1988 PONTIAC FIERO fuel filter

GENERAL INFORMATION OA-7
APPROXIMATE CAPACITIES
Fuel Injected Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE
5.OL V8 Oil Change
*Approximate capacity with or without oil filter change.
Crankcase capacities shown are approximate refill capacities. After refill, recheck oil as outlined in the Owner's Manual.
COOLING SYSTEM
2.8L V6 Without A/C
5.OL V8 Without A/C
Fig. OA-9 Fluid Capacties

F CARLINE
ITEM 10
TransmissionRransaxle Service
The manual transmission or transaxle fluid does not
require changing. (Corvette only.) Change fluid in over-
drive unit every 30,000 miles (50 000 km).
For automatic transmissions or transaxles, change
both the fluid and filter every 15,000 miles (25 000 km) if
the car is mainly driven under one or more of these
conditions:
@ In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
@ In hilly or mountainous terrain.
@ Frequent trailer pulling.
@ Uses such as found in taxi, police car or delivery
service.
If you do not use your car under any of these condi-
tions, change both the fluid and filter every 100,000 miles
(160 000 km). See you Owner's Manual for further
details.
ITEM 11
Spark Plug Service*
Replace spark plugs with type listed in your Owner's
Manual.
ITEM 12
Spark Plug Wire Inspection*
Clean wires and inspect for burns, cracks or other dam-
age. Check the wire boot fit at distributor and at spark plugs.
Replace wires as needed.
ITEM 13
Positive Crankcase Ventilation (PCV) Valve
Inspection*
Inspect valve for proper function. Replace valve if
necessary as well as any worn, plugged or collapsed
hoses.
ITEM 14
EGR System Service*
Conduct EGR System Service as referenced in the
EGR System Chart shown in the appropriate 6E Section.
Also, refer to your GM maintenance schedule booklet for
specific applications.
ITEM 15
Air Cleaner and PCV Filter Replacement*
On 1.6 and 2.0 liter engines, replace every 50,000
miles (80 000 km). On all other engines, replace every
30,000 miles (50 000 km). Replace more often under
dusty conditions. Ask your dealer for the proper replace-
ment interval for your driving conditions.
MAINTENANCE AND LUBRICATION 08-3
ITEM 16
Engine Timing Check*
Adjust timing to underhood label specifications. If
no specifications are shown, no adjustment is needed.
ITEM 17
Fuel Tank, Cap and Lines Inspection*
Inspect fuel tank, cap and lines (including fuel rails
and injection assembly, if so equipped) for damage or
leaks. Inspect fuel cap gasket for an even filler neck
imprint or any damage. Replace parts as needed.
ITEM 18
Thermostatically Controlled Air Cleaner
Inspection*
If your car is equipped, inspect all hoses and ducts
for proper hookup. Make sure valve works properly.
OWNER INSPECTIONS AND SERVICES
Listed below are inspections and services which
should be made by either you or a qualified technician at
the intervals shown to help ensure proper safety, emission
performance and dependability of your car. Take any
problems promptly to your dealer or another qualified
technician for service advice. Whenever repairs are neces-
sary, have them completed at once. For your safety and
that of others, any safety-related parts that could have
been damaged in an accident should be inspected and all
needed repairs should be done before operating your car.
Be sure to use the proper fluids and lubricants as shown in
Figure OB-2.
WHILE OPERATING YOUR VEHICLE
Automatic transmissionltransaxle shift indi-
cator operation - Make sure the indicator points to the
gear chosen.
Horn operation - Blow the horn occasionally to
make sure it works. Check all button locations.
I
Brake system operation -- Be alert to abnormal
sounds, increased brake pedal travel or repeated pulling to
one side when braking. Also, if a brake warning light
comes on or flashes, or the anti-lock warning light (if
equipped) comes on or remains on, something may be
wrong with part of the brake system. Have it inspected and
repaired at once.
Exhaust system operation - Be alert to any
changes in the sound of the system or any smell of fumes.
These are signs the system may be leaking or overheating.
.
Have it inspected and repaired at once. Also see "Engine
Exhaust Gas Caution (Carbon Monoxide)" and "Catalytic
Converter" in your Owner's Manual.
