1988 PONTIAC FIERO automatic transmission

V-8 ENGINE 6A3-27
3. When finish honing
a cylinder bore to fit a piston,
the hone should be moved up and down at a
sufficient speed to obtain very fine uniform
surface finish marks in a cross-hatch pattern of
approximately
45" to 65" included angle. The
finish marks should be clean but not sharp, free
from imbedded particles and torn or folded
metal.
4. Permanently mark
the piston for the cylinder to
which it has been fitted and proceed to hone
cylinders and fit the remaining pistons.
NOTICE: Handle the pistons with care and do not
attempt to force them through the cylinder until
the cylinder has been honed to correct size as this
type piston can be distorted through careless
handling.
5. Thoroughly
clean the bores with hot water and
detergent. Scrub well with a stiff bristle brush and
rinse thoroughly with hot water. It is extremely
essential that a good cleaning operation be
performed. If any of the abrasive material is
allowed to remain in the cylinder bores, it will
rapidly wear the new rings and cylinder bores in
addition to the bearings lubricated by the
contaminated oil, the bores should be swabbed
and then wiped with a clean dry cloth. Cylinder
should not be cleaned with kerosene or gasoline.
Clean the remainder of the cylinder block to
remove the excess material spread during the
honing operation.
Piston Selection
1. Check USED piston to cylinder bore clearance as
follows:
a. Measure
the "Cylinder Bore Diameter"
with a telescope gage
"2-1/2" (64mm) from
top of cylinder bore").
b. Measure
the
"Piston Diameter" (at skirt
across center line of piston pin).
c. Subtract
piston diameter from cylinder bore
diameter to determine "Piston to Bore
Clearance".
d. Determine if piston to bore clearance is in
the acceptable range.
2. If
used piston is not acceptable, check Piston Size
Chart and determine if a new piston can be
selected to fit cylinder bore within the acceptable
range.
3. If
cylinder bore must be reconditioned, measure
new piston diameter (across center line of piston
pin) then hone cylinder bore to correct clearance
(preferable range).
4. Mark the piston to identify the cylinder for which
it was fitted.
OIL FILTER BYPASS VALVE
Inspection and Replacement
With the oil filter removed, check the spring and
fibre valve for operation. Inspect for a cracked or
broken valve. If replacement is necessary, the oil filter
adapter and bypass valve assembly must be replaced as an
assembly. Clean valve chamber in cylinder block
thoroughly. Torque retaining screws to specifications.
ENGINE ASSEMBLY
Removal
1. Disconnect battery.
2. Remove air cleaner.
3. Remove hood.
4. Drain radiator.
5. Remove lower radiator hose.
6. Remove upper fan shroud.
7. Remove upper radiator hose and coolant
recovery hose.
8. Remove transmission cooler lines.
9. Remove radiator.
10. Remove fan assembly.
1 1. Remove heater hoses.
12. Disconnect
carburetor linkage, includes cruise
control detent cable.
13. Remove vacuum brake booster line.
14. Remove
distributor cap and lay wiring aside.
15. Disconnect necessary wires and hoses.
16. Remove power steering
pump and lay aside.
17. Raise vehicle.
18. Remove exhaust
pipes at exhaust manifold.
19. Remove dust cover.
20. Remove converter bolts.
2 1. Disconnect starter wires.
22. Remove bell housing bolts.
23. Remove
motor mount through bolts.
24. Disconnect fuel lines
at fuel pump.
25. Lower vehicle.
26. Support transmission.
27. Remove
A.I.R./Converter pipe bracket.
28. Remove engine, include removing wire
from
bracket at rear left of engine.
Installation
1. Position engine
assembly in vehicle.
2. Attach
motor mount to engine brackets and
lower engine in place.
3. Remove engine lifting device.
4. Remove transmission floor jack.
5. Raise vehicle on hoist.
6. Install mount "through" bolts. Torque to
specifications.
7. Install bell housing bolts. Torque to
specifications.
8. On vehicles with automatic transmissions, install
I
converter to flywheel attaching bolts. Torque to
specifications.
9. Install flywheel splash shield of converter
housing cover as applicable. Torque attaching
bolts to specifications.
