body. Remove throttle body and gasket. Remove EGR pipe-to-manifold bolts and remove EGR valve.
- Remove upper intake manifold bolts, manifold and gaskets. (Scheme 13) Remove accessory drive belt, alternator and bracket. Remove power steering pump with hoses attached and lay aside.
- Disconnect fuel lines, electrical connections and vacuum hoses at fuel rail. Remove fuel rail bolts and fuel rail. Use care not to damage fuel injectors.
- Disconnect coolant sensor and necessary coolant hoses and piping. Remove valve covers. Loosen rocker arms and remove push rods. Note push rod location for reassembly reference. Push rods are different lengths, as intake push rod is marked Orange and exhaust push rod is marked Blue.
- Remove lower intake manifold bolts, manifold and gasket. (Scheme 13) Note location of belleville washers on the 4 center manifold bolts.
- Ensure all sealing surfaces are clean. Apply bead of RTV sealant on sealing surfaces of cylinder block. Install new intake manifold gaskets on cylinder heads. Ensure all holes are aligned. CAUTION: Ensure gaskets are properly installed. Gaskets may be marked for proper direction of installation.
- Install intake manifold. Tighten bolts to specification in proper sequence. (Scheme 13) To install remaining components, reverse removal procedure using new gaskets and "O" rings. Coat fuel injector "O" rings with engine oil prior to installation.
- Install push rods in original location. Intake push rods are marked in Orange and exhaust push rods are marked in Blue. Coat rocker arms and pivot balls with Molykote. Install rocker arms and tighten retaining nuts to specification. See TORQUE SPECIFICATIONS table at end of article. CAUTION: Intake push rods are marked in Orange and exhaust push rods are marked in Blue. Ensure push rods are installed in correct location, as different length push rods are used.
- Tighten upper intake manifold bolts to specification. Install remaining components. Fill cooling system.
Scheme 13
- For left manifold removal, disconnect negative battery cable. Disconnect exhaust pipe at manifold. Remove power steering bracket. Remove manifold retaining nuts, bolts, manifold and gasket.
- To remove right manifold, disconnect negative battery cable. Disconnect exhaust pipe at manifold. Remove EGR valve adapter from manifold. Remove alternator bracket. Remove manifold retaining nuts and bolts.
- Remove serpentine belt from idler pulley. Remove idler pulley bracket brace. Remove manifold and gasket.
To install, reverse removal procedure using new gasket. Install remaining components.
- For left manifold removal, disconnect negative battery cable. Remove coolant recovery bottle, serpentine belt cover and belt. Remove A/C compressor with lines attached.
- Remove right torque strut and strut mounting bracket. Remove A/C compressor mounting bracket. Remove heat shield. Disconnect exhaust crossover pipe at manifold. Remove manifold retaining nuts, bolts, manifold and gasket.
- To remove right manifold, disconnect negative battery cable. Disconnect exhaust crossover pipe at manifold. Remove coolant recovery bottle. It may be necessary to disconnect strut rods at engine.
- Remove air cleaner, breather and mass airflow sensor (if equipped). Disconnect exhaust pipe at manifold. Disconnect accelerator and throttle valve cables. Remove manifold retaining nuts, bolts, manifold and gasket.
To install, reverse removal procedure using new gasket. Install remaining components.
CAMSHAFT
Note. For camshaft removal on 2.8L VIN S, engine does not require removal. On all other models, engine must be removed.
- Remove valve covers. Remove rocker arms, push rods and valve lifters. Mark component location for reassembly reference. Remove front timing case cover. See FRONT TIMING CASE COVER under REMOVAL & INSTALLATION in this article. CAUTION: Rocker arm components, push rods and valve lifter location must be marked for reassembly reference.
- Remove timing chain and sprockets. See TIMING CHAIN & SPROCKETS under REMOVAL & INSTALLATION in this article. Remove camshaft and camshaft bearings (if necessary).
Inspection
Inspect camshaft journal diameter, lobe lift and oil clearance. See ENGINE SPECIFICATIONS tables at end of article. Replace components if not within specification.
| CAUTION | Lubricate camshaft bearings and camshaft lobes with GM Lubricant (1051396) prior to installation. If camshaft is replaced, add GM Engine Oil Supplement (1052367) to the engine oil. |
- Install camshaft bearings (if removed). Ensure oil holes are aligned. Lubricate camshaft bearings and camshaft lobes with GM Lubricant (1051396) prior to installation. Install camshaft.
