Engine Mechanical - 1.8L (LV6): Other Pontiac Vibe I

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.

Finding the Leak

1. Determine if the fluid is one of the following types: Engine oil Automatic transmission fluid Power steering fluid
2. Use the following steps in order to determine the location of the fluid leak: 2.1 Run the vehicle at normal operating temperature. 2.2 Park the vehicle over a large sheet of paper. 2.3 After several minutes, observe the drops of fluid that fall on the paper. Use the drops on the paper in order to determine the location of the leak.
3. Visually inspect around the suspected component. Inspect around the gasket mating surfaces for leaks. Use a mirror in order to find leaks in areas that are difficult to reach.
4. If you cannot locate the leak, use one of the following items in order to clean the suspected area: A degreaser Steam A spray solvent
5. Thoroughly dry the area.
6. Operate the vehicle for several miles at normal operating temperature and varying speeds.
7. Visually inspect the suspected component. If you still cannot locate the leak, use the powder method or the black light and dye method in order to locate the leak.

Powder Method

Perform the following steps in order to diagnose the leak

1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot powder) to the suspected area.
3. Operate the vehicle under normal operating conditions.
4. Visually inspect the suspected component. Trace the leak path over the white powder surface to the source.

Black Light and Dye Method

Tools Required

1. J 28428-E High Intensity Black Light
2. J 28431-6 Fluorescent Oil Additive

Important: Follow the manufacturer's instructions that are included with the J 28431-6 .

1. Pour the specified amount of J 28431-6 into the leaking component. Refer to the manufacturer's instructions for the proper amount of oil additive.
2. Operate the vehicle under normal operating conditions.
3. Shine the J 28428-E onto the suspected area. The J 28431-6 fluid will appear as a yellow path leading to the source of the oil leak.

Repairing the Leak

After you find the source of the leak, determine the cause of the leak. This action will enable you to properly repair the faulty component.

Gaskets

Inspect for a bent sealing flange. Repair the surface if the sealing flange is bent. A new gasket will not repair the leak.

Inspect for the following conditions before repairing a leak

1. An incorrect fluid level
2. High pressure
3. Malfunctions in the crankcase ventilation system
4. Improperly tightened fasteners
5. Dirty or damaged threads on the fasteners
6. Warped flanges or sealing surfaces
7. Scratches, burrs or other damage to the sealing surface
8. A damaged or worn gasket
9. Cracking or porosity of the component
10. An improper sealant

Seals

Inspect for the following conditions before repairing a leak

1. An incorrect fluid level
2. High pressure
3. Malfunctions in the crankcase ventilation system
4. Any of the following conditions on the seal bore: Scratches Burrs Nicks
5. A damaged or worn seal
6. Improper installation
7. A cracked component
8. Inspect the shaft surface for the following conditions: Scratches Nicks Damage
9. A loose or worn bearing

Engine Support Fixture

Tools Required

1. J 28467-B Universal Engine Support Fixture
2. J 28467-VIBE Engine Support Fixture Adapter

Lifter Selection

Important: In order to maintain the specified valve clearance the proper lifter must be selected. Perform the following procedure in order to select the proper lifter

Scheme 730

1. Determine the valve(s) clearances that were out of specifications.
2. Remove the lifter(s) from the lifter bores of the out of specification valves.
3. Use a J 26900-1 to measure the thickness of the removed lifter.
4. After measuring the lifter, refer to the record of the out of specification valve clearances.
5. After determining the two measurements, select the proper lifter thickness for the required valve clearance.
6. After selecting the proper lifter, the camshaft must be re-installed and the valve clearance re-measured. To install the intake camshaft, refer to «INTAKE CAMSHAFT AND LIFTER REPLACEMENT»(ref-186672-S20363919962005083100000) or to install the exhaust camshaft, refer to «EXHAUST CAMSHAFT AND LIFTER REPLACEMENT»(ref-186672-S10981062512005083100000) .
7. After confirming the valve clearance is correct for all valves, re-assemble the timing chain and timing chain housing. Refer to the installation instructions in «TIMING CHAIN AND SPROCKETS REPLACEMENT»(ref-186672-S33557229922005083100000) .
8. Install the cylinder head cover. Refer to the installation instructions in «CYLINDER HEAD COVER REPLACEMENT»(ref-186672-S19290015572005083100000) . NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
9. Connect the negative battery cable.

Tighten

Tighten the bolt to 15 N.m (11 lb ft).