I
10. Install starter wires.
1 1. Connect fuel lines.
12. Connect exhaust pipe at manifold.
13. Lower vehicle on hoist.
14. Reinstall power steering pump, if so equipped.
15. Connect necessary wires and hoses.

6A3-28 V-8 ENGINE
16. Install
radiator and fan shroud and reconnect
radiator and heater hoses.
17. Fill cooling system.
18. Fill
crankcase with oil. See owner's manual for
specifications.
19. Install air cleaner.
20. Install hood.
21. Connect battery cables.
NOTICE: To avoid possible arcing of battery,
connect positive battery cable first.
22. Start engine, check for leaks and check timing.
CRANKSHAFT
The crankshaft can be removed while the engine
is disassembled for overhaul, as previously outlined, or
without complete disassembly.
Removal
With the engine removed from the vehicle and the
transmission and/or clutch housing removed
from the engine, mount engine in stand and
clamp securely.
Remove the oil dip stick and oil dip stick tube, (if
applicable).
Remove the starting motor, clutch assembly (if
equipped) and flywheel.
Remove the spark plugs.
Remove crankshaft pulley and torsional damper.
Remove oil pan and oil pump.
Remove crankcase front cover, and if so
equipped, remove timing chain and camshaft
sprocket.
Check the connecting rod caps for cylinder
number identification. If necessary, mark them.
Remove the connecting rod caps and push the
pistons to top of bores.
Remove main bearing caps and lift crankshaft out
of cylinder block.
Remove rear main bearing oil seal and main
bearings from cylinder block and main bearing
caps.
Cleaning and Inspection
1. Wash crankshaft in solvent and dry with
compressed air.
2. Measure dimensions of main bearing journals and
crankpins with a micrometer for out-of-round,
taper or undersize. (See Specifications.) 3.
Check crankshaft for run-out by supporting at
the front and rear main bearings journals in
"V"
blocks and check at the front and rear
intermediate journals with a dial indicator. (See
Specifications.)
4. Replace or recondition the crankshaft if out of
specifications.
SPROCKET OR GEAR REPLACEMENT
e Remove crankshaft sprocket using Tool
5-5825, install using Tool J-5590.
Installation
1.
Install rear main bearing oil seal in cylinder block
and rear main bearing cap grooves. Install with
lip of seal toward front of engine. Where seal has
two lips install lip with helix towards front of
engine.
2. Lubricate lips of seal with engine oil. Keep oil off
parting line surface.
3. Install main bearings in cylinder block and main
bearing caps then lubricate bearing surface with
engine oil.
4. Install crankshaft, being careful not to damage
bearing surfaces.
5. Recheck bearing clearances using plastigage.
6. Apply a thin coat of brush-on type oil sealing
compound to block mating surface and
corresponding surface of cap only. Do not allow
sealant on crankshaft or seal.
7. Install main bearing caps with arrows pointing
toward front of engine.
8. Torque all except rear main bearing cap bolts to
specifications. Torque rear main bearing cap bolts
to 10-12 lbs. ft. (14-16
N.m)then tap end of
crankshaft, first rearward then forward with a
lead hammer. This will line up rear main bearing
and crankshaft thrust surfaces.
Retorque all main
bearing cap bolts to specifications.
9. Measure crankshaft end play with a feeler gage.
Force crankshaft forward and measure clearance
between the front of the rear main bearing and the
crankshaft thrust surface.
10. Install flywheel and torque to specifications. A
wood block placed between the crankshaft and
cylinder block will prevent crankshaft from
rotating.
Align dowel hole in flywheel with dowel
hole in crankshaft. On vehicles equipped
with automatic transmissions, install
flywheel with the converter attaching pads
towards transmission.
GENERAL DATA
TYPE .................................................................................................................................. 90" V-8
DISPLACEMENT
............................................................................... 305 Cu. In., 350 Cu. In.