- To install remaining components, reverse removal procedure. Ensure components are installed in original location. Ensure timing marks are aligned.
- Remove intake manifold. See INTAKE MANIFOLD under REMOVAL & INSTALLATION in this article. Remove exhaust manifold. See EXHAUST MANIFOLD under REMOVAL & INSTALLATION in this article.
- Remove oil dipstick (if necessary). Remove cylinder head bolts, cylinder head and gasket.
Inspect cylinder head warpage. See CYLINDER HEAD under OVERHAUL in this article.
- Ensure cylinder head bolt threads and cylinder block holes are clean. Install gasket on cylinder block with note "THIS SIDE UP" showing (if equipped). Ensure all holes align with cylinder block.
- Install cylinder head. Apply GM Sealant (1052080) to head bolt threads and install. Tighten bolts to specification in proper sequence. (Scheme 14) Install remaining components. Ensure all components are installed in original location.
Scheme 14
- Remove front timing case cover. See FRONT TIMING CASE COVER under REMOVAL & INSTALLATION in this article. Rotate crankshaft and align timing marks on camshaft and crankshaft sprockets with No. 1 or No. 4 cylinder at TDC. (Scheme 15)
- Remove camshaft sprocket bolts. Remove camshaft sprocket and timing chain. Remove crankshaft sprocket (if necessary).
Scheme 15
- Install crankshaft sprocket (if removed). Apply Molykote to camshaft sprocket thrust surface. Install timing chain over camshaft sprocket. Hold sprocket vertically with chain hanging downward. Align all timing marks. (Scheme 15)
- Install timing chain and camshaft sprocket on camshaft. Ensure sprocket dowel pin hole aligns with camshaft dowel pin. Install camshaft sprocket. Ensure all timing marks are aligned. Lubricate timing chain with engine oil. Install remaining components.
- Disconnect negative battery cable. Remove oil pan. See appropriate OIL PAN REMOVAL article in this section. Remove water pump. See WATER PUMP under REMOVAL & INSTALLATION in this article.
- Remove serpentine belt. Remove power steering pump and bracket. Remove crankshaft accessory drive pulley from crankshaft damper. Remove crankshaft damper retaining bolt.
- Using puller, remove crankshaft damper. Disconnect lower radiator hose. Remove front timing case cover bolts and cover. Remove seal if necessary.
- If seal was removed, install seal with seal lip toward the engine using Seal Installer (J-35468). Lubricate seal with engine oil. To install, reverse removal procedure using new gasket.
- Install crankshaft damper using Damper Installer (J-29113) so that at least .20" (5.1 mm) of thread engagement exists. Install remaining components. Fill cooling system. Ensure arrows on radiator cap are aligned with overflow tube.
- Drain cooling system. Disconnect negative battery cable. Remove serpentine belt, alternator and power steering pump with hoses attached.
- Remove inner splash shield (if equipped). Remove crankshaft damper retaining bolt. Using puller, remove crankshaft damper. Remove idler pulley for serpentine belt.
- Remove oil pan. See appropriate OIL PAN REMOVAL article in this section. Disconnect radiator hose at water pump, coolant overflow hoses and heater hose at fill pipe. Disconnect canister purge hose. Remove front timing case cover bolts and cover. Remove seal if necessary.
- If seal was removed, install seal with seal lip toward the engine using Seal Installer (J-35468-A). Lubricate seal with engine oil.
- To install case cover, reverse removal procedure using new gasket. Apply Sealant (1052080) to lower corners of new case gasket prior to installation.
- Apply sealant to Woodruff key in crankshaft and crankshaft damper keyway prior to installation. Using Damper Installer (J-29113), install crankshaft damper so that at least .20" (5.1 mm) of thread engagement exists.
| CAUTION | Thread sealant must be applied to Woodruff key in crankshaft and crankshaft damper keyway prior to installation. |
- Disconnect negative battery cable. Remove serpentine belt cover (if equipped) and serpentine belt. Remove drive pulley from crankshaft damper (if equipped).
- Remove crankshaft damper retaining bolt. Using puller, remove crankshaft damper. Pry seal from front timing case cover.
- Seal must be installed with seal lip toward the engine and lubricated with engine oil.