Cylinder Honing

Scheme 731

1. When honing the cylinder bores, follow the manufacturer's recommendations for equipment use, cleaning, and lubrication. Use only clean sharp stones of the proper grade for the amount of material to be removed. Dull, dirty stones cut unevenly and generate excessive heat DO NOT hone to a final grade with a coarse or medium-grade stone. Leave sufficient metal so that all the stone marks will be removed with the fine grade stones. Perform the final honing with a fine-grade stone and hone the cylinder bore in a cross hatch pattern at 45-65 degrees to obtain the proper clearance.
2. During the honing operation, thoroughly check the cylinder bore. Repeatedly check the cylinder bore fit with the selected piston. All measurements of the piston or cylinder bore should be made with the components at normal room temperature.
3. When honing to eliminate taper in the cylinder bore, use full strokes the complete length of the cylinder bore. Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore. The finish marks should be clean but not sharp. The finish marks should be free from imbedded particles or torn or folded metal.
4. By measuring the selected piston at the sizing point and then by adding the average of the clearance specification, the final cylinder bore honing dimension required can be determined.
5. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and taper requirements.
6. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and detergent. 6.1 Scrub the cylinder bores with a stiff bristle brush. 6.2 Rinse the cylinder bores thoroughly with clean hot water. 6.3 Dry the cylinder bores with a clean rag. 6.4 Do not allow any abrasive material to remain in the cylinder bores. Abrasive material may cause premature wear of the new piston rings and the cylinder bores. Abrasive material will contaminate the engine oil and may cause premature wear of the bearings.
7. Perform final measurements of the piston and the cylinder bore.
8. Permanently mark the top of the piston for the specified cylinder to which it has been fitted.
9. Apply clean engine oil to each cylinder bore in order to prevent rusting.

Boring Procedure

Scheme 732

1. Before starting the honing or reboring operation, measure all the new pistons with the micrometer contacting at points exactly 90 degrees from the piston pin centerline.
2. File the top of the cylinder block in order to remove any dirt or burrs before using any type of boring bar.
3. Follow the instructions furnished by the manufacturer regarding use of the boring equipment.
4. When reboring the cylinders, make sure all the crankshaft bearing caps are installed in the original position and direction.
5. Tighten the crankshaft bearing caps to the proper torque specifications in order to avoid distortion of the cylinder bores in the final assembly.
6. When making the final cut with the boring bar, leave 0.03 mm (0.001 in) on the cylinder bore diameter for finish honing. This gives the required position to the cylinder clearance specifications. (Carefully perform the honing and boring operation in order to maintain the specified clearances between the pistons, the piston rings, and the cylinder bores).

Crankshaft Main Bearing Selection

Tools Required

J 36660-A Torque Angle Meter

Scheme 733

Scheme 734

Scheme 735

Scheme 736

Scheme 737

Scheme 738

1. The crankshaft bearings are of the precision insert type. The crankshaft bearings are available in standard and various undersizes. Important: If crankshaft bearing failure is due to other than normal wear, investigate the cause. Inspect the crankshaft bearing bores.
2. Inspect the crankshaft main bearing bores using the following procedure: 2.1 Tighten the bearing cap to specification. 2.2 Measure the bearing bore for taper and out-of-round. 2.3 No taper or out-of-round should exist.
3. Install the original crankshaft main bearing inserts on to the cylinder block and the lower crankcase assembly.
4. Carefully place the crankshaft on to the bearing inserts in the cylinder block.
5. Lay a piece of gaging plastic across each crankshaft main journal. Important: Do not turn the crankshaft while measuring the bearing clearance.
6. Carefully place the lower crankcase assembly on to the cylinder block. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
7. Install the ten main bearing cap bolts. Tighten Tighten the crankshaft main bearing cap bolts in the sequence shown, use three progressive steps to obtain 44 N.m (32 lb ft), then use a J 36660-A and tighten the main bearing cap bolts an additional 90 degrees.
8. After reaching the proper torque, remove the ten crankshaft main bearing cap bolts.
9. Carefully remove the lower crankcase assembly from the cylinder block.
10. Measure the gaging plastic at its widest point. Standard Oil Clearance: 0.016-0.032 mm (0.0006-0.0013 in) Maximum Oil Clearance: 0.080 mm (0.0031 in)
11. If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by determining the numbers imprinted on the cylinder block (1-5).
12. If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by determining the numbers imprinted on the crankshaft (1-5). Refer to the Main Bearing Selection Table in «ENGINE MECHANICAL SPECIFICATIONS»(ref-186672-S36079776632005083100000) .