......................................................... LITER (VIN) ................................... ...... 5.0, (E), (F), 5.7 (8)
RPO ......................................................................................................................... L03, LB9, L98
BORE ........................................................................................................................ 3.736, 4.000
STROKE
........................... .. ....................................................................................... 3.480, 3.480
COMPRESSION RATIO
................................................................................... 931, 931, 9.5:1
FIRING ORDER .................................................................................................... 1-8-4-3-6-5-7-2

ENGINE COOLING 6B-1
SECTION 6B
NE COOL
General Description ................................ 6B- 1 Off-Vehicle Leak Testing ............................... 6B-9
Radiator
...................................................... 6B- 1 Repairable Leaks ........................ ... .......... 6B- 10
Radiator Cap
......................... .. ............... 6B- 1 Repair Methods ................................................ 6B- 10
Recovery Bottle ......................................... 6B-2 Cooling Fin Removal ................................ 6B- 10 - ............................................. Fans ............................................................... 6B-2 Tube Blocking 6B- 1 1 ............ Header Repair ....................... .... 6B- 1 1 Temperature Switch ..................................... 6B-2 General Core Repair 6B- 1 1 ....................................
........................... Coolant Temperature Fan Switch ................ 6B-2 Tank
Gasket ~eik Repair 6B- 12
................... Thermostat .. 6B-3 Oil
Cooler Gasket Replacement
6B- 13 ............... ................................
...........................................................
Coolant Recovery System 6B-3 Recore 6B- 14 ............................. Special Tools ..................................................... 6B- 14 Diagnosis ..................................................... 6B-3
.............................. ..................................... Service Procedures 6B-3 On-Vehicle Service 6B-14
Cooling System Care
............................... 6B-3 Thermostat ....................................... 6B-14
Draining and Refilling the Cooling Electric Cooling Fan ............................. 6B-15
System
................................................... 6B-7 Water Pump .................... .... ......... 6B-15
Drive Belt
...................... .. .......................... 6B-7 Coolant Recovery Bottle ........................ 6B-16
.......................................... Aluminum Radiator Service .................... 6B-8 Radiator 6B-17
Diagnosis .................................................... 6B-8
Leak Testing
.............................................. 6B-8
On-Vehicle Pressure Testing
...................... .... 6B-9
GENERAL DESCRIPnIBN
The cooling system maintains engine temperature
5" below the filler neck which reads, "Important - for
at an efficient level during all engine operating repair see Harrison Service Manual". Service
conditions. When the engine is cold the system cools procedures for the aluminum plastic radiator are
slowly, or not at all, to allow the engine to warm up described in that manual and in this section.
quickly.
The cooling system includes a radiator and
Radiator Cap
recovery sub-system, cooling fan, thermostat and
housing, water pump, and drive belts.
Operation of the cooling system requires proper
functioning of all components. Coolant is drawn from
the radiator by the water pump and circulated through
water jackets in the engine block, intake manifold, and
cylinder
head(s), and then directed back to the radiator
where it's cooled.
This system directs some coolant through hoses
to the heater core, to provide for heating and
defrosting. A recovery bottle is connected to the
radiator to recover coolant displaced by expansion
from high temperatures and maintain correct coolant
level. As the coolant cools and contracts it is drawn
back into the radiator by vacuum.
RADIATOR
A cross-flow radiator is used on all models. Tanks
in this type radiator are located to the right and left of
the core, instead of above and below.
Radiators used with automatic transmissions
have oil coolers with inlet and outlet fittings for
transmission fluid circulation. Cars with manual
transmissions use radiators without oil coolers.
Vehicles equipped with air conditioning use a radiator
with extra cooling capability.
An aluminum-plastic radiator, used on some
models, can be identified by a note on the outlet tank A pressure-vent
cap is used on the cross-flow
radiator to allow a buildup of
103 kPa (15 psi) in the
cooling system. This pressure raises the boiling point
of coolant to approximately 125°C (262°F) at sea level.
Do not remove radiator cap to check engine
coolant level; check coolant visually at the
see-through coolant reservoir. Coolant should
be added only
to the reservoir.
CAUTION: As long as there
is
pressure in the cooling system, the
temperature can be considerably
higher than the boiling temperature
of
the solution in the radiator without
causing the solution to boil. Removal
of the radiator cap while engine is hot
and pressure is high will cause
the
solution to boil instantaneously and
possibly with explosive
force, spewing
the solution over engine, fenders and
person removing cap. If the solution
contains flammable antifreeze, such
as alcohol (not recommended for use
at any time), there is also the
possibility
of causing a serious fire.