*An Emission Control Service

ENGINE GENERAL INFORMATION 6-3
B, Section 6E2 - Fuel Injection (TBI)
B, Section 6E3 - Fuel Injection (Ported)
ENGINE MECHANICAL DIAGNOSIS
The following diagnostic information covers common problems and possible causes. When
the proper diagnosis is made, the problem should be corrected by adjustment, repair or part
replacement as required. Refer to the appropriate section of the manual for these procedures.
EXCESSIVE OIL LOSS
B, External oil leaks. Tighten bolts and/or replace o Continuous high speed driving, and/or severe
gaskets and seals as necessary. usage
such as trailer hauling, will normally cause
decreased oil mileage.
e Improper reading of dipstick. Check oil with car PCV system malfunctioning. on a level surface and allow adequate drain-down Valve guides and/or valve stem seals worn, or time.
seals omitted. Ream guides and install oversize
service valves and/or new valve stem seals.
Improper Use S.A'E' Piston rings broken, worn, or not seateded. Allow viscosity for prevailing temperatures. See
adequate time for rings to seat. Replace broken
Owner's Manual for proper specifications.
or worn rings, as necessary.
Piston improperly installed or misfitted.
LOW OIL PRESSURE
Slow idle speed. Set idle speed to correct
specification, if not ECM controlled.
Incorrect, or malfunctioning, oil pressure switch.
Incorrect, or malfunctioning, oil pressure gage.
Replace with proper gage.
.*
Improper oil viscosity, or diluted oil. install oil of
proper viscosity for expected temperature, or
install new oil if diluted with moisture or
unburned fuel mixtures.
o Oil pump worn or dirty.
e Plugged oil filter.
e Oil pickup screen loose or plugged.
B, Hole in oil pickup tube.
e Excessive bearing clearance. Replace if necessary.
o Cracked, porous or plugged oil galleys. Repair or
replace block.
o Galley plugs missing or misinstalled. Install
plugs, or repair as necessary.
VALVE TRAIN NOISE
e Low oil pressure. Repair as necessary. (See o Broken valve spring.
preceding diagnosis for low oil pressure.)
o Sticking valves.
o Loose rocker arm attachments. Inspect and B, Lifters worn, dirty, or defective. Clean, inspect,
test and replace as necessary.
repair as necessary.
o Camshaft worn, or poor machining. Replace
o Worn rocker arm and/or pushrod. camshaft.
B, Worn valve guides.
ENGINE KNOCK DIAGNOSIS
KNOCKS COLD AND CONTINUES FOR TWO TO THREE MINUTES
INCREASES
WITH TORQUE
o Vacuum operated EFE engines may have valve o Excessive piston to bore clearance. Replace
knock. Replace EFE valve. piston.
e Flywheel contacting splash shield. Reposition
splash shield.
e Loose or broken balancer or drive pulleys.
Tighten, or replace as necessary. Cold engine piston knock usually
disappears when the cylinder is grounded
out. Cold engine piston knock which
disappears in 1.5 minutes should be
considered acceptable.

6A2-16 2.8 LITER V-6
Figure 6A2-19 Camshaft Timing
2. Align dowel in camshaft with dowel hole in
camshaft sprocket, then install sprocket on
camshaft.
3. Draw the camshaft sprocket onto camshaft using
the mounting bolts. Torque to specifications.
4. Lubricate timing chain with engine oil.
5. Install crankcase front cover as previously
outlined.
Figure 6A2-20 Measuring Camshaft Lobe Lift
CAMSHAFT
Measuring Lobe Lift Procedure is similar to that
used for checking valve timing. If improper valve
operation is indicated, measure the lift of each push rod
in consecutive order and record the readings.
1. Remove the valve mechanism, as previously
outlined.
2. Position
indicator with ball socket adapater (Tool
5-8520) on push rod. Make sure push rod is in the
lifter socket.
3. Rotate the crankshaft slowly in the direction of
rotation until the lifter is on the heel of the cam lobe.
At this point, the push rod is in its lowest
position.
4. Set the dial indicator on zero, then rotate the
crankshaft slowly, or attach an auxiliary starter
switch and "bump" the engine over, until the
push rod is in the fully raised position (Figure
6A2-20).