- On 2.8L VIN S models, use Seal Installer (J-35468) to install seal. Install crankshaft damper using Damper Installer (J-29113) so that at least .20" (5.1 mm) of thread engagement exists. Install remaining components.
- On all other models, use Seal Installer (J-35468-A) to install seal. Apply sealant to Woodruff key in crankshaft and crankshaft damper keyway prior to installation. Using Damper Installer (J-29113), install crankshaft damper so that at least .20" (5.1 mm) of thread engagement exists. Install remaining components.
- Remove transaxle or transmission assembly. Place reference mark on clutch pressure plate (M/T) and flywheel for reassembly reference.
- Remove pressure plate and clutch disc (if equipped) and flywheel. Pry seal from housing. Use care not to damage crankshaft or seal surface. Note direction of seal installation.
- Coat inner and outer seal surfaces with engine oil. Install seal on mandril of Seal Installer (J-34686) until dust lip bottoms against tool collar. (Scheme 16)
- Align seal installer dowel pin with alignment hole of crankshaft. (Scheme 16) Install seal installer on crankshaft. Tighten seal installer bolts to 60 INCH lbs. (7 N.m).
- Tighten seal installer handle to install seal in seal bore until seal installer collar is even with cylinder block. To install remaining components, reverse removal procedure. On M/T models, ensure reference marks are aligned on pressure plate and flywheel.
Scheme 16
Remove intake manifold. See INTAKE MANIFOLD under REMOVAL & INSTALLATION in this article. With rocker arms and push rods removed, remove valve lifters. Mark component location for reassembly reference.
| CAUTION | Rocker arm, push rod and valve lifter location must be marked for reassembly reference. Some engines may contain standard and oversized valve lifters. Oversized lifter usage is indicated by small amount of White paint and or ".25 mm O.S." stamped near lifter bore. |
If new lifter is being installed, coat convex foot area of lifter with Molykote. Install lifter in original bore. Install remaining components in original location.
- Disconnect negative battery cable. Drain cooling sytem. Remove air intake duct. Remove water pump drive belt. Disconnect necessary coolant hoses.
- Remove power steering pump bracket. Remove water pump bolts. Note bolt location. Remove water pump and gasket.
To install, reverse removal procedure using new gasket. Apply thread sealant to bolts prior to installation. Tighten bolts to proper specification. (Scheme 17) Fill cooling system.
Scheme 17
- Disconnect negative battery cable. Drain cooling system. Remove air cleaner (if necessary). Remove serpentine belt. Remove water pump pulley.
- Note position of locator tab on top of the water pump for reassembly reference. Remove water pump and gasket.
To install, reverse removal procedure using new gasket. Apply thread sealant to bolts prior to installation. Ensure locator tab on top of water pump housing is positioned vertically.
OIL PAN (VIN W)
Disconnect negative battery cable. Raise and support vehicle. Drain crankcase. Remove flywheel access cover and starter. Support engine and remove engine mount bolts. Remove oil pan bolts. Raise engine and remove oil pan.
OIL PAN (VIN S)
- Disconnect negative battery cable. Remove air cleaner and distributor cap. Remove upper half of fan shroud. Raise vehicle and drain crankcase.
- Remove flywheel access cover, starter, converter dust cover. Disconnect exhaust pipe at manifold. Remove engine mount through bolts and raise engine. Remove oil pan bolts. Remove oil pan.
Information not available from manufacturer on 2.8L VIN S models. On all other models, inspect cylinder head for warpage at deck surface and manifold surfaces. Resurface cylinder head if warpage exceeds specification. See ENGINE SPECIFICATIONS tables at end of article. Replace cylinder head if metal removed exceeds .010" (.25 mm).
VALVE SEATS
No replacement procedure given from manufacturer.
VALVE GUIDES
Valve guides must be reamed for an oversized valve if valve stem oil clearance is not within specification. See ENGINE SPECIFICATIONS tables at end of article.
SEAT CORRECTION ANGLES
Information not available from manufacturer on 2.8L VIN S models. On all other models, if seat width is too wide, use 20 degree and 70 degree stone for seat adjustment. The 20 degree stone will lower the seat and the 70 degree will raise the seat.
Valves
On all models except the 2.8L VIN S, new valves MUST NOT be lapped. Protective coating will be damaged if valve is lapped.