The pressure-type radiator filler cap contains a
blow off or pressure valve and a vacuum or
atmospheric valve (Figure
1). The pressure valve is
held against its seat by a spring of pre-determined

ENGINE COOLING BB-7
NOTICE: If recommended quality antifreeze is
used, supplemental inhibitors or additives claiming
to provide increased cooling capability are not
necessary. They may be detrimental to the efficient
operation of the system, and represent an
unnecessary operating expense.
Every 12 months or 15,000 miles, the cooling
system should be serviced as follows;
1. Wash radiator cap and filler neck with clean
water.
2. Check coolant for proper level and freeze
protection.
3. Pressure test system and radiator cap for proper
pressure holding capacity, 103
kPa (15 psi). If
replacement of cap is required, use the proper cap
specified for car model.
4. Tighten hose clamps and inspect all hoses. Replace
hoses whenever cracked, swollen or otherwise
deteriorated.
5. Clean frontal area of radiator core and air
conditioning condenser.
DRAINING AND REFILLING THE COOLING
SYSTEM
Replace hoses every 24 months or 30,000 miles or
earlier if cracked, swollen or otherwise deteriorated.
Every two years or 30,000 miles, whichever first
occurs, the cooling system should be flushed and
refilled using the following recommended procedure:
1. Remove radiator cap, or thermostat housing cap
(VIN
0, J, R and U), when engine is cool by:
a. Slowly
rotating cap counterclockwise to
detent. (Do not press down while rotating.)
b. Wait until any
residual pressure (indicated
by a hissing sound) is relieved.
c. After all hissing ceases, press down on cap
while continuing to rotate
counterclockwise.
CAUTION: To avoid the danger of
being burned, do not remove radiator
cap while engine and radiator are still
hot. Scalding fluid and steam may be
blown out under pressure.
2. Remove the thermostat by using the wire handle
to lift it out of the housing (VIN
0, J, R and U).
3. With the thermostat removed, reinstall the
thermostat housing cap (VIN
0, J, R and U).
4. Open radiator drain valve and block drain plugs
to drain coolant. On VIN R and
9 (P series)
engines, open coolant pipe plugs.
5. Close valve. Reinstall drain plugs, and add
sufficient water to fill system.
6. Run engine, drain and refill the system, as
described in steps
4 and 5 a sufficient number of
times, until the drained liquid is nearly colorless.
Important
BLOCK DRIVE WHEELS, place
transmission in PARK (automatic
transmission) or NEUTRAL (manual
transmission) and set the parking brake. 7.
Allow system to drain completely. Then close
radiator drain valve tightly, and reinstall block
drain plugs.
8. Remove recovery cap leaving hoses in place.
Remove coolant recovery tank and empty of
fluid. Flush tank with clean water, drain and
reinstall.
9. Add sufficient ethylene glycol coolant, meeting
GM specification 1825-M, to provide the
required freezing and corrosion protection
- at
least 50 percent solution -37°C (-34°F). Fill
radiator to the base of the radiator fill neck and
add sufficient coolant to the recovery tank to
raise level to the "FULL" mark. Reinstall
recovery tank cap.
10. Run engine, with radiator cap or thermostat
housing cap removed, until normal operating
temperature is reached. (Radiator upper hose
becomes hot.)
11. With engine idling, add coolant until level
reaches bottom of filler neck and reinstall cap,
making certain arrows line up with overflow tube.
CAUTION: Under some conditions, the
ethylene glycol in engine coolant is
flammable. To help avoid being
burned when adding coolant, DO NOT
spill
it on the exhaust system or hat
engine parts.
It is the owner's responsibility to keep the freeze
protection at a level appropriate to the
temperatures which may occur in the area of
vehicle operation.
a. Maintain
cooling system freeze protection
at
-37°C (-34"F), to ensure protection
against corrosion and loss of coolant from
boiling, even though freezing temperatures
are not expected.
b. Add ethylene glycol base coolant that meets
GM Specification 1825-M, when coolant
additions are required because of coolant
loss, or to provide additional protection
against
freezing at temperatures lower than
-37°C (-34°F).