CAUTION: Whenever the engine is
cranked remotely at the starter, with
a special jumper cable or other means,
the distributor primary lead must be
disconnected from the coil to prevent
electrical shock.
5. Compare the total lift recorded from the dial
indicator with the specifications.
6. If camshaft readings for all lobes are within
specifications, remove dial indicator assembly.
7. Install and adjust valve mechanism, as previously
outlined.
Removal
1. Remove valve lifters as previously outlined.
2. Remove crankcase front cover as previously
outlined.
3. Remove fuel pump and push rod.
4. Remove timing chain and sprocket as previously
outlined.
5. Remove camshaft.
NOTICE: All camshaft journals are the same
diameter and care must be exercised in removing
camshaft to avoid damage to bearings.
Inspection
The camshaft bearing journals should be
measured with a micrometer for an out-of-round
condition. If the journals exceed
.025mm out-of-round,
the camshaft should be replaced.
Installation
Whenever a new camshaft is installed, coat
camshaft lobes with
GM E.O.S, or equivalent.
Whenever a new camshaft is installed, install new
oil, new filter and replacement of all valve lifters is
recommended to insure durability of the camshaft
lobes and lifter feet.
1. Lubricate camshaft journals with engine oil and
install camshaft.
2. Install timing chain, as previously outlined.
3. Install fuel pump push rod and fuel pump.
4. Install crankcase cover, as previously outlined.
5. Install
lifters, as previously outlined.
6. Complete build up of engine.
CAMSHAFT BEARINGS
Removal
Camshaft bearings can be replaced while engine
is disassembled for overhaul or without complete
disassembly of the engine. To replace bearings without
complete disassembly remove the camshaft and
crankshaft leaving cylinder heads attached and pistons
in place. Before removing crankshaft, tape threads of

6A3-2 V-8 ENGINE
VALVE TRAIN
A very simple ball pivot-type train is used.
Motion is transmitted from the camshaft through the
hydraulic lifter and push rod to the rocker arm. The
rocker arm pivots on its ball and transmits the
camshaft motion to the valve. The rocker-arm ball is
retained by a nut.
HYDRAULIC VALVE LIFTERS
Hydraulic Valve Lifters are used to keep all parts
of the valve train in constant contact.
The hydraulic lifter assembly consists of: a roller,
the lifter body, which rides in the cylinder block boss,
a plunger, a push rod seat, a metering valve, a plunger
spring, a check ball and spring, a check ball retainer
and a push rod seat retainer.
When the lifter is riding on the low point of the
cam, the plunger spring keeps the plunger and push rod
seat in contact with the push rod.
When the lifter body begins to ride up the cam
lobe, the check ball cuts off the transfer of oil from the
reservoir below the plunger. The plunger and lifter
body then rise as a unit, pushing up the push rod and
opening the valve.
As the lifter body rides down the other side of the
cam, the plunger follows with it until the valve closes.
The lifter body continues to follow the cam to its low
point, but the plunger spring keeps the plunger in
contact with the push rod. The ball check valve will then
move off its seat and the lifter reservoir will
remain full.
INTAKE MANIFOLD
The intake manifold for those engines with
carburetors are made of cast iron or aluminum double
level design for efficient fuel distribution. An Exhaust
Gas Recirculation (EGR) port is also cast into the
manifold for the mixture of exhaust gases with the fuel
air mixture.
The intake manifold for those vehicles equipped
with
PFI is a cast aluminum unit. It centrally supports
a fuel rail with
8 fuel injectors.
EXHAUST MANIFOLDS
Two cast iron exhaust manifolds are used to
direct exhaust gases from the combustion chambers to
the exhaust system. The left hand side manifold
receives a heat shield that is used to route heated air
to the air cleaner. for better fuel vaporization during
warm-up.
COMBUSTION CHAMBERS
Combustion Chambers are cast to insure uniform
shape for all cylinders. Spark plugs are located between
the intake and exhaust valves. The contoured wedge
shape of the combustion chamber minimizes the
possibility of detonation, facilitates breathing and
provides swirling turbulence for smooth, complete
combustion.