VALVE SPRING INSTALLED HEIGHT
- Measuring procedure not available from manufacturer on 2.8L VIN W & 3.1L models. On 2.8L VIN S models, measure valve spring installed height from top of spring seat to top of oil shield (exhaust only) or spring retainer (intake only). (Scheme 18)
- Spring height must be within specification. See ENGINE SPECIFICATIONS tables at end of article. If measurement exceeds specification, install.030" (.75 mm) shim at spring seat. Ensure spring height with shim does not result in installed height under minimum specification of 1.6" (40.1 mm).
Scheme 18
VALVE STEM OIL SEALS
Oversized valve stem oil seals are used for oversized valves. Intake and exhaust valve stem oil seals are different.
PISTON RING INSTALLATION
Piston rings must be installed with identification mark toward top of piston and rings properly spaced. (Scheme 19)
Scheme 19
| CAUTION | Mark piston position on connecting rod if piston is to be removed from connecting rod. Information for connecting rod-to-piston positioning not available from manufacturer. |
PISTON & ROD ASSEMBLY
Piston must be installed in cylinder block with arrow or notch on top of the piston toward the front of the engine.
FITTING PISTONS (2.8L VIN S)
- Remove all rings from piston and ensure piston is clean. Install piston in cylinder bore with top of piston away from deck surface.
- Piston should free fall in cylinder bore when the bottom of piston skirt is 1/2-1" (12-25 mm) from top of deck surface. Try piston in different bore if piston fails to free fall.
- If piston free falls, correct fit must be determined. Install piston and a .0025" (.063 mm) feeler gauge for used pistons or .0020" (.051 mm) feeler gauge for new pistons in cylinder bore. Feeler gauge must be at least 6" (152 mm) long and no more than 1/2" (12 mm) wide and be positioned at 90 degree angle to piston pin.
- With piston at 1/2-1" (12-25 mm) from top of deck surface, note if piston free falls. If piston fails to free fall, piston is correctly fitted for that cylinder. If piston free falls, select a larger diameter piston. Mark piston and cylinder for reassembly reference.
FITTING PISTONS (VIN W)
Piston diameter should be measured 3/4" below center line of piston pin bore. Piston taper should be measured at the center and bottom of the piston skirt. Oversized pistons must not be machined down or engine balance will be affected.
VALVE LIFTER BORES
Oversized valve lifters may be used. Oversized lifter usage is indicated by small amount of White paint and or ".25 mm O.S." stamped near lifter bore.
CRANKSHAFT & BEARINGS (VIN S)
- To align crankshaft thrust surfaces, install bearings, crankshaft and main caps with arrow on cap toward front of engine.
- Tighten all main bearing cap bolts EXCEPT No. 3 main cap to 73 ft. lbs. (99 N.m). Pry crankshaft toward rear of engine and then toward front of engine. Tighten all main bearing cap bolts to specification.
CRANKSHAFT & BEARINGS (VIN W)
To align crankshaft thrust surfaces, install all bearings and main caps with cap bolts loosely installed. Pry crankshaft toward rear of engine and then toward front of engine. Tighten main bearing cap bolts to specification.
CRANKSHAFT FLANGE RUNOUT (VIN W)
- With engine removed and crankshaft installed, measure crankshaft flange runout. Mount dial indicator gauge plate flat against crankshaft flange. Place dial indicator stem on lower left transmission mounting bolt boss (flat area around bolt hole). Adjust indicator to zero.
- Observe and record readings obtained on all mounting bolt hole bosses. Measurements should not vary more than .010" (.25 mm). If readings exceed specification, remount dial gauge plate and recheck flange runout. Replace crankshaft if runout exceeds specification.
CYLINDER BLOCK INSPECTION
Information not available from manufacturer on 2.8L VIN S models. On all other models, use feeler gauge and straightedge, inspect deck surface for warpage. Replace cylinder block if more than .010" (.30 mm) material is removed from deck surface.
ENGINE OILING SYSTEM
The camshaft driven gear-type oil pump provides pressurized lubrication through the oil filter to the main gallery above the left side of the camshaft center line. This gallery provides lubrication to the valve lifters on the left bank, camshaft bearings, crankshaft and right gallery.