NOTICE: Alcohol or methanol base coolants, or
plain water, are not recommended at any time.
DRlVE BELT
NOTICE: Routine inspection of the belt may
reveal cracks in the belt ribs. These cracks will
not impair belt performance and therefore should
not be considered a problem requiring belt
replacement. However, the belt should be
replaced if belt slip occurs or if sections of the
belt ribs are missing.
A single (serpentine) belt is used to drive all
engine accessories formerly driven by multiple drive
belts. All belt driven accessories are ridgedly mounted
with belt tension maintained by a spring loaded
tensioner.
The drive belt tensioner has the ability to control
belt tension over a fairly broad range of belt lengths.

ENGINE COOLING 68.17
RADIATOR
Remove or Disconnect
1. Negative battery cable.
2. Engine coolant.
3. Fan blade. On fan clutch equipped cars, store
clutch in upright position to prevent seal leakage.
4. Upper and lower radiator hoses.
5. On vehicles equipped with automatic
transmission, plug transmission cooler lines.
6. Fan shield assembly, if applicable.
7. Radiator and shroud assembly, lift straight up.
The radiator assembly is held at the bottom by
two cradles secured to the radiator support.
Install or Connect
1. If new radiator, transfer fittings from old radiator
to new radiator.
Radiator in car, locating bottom of radiator in
lower mounting pads.
Transmission/Engine oil cooler lines at radiator.
Coolant recovery bottle hose at radiator.
Coolant hoses at radiator.
6. Upper radiator support bracket.
7. Engine coolant.
8. Negative battery cable.
Inspect -
e For proper completion of repair.
e For fluid leaks.

6B-20 ENGINE COOLING
1. GENERATOR 5. WATER PUMP
2. TENSIONER 6. CRANKSHAFT
3. BELT 7. BELT IDLER
J10010-6B-F
Fig. 612 Belt Diagram - V.I.N. S (Automatic Transmission)

6D1-4 BATTERY
VOLTAGE
A. 16.0 or more
B. 14.0
- 15.9
C. 13.9 or less HOURS
1. Set parking brake and place automatic
Up to 4 Hours transmission in "PARK" (NEUTRAL for
Up to 8 Hours manual transmission.) Turn off the ignition,
Up to 16 Hours turn off lights, and all other electrical
If the charge current is still not
measurable
at the end of the above charging
times, the battery should be replaced.
If the charge current is measurable during
the charging time, the battery is considered to be
good and charging should be completed in the
normal manner.
5. It
is important to remember that a completely
discharged battery must be recharged for a
sufficient number of ampere hours (AH) to
restore it to a usable state. As a general rule of
thumb, using the reserve capacity rating (RC) of
the battery as the number of ampere hours of
charge will usually bring the green dot into view.
For example, if battery is rated at 75 RC minutes,
it would be completely recharged as follows:
10 ampere charge x 7-1/2 hours
= 75 AH
25 ampere charge x 3 hours = 75 AH, etc.
6. It
is recommended that any battery recharged by
this procedure be
LOAD TESTED to establish
serviceability.
JUMP STARTING IN CASE OF EMERGENCY
WITH AUXILIARY (BOOSTER) BAVEEWY
NOTICE: Do not push or tow the vehicle to start.
Damage to the emission system, or to other parts
of the vehicle may result.
Both booster and discharged battery should be
treated carefully when using jumper cables. Follow the
procedure outlined below, being careful not to cause
sparks:
CAUTION: Departure from these
conditions or the procedure below
could result in:
(1) Serious personal
injury (particularly to eyes) or property
damage from such causes as battery
explosion, battery acid, or electrical
burns; and/or
(2) damage to electronic
components of either vehicle.
Never expose battery to open flame or electric
spark
- batteries generate a gas which is flammable and
explosive.
Remove rings, watches, and other jewelry. Wear
approved eye protection.
Do not allow battery fluid to contact eyes, skin,
fabrics, or painted surfaces
- fluid is a corrosive acid.
Flush any contacted area with water immediately and
thoroughly. Be careful that metal tools or jumper
cables do not contact the positive battery terminal (or
metal in contact with it) and any other metal on the
car, because a short circuit could occur. Batteries
should always be kept out of the reach of children.
loads.