Connecting Rod Bearing Selection

Tools Required

J 36660-A Torque Angle Meter

The connecting rod bearings are of the precision insert type. The connecting rod bearings are available in standard and various undersizes.

Important: If crankshaft bearing failure is due to other than normal wear, investigate the cause. Inspect the crankshaft or connecting rod bearing bores.

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

1. Inspect the connecting rod bearing bores using the following procedure: 1.1 Tighten the bearing cap to specification. 1.2 Measure the bearing bore for taper and out-of-round. 1.3 No taper or out-of-round should exist. Important: The crankshaft and the lower crankcase assembly must be installed and properly torqued before measuring the connecting rod clearances.
2. Starting with the number one connecting rod, remove the connecting rod cap bolts.
3. Remove the connecting rod cap by partially reinserting the connecting rod cap bolts into the connecting rod cap and wiggle the connecting rod cap left and right.
4. Lay a piece of gaging plastic across the crankshaft number one connecting rod journal. Important: Do not turn the crankshaft while measuring the bearing clearance.
5. Carefully place the connecting rod cap onto the connecting rod. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
6. Install the 2 connecting rod bearing cap bolts. Tighten Tighten the connecting rod bearing cap bolts to 30 N.m (22 lb ft), then rotate 90 degrees using the J 36660-A .
7. After reaching the proper torque, remove the 2 crankshaft connecting rod bearing cap bolts.
8. Carefully remove the connecting rod cap from the connecting rod.
9. Measure the gaging plastic at its widest point. Standard Oil Clearance: 0.028-0.052 mm (0.0011-0.0020 in) Maximum Oil Clearance: 0.08 mm (0.0031 in)
10. If using a standard bearing, replace it with one having the same number. There are 3 sizes of standard bearings.

Thread Repair

Damaged threads may be reconditioned by drilling out, rethreading and installing a suitable thread insert. General purpose thread repair kits are available commercially.

Important: Refer to the kit manufacturer's instructions regarding the size of the drill and tap to be used.

Scheme 744

Scheme 745

1. Determine the size, pitch and depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.
2. Drill out the damaged thread.
3. Clean the drilling chips out of the hole. Important: Avoid a buildup of chips. Back out of the tap every few turns and remove the chips.
4. Tap the hole. Lubricate the tap with light engine oil (except aluminum).
5. Thread the insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel. Important: When correctly installed, the insert should be flush to one turn below the surface.
6. Lubricate the insert with light engine oil, except when installing into aluminum, and install the insert.
7. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift punch.

Cylinder Block

The cylinder block is an aluminum casting with four cast iron cylinder sleeves. The cylinder block has four in-line cylinders which are numbered 1 through 4 starting from the crankshaft pulley. The cylinder block contains coolant jackets through which coolant flows around the cylinders, to cool the cylinder block and maintain a constant operating temperature.

The lower crankcase of the cylinder block is also an aluminum casting with cast iron inserts at the main bearing locations. The lower crankcase runs the entire perimeter of the cylinder block.

Crankshaft

The crankshaft is cast nodular iron with eight counterweights. Oil holes run through the center of the crankshaft to supply oil to the connecting rods, bearings, pistons and other components. The end thrust load is taken by the thrust washers installed at the center number three bearing journal.

Connecting Rod and Piston

The connecting rods are forged steel, heat treated and shot peened. The connecting rod incorporates the semi-floating type pin. The pistons are cast aluminum. The piston rings are of a low tension type to reduce friction. The top compression ring is stainless steel. The second compression ring is cast iron. The oil ring is a 3-piece spring construction.

Oil Pan

The oil pan is constructed of stamped steel and is mounted to the lower crankcase. The oil pan includes a baffle that helps prevent the oil from shifting away from the oil pump suction pipe during hard turns, acceleration or stopping.

Cylinder Head

The cylinder head is an aluminum casting with pressed-in valve guides and valve seat inserts. The fuel injection nozzles are located in the intake ports.

Valves

There are two intake and two exhaust valves per cylinder. The valve springs are conical-shaped. Positive valve stem seals are used on all valves.

Camshaft

Two camshafts are used, one for all intake valves, the other for all exhaust valves. The camshafts are cast iron. The intake camshaft also has the camshaft position sensor lobe cast onto it.

Camshaft Housings and Covers

The camshaft housings and covers are cast aluminum. The camshafts run directly in cylinder head housing covers without bearing inserts.

Camshaft Drive

An inverted tooth chain is used. A mechanical tensioner and two guides control chain motion.

Timing Chain Housing and Cover

The timing chain housing is die cast aluminum and retains the crankshaft front seal.