The right gallery supplies oil to valve lifters on the right bank. Rocker arms are lubricated by passages in the push rods. Slot in front camshaft bearing provides lubrication to the timing chain. Pressure regulator valve is mounted in oil pump body.
CRANKCASE CAPACITY
Engine oil capacity is approximately 4 qts. (3.7L) with filter change. Recheck oil level after changing filter.
NORMAL OIL PRESSURE
Normal oil pressure is 50-65 psi (3.5-4.5 kg/cm 2 ) at 1200 RPM.
Disconnect negative battery cable. Remove oil pan. See appropriate OIL PAN REMOVAL article in this section. Remove oil pump bolt, oil pump and extension shaft from rear main bearing cap.
Disassembly & Inspection
- Information not available from manufacturer on 2.8L VIN S models. On all other models, Remove pump cover. Mark teeth on both gears for reassembly reference. Remove idler gear, drive gear and shaft from pump body. WARNING: Pressure regulator valve spring is under pressure. Use care when removing to prevent personal injury.
- Remove pressure regulator valve retaining pin, valve and spring. DO NOT remove pick-up screen and pipe. Pump cover must be replaced if pick-up screen and tube are damaged.
- Inspect components for damage. Using straightedge and feeler gauge, measure gear end clearance. Measure housing gear pocket depth and diameter, and gear diameter and length.
- Measure side clearance between gear and housing, and gear lash clearance the teeth of the gears. Check clearance between pressure regulator valve and bore. Replace components or pump assembly if not within specification. See OIL PUMP SPECIFICATIONS table.
| Application | In. (mm) | |
|---|---|---|
| Gear End Clearance | .002-.005 (.05-.13) | |
| Gear Lash | .009-.015 (.23-.38) | |
| Gear Side Clearance | .003-.004 (.08-.10) | |
| Housing Pocket | ||
| Depth | 1.195-1.198 (30.35-30.43) | |
| Diameter | 1.503-1.506 (38.18-38.25) | |
| Pressure Regulator | ||
| Valve-to-Bore | .0015-.0035 (.038-.089) | |
| Pump Gears | ||
| Diameter | 1.498-1.500 (38.05-38.10) | |
| Length | 1.199-1.200 (30.45-30.48) | |
OIL PUMP SPECIFICATIONS
| CAUTION | Only original equipment gaskets should be used for oil pump service as gasket thickness is critical. Ensure pump components are coated with engine oil prior to installation. Coat pressure regulator valve plug with thread sealant (if used). |
Reassembly & Installation
- To reassemble, reverse removal procedure using new cover gasket. Coat all components with engine oil. Ensure reference mark is aligned on gears.
- To install, reverse removal procedure. Ensure pump extension shaft is fully engaged. Install remaining components.
TORQUE SPECIFICATIONS
| Application | Ft. Lbs. (N.m) | |||
|---|---|---|---|---|
| Camshaft Sprocket Bolt | 18 (24) | |||
| Connecting Rod Cap Nut | 37 (51) | |||
| Crakshaft Damper Bolt | 77 (104) | |||
| Cylinder Head Bolt | ||||
| 2.8L (VIN S) | (1) | |||
| All Others | (2) | |||
| Exhaust Manifold Bolt | 18 (24) | |||
| Flywheel Bolt | 52 (71) | |||
| Front Timing Case Cover Bolt | ||||
| 2.8L (VIN S) | (3) | |||
| All Others | ||||
| 8 mm | 13-26 (18-35) | |||
| 10 mm | 20-35 (27-47) | |||
| Intake Manifold Bolt | ||||
| 2.8L (VIN S) | ||||
| Lower Manifold | (4) 13-25 (18-34) | |||
| Intermediate & Upper Manifold | (4) 18 (24) | |||
| All Others | ||||
| Lower Manifold | ||||