ENGINE LUBRICATION
Full pressure lubrication through a full flow oil through drilled passages, to the camshaft and
filter, is furnished by a gear-type oil pump. The crankshaft to lubricate the bearings. The valve lifter oil
distributor, driven by a helical gear on the camshaft,
gallery feeds the valve lifters which, through hollow
drives the oil pump. The main oil gallery feeds oil,
push rods, feed the individually mounted rocker arms.

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.

ENGINE FUEL BC-1
SECTION 6C
NE FUEL
CONTENTS
General Description ..................................... 6C-1 Fuel
Cap ........................................................... 6C-3
.................................................. ............................................. Alcohol-In-Fuel 6C- 1 Fuel Filter Neck 6C-3
................... ............ Fuel Metering .................................................. 6C-2 Fuel Gage Sending Unit .. 6C-4
....................... ............................... Throttle Body Injection (TBI) .... 6C-2 Diagnosis ,. 6C-4 ................... Service
Procedures ............................................. 6C-4
Port Fuel Injection ...................................... 6C-2
Pressure Relief ........................................... 6C-4
Fuel Feed and Return Pipe
............................... 6C-2
Flow Test .................................................... 6C-4
Fuel Pipes (MPFI)
.......................................... 6C-3
Pressure Test - TBI ................................... 6C-4
Fuel and Vapor Hoses
....................................... 6C-3
Pressure Test - MPFI .................................... 6C-4
Fuel Pump ........................................................ 6C-3 ...................................................... Fuel Pump Relay .............................................. 6C-3 Fuel Tank 6C-4
Fuel Filter
......................................................... 6C-3 Accelerator Controls ...................................... 6C-5
Fuel Tank
....................................................... 6C-3
All new General Motors vehicles are certified by
the United States Environmental Protection Agency as
conforming to the requirements of the regulations for
the control of air pollution from new motor vehicles.
This certification is contingent on certain adjustments
being set to factory standards. In most cases, these
adjustment points either have been permanently
sealed and/or made inaccessible to prevent
indiscriminate or routine adjustment in the field. For
this reason, the factory procedure for temporarily
removing plugs, caps, etc., for purposes of servicing the
product must be strictly followed and, wherever
practicable, returned to the original intent of the
design.
GENERAL DESCRIPTION
All gasoline engines are designed to use only
unleaded gasoline. Unleaded gasoline must be used for
proper emission control system operation. Its use will
also minimize spark plug fouling and extend engine oil
life. Using leaded gasoline can damage the emission
control system and could result in loss of emission
warranty coverage.
All cars are equipped with an Evaporative
Emission System. The purpose of the system is to
minimize the escape of fuel vapors to the atmosphere.
Information on this system will be found in Section
6E2, or 6E3.
When working on the fuel system, there are
several things to keep in mind.
@ Any time fuel system is being worked on,
disconnect the negative battery cable
except for those tests where battery
Adhere to all Notices and Cautions.
Always keep a dry chemical (Class B) fire
extinguisher near the work area.
-
Always use a backup wrench when loosening or
tightening a screw couple fitting.
The torque on a screw fitting is
30 N-m (22 lb.
ft.).
Pipe is used on all MPFI, TPI, SFI, and TBI
applications. Fittings require the use of an
"0"
Ring. Replace all pipe with the same type of pipe
and fittings that were removed.
All fuel pipes must meet GM Specification
124-M, or its equivalent.
All fuel hoses must meet GM Specification
6163-M, or its equivalent.
Do not replace fuel pipe with fuel hose.
voltage is required.
@ On MPFI, TPI, SF1 and TBI systems, always A1cohol-ln-Fuel
relieve the line pressure before servicing any fuel Certain driveability complaints such as
system components. hesitation, lack of power, stall, no start, etc., may be
@ Do not repair the fuel system until you have read caused
by an excessive amount of alcohol-in-fuel. The
the copy and checked the illustrations relating to complaints
may be due to fuel system corrosion and
that repair. subsequent
fuel filter plugging, deterioration of rubber

ENGINE FUEL 6C.3
a Fuel feed and return pipes are secured to the
underbody with clamps and screw assemblies.