Intake and Exhaust Manifold

The intake manifold is made of aluminum. The exhaust manifold is cast iron.

Cleanliness and Care

An automobile engine is a combination of many machined, honed, polished, and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces during initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.

When valve train components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

Separating Parts

Important: Many internal engine components will develop specific wear patterns on their friction surfaces.

When disassembling the engine, internal components MUST be separated, marked, or organized in a way to ensure reinstallation to their original location and position.

Separate, mark, or organize the following components

1. Piston and the piston pin
2. Piston to the specific cylinder bore
3. Piston rings to the piston
4. Connecting rod to the crankshaft journal
5. Connecting rod to the bearing cap A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near the bearing bore may affect component geometry.
6. Crankshaft main and connecting rod bearings
7. Camshaft and valve lifters
8. Valve lifters, lifter guides, pushrods and rocker arm assemblies
9. Valve to the valve guide
10. Valve spring and shim to the cylinder head location
11. Engine block main bearing cap location and direction
12. Oil pump drive and driven gears

Gasket Reuse and Applying Sealants

1. Do not reuse any gasket unless specified.
2. Gaskets that can be reused will be identified in the service procedure.
3. Do not apply sealant to any gasket or sealing surface unless called out in the service information.

Separating Components

1. Use the proper prying points to separate components.
2. Use caution when separating all RTV sealed components.

Cleaning Gasket Surfaces

1. Remove all gasket and sealing material from the part using the J 28410
2. Care must be used to avoid gouging or scraping the sealing surfaces.
3. Do not use any other method or technique to remove sealant or gasket material from a part.
4. Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. These methods of cleaning can cause damage to the component sealing surfaces. Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and has been known to cause internal engine damage.

Pipe Joint Compound

Important: Three types of sealer are commonly used in engines. These are RTV sealer, anaerobic gasket eliminator sealer, and pipe joint compound. The correct sealer and amount must be used in the proper location to prevent oil leaks. DO NOT interchange the three types of sealers. Use only the specific sealer or the equivalent as recommended in the service procedure.

1. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «REPLACING ENGINE GASKETS»(ref-186672-S25076193702005083100000) .
2. Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when the bolt is tightened.
3. Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed must be clean and dry.
4. Tighten the bolts to specifications. Do not overtighten.

RTV Sealer

1. Room Temperature Vulcanizing (RTV) sealant hardens when exposed to air. This type sealer is used where two non-rigid parts (such as the intake manifold and the engine block) are assembled together.
2. Do not use Room Temperature Vulcanizing (RTV) sealant in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where a gasket eliminator is specified.
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «REPLACING ENGINE GASKETS»(ref-186672-S25076193702005083100000) .
4. Apply RTV to a clean surface. Use a bead size as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause damage when the bolt is tightened.
5. Assemble components while RTV is still wet, within 3 minutes. Do not wait for RTV to skin over.
6. Tighten bolts to specifications. Do not overtighten.

Anaerobic Sealer

1. Anaerobic gasket eliminator hardens in the absence of air. This type sealer is used where two rigid parts, such as castings, are assembled together. When two rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.
2. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «REPLACING ENGINE GASKETS»(ref-186672-S25076193702005083100000) .
3. Apply a continuous bead of gasket eliminator to one flange. Surfaces to be resealed must be clean and dry.
4. Spread the sealer evenly with your finger to get a uniform coating on the sealing surface.
5. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause damage when tightened. Important: Anaerobic sealed joints that are partially torqued and allowed to cure more than five minutes may result in incorrect shimming and sealing of the joint. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from seating properly or cause damage when the bolt is tightened.
6. Tighten bolts to specifications. Do not overtighten.
7. After properly tightening the fasteners, remove the excess sealer from the outside of the joint.

Tools and Equipment

Special tools are listed and illustrated throughout this section with a complete listing at the end of the section. These tools (or their equivalents) are specially designed to quickly and safely accomplish the operations for which they are intended.

The use of these special tools will also minimize possible damage to engine components. Some precision measuring tools are required for inspection of certain critical components. Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners.

To properly service the engine assembly, the following items should be readily available

1. Approved eye protection and safety gloves
2. A clean, well-lit, work area
3. A suitable parts cleaning tank
4. A compressed air supply
5. Trays or storage containers to keep parts and fasteners organized
6. An adequate set of hand tools
7. Approved engine repair stand
8. An approved engine lifting device that will adequately support the weight of the components

Scheme 746

Scheme 747

Scheme 748

Scheme 749