| Step 1 | (5) 16 (22) | |||
| Step 2 | (5) 23 (31) | |||
| Upper Manifold | 16 (22) | |||
| Main Bearing Cap Bolt | 73 (99) | |||
| Oil Pan Bolt | ||||
| 6 mm | 6-9 (8-12) | |||
| 8 mm | 14-22 (19-30) | |||
| Oil Pump Bolt | 30 (41) | |||
| Rocker Arm Nut | ||||
| 2.8L (VIN S) | (6) | |||
| All Others | 18 (24) | |||
| Timing Chain Damper Bolt | 15 (20) | |||
| (1) Apply thread sealant to bolts and tighten to 40 ft lbs. (54 N.m) plus an additional 90 degrees in proper sequence. (Scheme 14) (2) Apply thread sealant to bolts and tighten to 33 ft lbs. (45 N.m) plus an additional 90 degrees in proper sequence. (Scheme 14) (3) On VIN S, tigthen bolts to specification. (Scheme 17) (4) Tighten to specification in proper sequence. (Scheme 12) (5) Tighten to specification in proper sequence. (Scheme 13) (6) Valve adjustment required. | ||||
| (1) | Apply thread sealant to bolts and tighten to 40 ft lbs. (54 N.m) plus an additional 90 degrees in proper sequence. (Scheme 14) |
| (2) | Apply thread sealant to bolts and tighten to 33 ft lbs. (45 N.m) plus an additional 90 degrees in proper sequence. (Scheme 14) |
| (3) | On VIN S, tigthen bolts to specification. (Scheme 17) |
| (4) | Tighten to specification in proper sequence. (Scheme 12) |
| (5) | Tighten to specification in proper sequence. (Scheme 13) |
| (6) | Valve adjustment required. |
TORQUE SPECIFICATIONS
ENGINE SPECIFICATIONS
| Application | In. (mm) | |
|---|---|---|
| Displacement | ||
| Cubic Inches | 173 | |
| Liters | 2.8 | |
| Fuel System | MPFI | |
| HP @ RPM | 130 @ 4500 | |
| Torque Ft. @ RPM | 160 @ 3600 | |
| Compression Ratio | 8:9:1 | |
| Bore | 3.5 (89.0) | |
| Stroke | 3.0 (76.0) | |
GENERAL ENGINE SPECIFICATIONS (VIN W)
| Application | In. (mm) | |
|---|---|---|
| Displacement | ||
| Cubic Inches | 173 | |
| Liters | 2.8 | |
| Fuel System | MPFI | |
| HP @ RPM | 135 @ 4900 | |
| Torque Ft. @ RPM | 160 @ 3900 | |
| Compression Ratio | 8:9:1 | |
| Bore | 3.5 (89.0) | |
| Stroke | 3.0 (76.0) | |
GENERAL ENGINE SPECIFICATIONS (VIN S)
| Application | In. (mm) | ||
|---|---|---|---|
| Piston Clearance | .0009-.0022 (.023-.056) | ||
| Pins | |||
| Diameter | .9052-.9054 (22.992-22.997) | ||
| Piston Fit | .00025-.00036 (.0064-.0091) | ||
| Rod Fit | Press | ||
| Rings | |||
| Ring No. 1 & 2 | |||
| End Gap | .010-.020 (.25-.50) | ||
| Side Clearance | .0020-.0035 (.051-.089) | ||
| Oil Ring (No. 3) | |||
| End Gap | .010-.030 (.25-.76) | ||
| Side Clearance | .008 (.20) | ||
PISTONS, PINS & RINGS SPECIFICATIONS (VIN W)
| Application | In. (mm) | ||
|---|---|---|---|
| Piston Clearance | .0007-.0017 (.018-.043) | ||
| Pins | |||
| Diameter | .9052-.9054 (22.992-22.997) | ||
| Piston Fit | .00025-.00036 (.0064-.0091) | ||
| Rod Fit | Press | ||
| Rings | |||
| Ring No. 1 | |||
| End Gap | .010-.020 (.25-.50) | ||
| Side Clearance | .0012-.0028 (.030-.071) | ||
| Ring No. 2 | |||
| End Gap | .010-.020 (.25-.50) | ||
| Side Clearance | .0015-.0037 (.038-.094) | ||
| Oil Ring (No. 3) | |||
| End Gap | .020-.055 (.51-1.39) | ||
| Side Clearance | .008 (.20) | ||
PISTONS, PINS & RINGS SPECIFICATIONS (VIN S)
| Application | In. (mm) | |
|---|---|---|
| Crankshaft | ||
| Crankshaft End Play | .002-.008 (.05-.20) | |
| Journal Taper | .0002 (.005) | |
| Journal Out-Of-Round | .0002 (.005) | |
| Main Bearings | ||