The pipes should be inspected occasionally for
leaks, kinks or dents.
e Follow the same routing as the original pipe.
e Pipes must be properly secured to the frame to
prevent chafing. A minimum of 6 mm
(1/4")
clearance must be maintained around a pipe to
prevent contact and chafing.
MPFl Fuel Pipes
Due to the fact that fuel pipes are under high
pressure, these systems require special consideration for service.
Many feed and return pipes use screw couplings
with
"0" Rings. Any time these fittings are loosened
to service or replace components, ensure that:
a A backup wrench is used while loosening and
tightening the fitting.
e Check all "0" rings at fitting locations (if
applicable) for cuts or any damage and replace
any that appear worn or damaged.
e Use correct torque when tightening fittings.
If pipes are replaced always use original
equipment parts, or parts that meet GM
specifications.
Fuel and Vapor Hoses
NOTICE: Fuel and vapor hoses are specially
manufactured. If replacement becomes necessary,
it is important to use only replacement hoses
meeting GM Specification 6163-M. These hoses
are identified with the words "Fluoroelastomer"
on them. Hoses not so marked could cause early
failure, or fail to meet emission standards.
e Do not use rubber hose within 4" of any part of
the exhaust system, or within
10" of the catalytic
converter.
FUEL PUMP
The electric fuel pump is in the fuel tank. The
tank has an outlet for a vapor return system. Any vapor
which forms is returned to the fuel tank along with hot
fuel through a separate line. This greatly reduces any
possibility of vapor lock by keeping cool fuel from the
tank constantly circulating through the fuel pump.
FUEL PUMP RELAY
To control fuel pump operation, a fuel pump
relay is used.
When the ignition switch is turned to "RUN"
position, the fuel pump relay activates the electric fuel
pump for
1.5 to 2.0 seconds to prime the injector(s). If
the ECM does not receive reference pulses from the
distributor after this time, the ECM signals the relay
to turn off the fuel pump. The relay will once again
activate the fuel pump when the
ECM receives
distributor reference pulses.
Fuel Filter
CAUTION: To reduce the risk of fire
and personal injury, it is necessary
to
relieve the fuel system pressure
before servicing fuel system
components. (See Fuel System
Pressure Relief.)
The inline filters can be found on the rear
crossmember of the vehicle. Always use a backup
wrench any time that the fuel filter is removed or
installed. Also make sure that a good
"0" Ring is used
at all screw couple locations. Torque on fittings is
30
N-m (22 lb. ft.).
FUEL TANK
The fuel tank is usually located under the rear of
the vehicle and a number of shapes and sizes are used
depending on the application.
The tank is held in place by two metal straps,
hinged (with a bolt through the hinge) and secured at
the opposite end with a nut and bolt assembly.
Anti-squeak pieces are used on top of the tank to
reduce rattles and other annoying noises.
The fuel tank, cap and lines should be inspected
for road damage, whch could cause leakage. Inspect
fuel cap for correct sealing and indications of physical
damage. Replace any damaged or malfunctioning
parts.
Before attempting service of any type on the fuel
tank, always
(1) remove negative battery cable from
battery, (2) place "no smoking" signs near work areas,
(3) be sure to have C02 fire extinguisher handy, (4)
wear safety glasses and
(5) siphon or pump fuel into an
explosion proof container.
Fuel Filler Gap
The fuel tank filler neck is equipped with a
screw-type cap. The threaded part of the cap requires
several turns counterclockwise to remove. The long
threaded area is designed to allow any remaining fuel
tank pressure to escape while the cap is being removed.
A built-in torque-limiting device prevents
overtightening. To install, turn the cap clockwise until
a clicking noise is heard. This signals that the correct
torque has been reached and the cap is fully seated.
N OTI G E: If a fuel filler cap requires replacement,
use only a cap with the same features. Failure to
use the correct cap can result in a serious
malfunction of the system.
Available on some models is an electric locking
fuel filler cap. Information on this option will be found
in Section
9E.
FUEL TANK FILLER NECK
To help prevent refueling with leaded gasoline,
the fuel filler neck on gasoline engine cars has a built-in
restrictor and deflector. The opening in the restrictor
will only admit the smaller unleaded gas nozzle spout,
which must be fully inserted to bypass the deflector.
Attempted refueling with a leaded gas nozzle or failure