2. Check the built-in hydrometer. If it is clear or
light yellow, replace the battery.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery and the other end
of the same cable to the positive terminal of the
discharged battery. Do not permit vehicles to
touch each other as this could cause a ground
connection and counteract the benefits of this
procedure. (Use 12-volt battery only to jump start
the engine).
4. Attach one end of the remaining negative cable
to the negative terminal of the booster battery,
and the other end to a solid engine ground (such
as
A/C compresser bracket or generator
mounting bracket) at least 18 inches from the
battery of the vehicle being started (DO NOT
CONNECT DIRECTLY TO THE NEGATIVE
TERMINAL OF THE DEAD BATTERY).
5. Start the engine of the vehicle that is providing
the jump start and turn off electrical accessories.
Then start the engine in the car with the
discharged battery.
6. Reverse these directions exactly when removing
the jumper cables. The negative cable must be
disconnected from the engine that was jump
started first.
I-FENDER 4-BATTERY (REF.)
2- BOLTISCREW 5-FENDER SKIRT
3-RETAINER
520028-60
Fig. 5 Battery Hold-Down (Typical)

DRIVEABILITY AND EMISSIONS - 5.OL (VIN El CEZ-C2-9
u PART IDENTIFICATION NUMBER
VENDOR IDENTlFlCATl
Figure C2-12 - Fuel Injector Part Number Location
Remove or Disconnect
lectrical connectors to fuel injectors. (Squeeze
plastic tabs and pull straight
up.)
2. Fuel meter
cover assembly following above
procedure.
3. With fuel meter cover gasket in place to prevent
damage to casting, use a screwdriver and fulcrum
to carefully lift out each injector (Figure
C2-11).
4. Lower (small) o-rings from nozzle of injectors and
discard.
5. Fuel meter cover gasket and discard.
6. Upper (large o-rings and steel backup washers
from top of each fuel injector cavity and discard.
Inspect
@ Fuel injector filter for evidence of dirt and
contamination.
If present, check for presence of
dirt in fuel lines and fuel tank.
Important
Be sure to replace the injector with an identical
part. Injectors from other models can fit in Model
220 TBI, but are calibrated for different flow rates.
(See Figure
C2-12 for part number location.)
Install or Connect
1. Lubricate new lower (small) o-ring with automatic
transmission fluid and push on nozzle end of
injector until it presses against
in,jector fuel filter.
2. Steel injector backup washer in counterbore of fuel
meter body.
3. Lubricate new upper (large) o-ring with automatic
transmission fluid and install directly over
the
backup washer. Be sure o-ring is seated properly
and is flush with top of fuel meter body surface.
I I 1 I FUEL INJECTOR ASSEMBLY
FUEL METER BODY ASSEMBLY
~p,~9~~~As
Figure C2-13 - Installing Fuel Injector
NOTICE: Backup washers and o-rings must be
installed before injectors, or improper
seating of large o-ring
could cause fuel
to leak.
4. Injector, aligning raised lug on each injector base
with notch in fuel meter body cavity. Push down
on injector until it is fully seated in fuel meter
body (Figure
C2-13). (Electrical terminals of
injector should be parallel with throttle shaft.)
5. Fuel meter cover gasket.
6. Fuel meter cover (see above procedure).
7. Fuel meter cover attaching screws, coated with
appropriate thread locking compound.
8. Electrical connectors to fuel injectors.
9. With engine "OFF" and ignition "ON", check for
fuel leaks.
FUEL METER BODY ASSEMBLY
Replacement (Figure
CZ-14)
a Remove or Disconnect
1. Electrical connections to fuel injectors. (Squeeze
plastic tabs and pull straight up.)
2. Fuel meter cover assembly, (see previous
procedure).
3. Fuel
meter cover assembly, following above
procedure.
4. Fuel injectors, following above procedure.
5. Fuel inlet and return lines. Discard o-rings.
6. Fuel inlet and outlet nuts and gaskets from the
fuel meter body assembly. Discard gaskets.
Important
Note locations of nuts, for proper reassembly
later. Inlet nut has a larger passage than
outlet nut.
7. Fuel meter body to throttle body attaching screw
assemblies.