| Journal Diameter | 2.6743-2.6483 (67.241-67.267) | |
| Oil Clearance | .0012-.0027 (.030-.069) | |
| Connecting Rod Bearings | ||
| Journal Diameter | 1.9983-1.9994 (50.757-50.785) | |
| Oil Clearance | .0014-.0036 (.036-.091) | |
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS
| Application | In. (mm) |
|---|---|
| Side Play | (1) .014-.027 (.36-.68) |
| (1) VIN W is listed. VIN S is .006-.017" (.15-.43 mm). | |
| (1) | VIN W is listed. VIN S is .006-.017" (.15-.43 mm). |
CONNECTING ROD SPECIFICATIONS
| Application | In. (mm) | ||
|---|---|---|---|
| Maximum Cylinder Head Warp | (1) | ||
| Intake | |||
| Valve Seats | |||
| Seat Angle | 46° | ||
| Maximum Runout | .001 (.02) | ||
| Seat Width | .049-.059 (1.24-1.50) | ||
| Valve Guides (Valve Stem Oil Clearance) | .0010-.0027 (.025-.069) | ||
| Exhaust | |||
| Valve Seats | |||
| Seat Angle | 46° | ||
| Maximum Runout | .001 (.02) | ||
| Seat Width | .062-.075 (1.57-1.91) | ||
| Valve Guides (Valve Stem Oil Clearance) | .0010-.0027 (.025-.069) | ||
| (1) Information not available on VIN S. | |||
| (1) | Information not available on VIN S. |
CYLINDER HEAD SPECIFICATIONS (VIN S)
| Application | In. (mm) | ||
|---|---|---|---|
| Cylinder Head Warpage | (1) | ||
| Intake | |||
| Valve Seats | |||
| Seat Angle | 46° | ||
| Maximum Runout | .001 (.02) | ||
| Seat Width | .061-.073 (1.55-1.85) | ||
| Valve Guides (Valve Stem Oil Clearance) | .0010-.0027 (.025-.069) | ||
| Exhaust | |||
| Valve Seats | |||
| Seat Angle | 46° | ||
| Maximum Runout | .001 (.02) | ||
| Seat Width | .067-.079 (1.70-2.01) | ||
| Valve Guides (Valve Stem Oil Clearance) | .0010-.0027 (.025-.069) | ||
| (1) Replace cylinder head if material removed exceeds .010" (.25 mm). | |||
| (1) | Replace cylinder head if material removed exceeds .010" (.25 mm). |
CYLINDER HEAD SPECIFICATIONS (VIN W)
| Application | In. (mm) | |
|---|---|---|
| Maximum Block Warp | (1) | |
| Cylinder Bore | ||
| Standard Diameter | 3.5033-3.5046 (88.983-89.017) | |
| Maximum Taper | .0005 (.013) | |
| Maximum Out-of-Round | .0005 (.013) | |
| (1) Information not available on VIN S. On all others, replace block if material removed exceeds .010" (.25 mm). | ||
| (1) | Information not available on VIN S. On all others, replace block if material removed exceeds .010" (.25 mm). |
CYLINDER BLOCK SPECIFICATIONS
| Application | In. (mm) | ||
|---|---|---|---|
| Valves | |||
| Face Angle | 45° | ||
| Minimum Margin | (1) | ||
| Valves Springs | |||
| Free Length | 1.91 (48.51) | ||
| Out-of-Square | .0625 (1.589) | ||
| Installed Height | 1.575 (40.01) | ||
| Pressure (2) | |||
| Valve Closed | 90 @ 1.701 | ||
| Valve Open | 215 @ 1.291 (97 @ 32.79) | ||
| (1) VIN S is .03" (.8 mm). Information not available from manufacturer for other models. (2) Lbs. @ In. (Kg @ mm). | |||
| (1) | VIN S is .03" (.8 mm). Information not available from manufacturer for other models. |
| (2) | Lbs. @ In. (Kg @ mm). |
VALVES & VALVE SPRINGS SPECIFICATIONS
| Application | In. (mm) |
|---|---|
| Journal Diameter | 1.8678-1.8815 (47.442-47.790) |
| Oil Clearance | .001-.004 (.02-.10) |
| Lobe Lift | (1) |
| (1) Lobe lift for intake valves is .2626" (6.670 mm) for exhaust valves. | |
| (1) | Lobe lift for intake valves is .2626" (6.670 mm) for exhaust valves. |
CAMSHAFT SPECIFICATIONS