Post by TexasG8 on Jul 10, 2009 13:25:35 GMT -6
V6
Oil Pressure......................................... 15 PSI minimum at 2000 RPM
Compression Pressure............................ 100 to 150 PSI
Maximum variation between cylinders....... 20%
Firing Order......................................... 1-2-3-4-5-6
Valves and Related Components
Valve face angle................................... 45 Degrees
Valve seat angle................................... 46 Degrees
Valve seat width
--Intake.............................................. 0.049 to 0.059 inch
--Exhaust............................................ 0.063 to 0.075 inch
Valve seat run out................................. 0.002 inch maximum
Stem to guide clearance......................... 0.001 to 0.0028 inch
Valve spring height................................ 1.57 inches
Valve Spring free length.......................... 1.91 inches
Crankshaft and Connecting Rods
Crankshaft endplay................................ 0.002 to 0.007 inch
Connecting rod endplay (side clearance).... 0.006 to 0.017 inch
Main bearing journal diameter
--1982 (all).......................................... 2.4937 to 2.4946 inches
--1983 and 1984
----Journals 1, 2 and 4 .......................... 2.4937 to 2.4946 inches
----Journal 3........................................ 2.4932 to 2.4941 inches
--1985 and later.................................... 2.647 to 2.648 inches
Main bearing oil clearance
--1982 (all).......................................... 0.0017 to 0.0030 inch
--1983 and 1984
----Journals 1,2, and 4........................... 0.0016 to 0.0032 inch
----Journal 3........................................ 0.0021 to 0.0033 inch
--1985 and later................................... 0.0012 to 0.0030 inch
Connecting rod bearing journal diameter .... 1.9983 to 1.9994 inches
Connecting rod bearing oil clearance......... 0.0012 to 0.0037 inch
Crankshaft Journal taper/out-of-round limit. 0.0002 inch
Engine Block
Cylinder bore diameter............................ 3.504 to 3.507 inches
Out-of-round limit.................................. 0.0005 inch
Taper limit............................................ 0.0005 inch
Pistons and Rings
Piston-to-bore clearance......................... 0.0012 to 0.0026 inch
Compression Ring side clearance
--1989 and earlier
----Top Ring......................................... 0.0012 to 0.0027 inch
----Second Ring.................................... 0.0016 to 0.0037 inch
--1990 and later.................................... 0.0020 to 0.0035 inch
Oil ring side clearance............................. 0.0080 inch maximum
Piston ring end gap
--Compression rings................................ 0.0010 to 0.0020 inch
--Oil ring.............................................. 0.055 inch maximum
Camshaft
Bearing journal diameter.......................... 1.868 to 1.870 inches
Bearing oil clearance............................... 0.001 to 0.004 inches
Lobe lift
--1984 and earlier
----Intake............................................ 0.231 inch
----Exhaust.......................................... 0.262 inch
--1985 and later
----Intake............................................ 0.231 inch
----Exhaust.......................................... 0.273 inch
Torque Specs Ft-lbs
Rocker arm stude to cylinder head............. 45
Main bearing cap bolts............................. 73
Connecting rod cap bolts......................... 39
Cylinder head bolts
--1989 and eariler................................... 70
--1990 and later
----Step 1............................................. 40
----Step 2............................................. Tighten and turn additional 90*
Camshaft rear cover bolts......................... 84 inch pounds
Camshaft sprocket bolts........................... 18
Clutch cover to flywheel bolts.................... 15
Connecting rod cap nuts........................... 37
Crankshaft Pulley bolts............................. 25
Crankshaft pulley hub bolt......................... 75
Cylinder Head Bolts
--2.8L................................................... 70
--3.1L
----Step 1............................................. 40
----Step 2............................................. Tighten Additional 90*
Distributor Hold down............................... 25
Driveplate-to-torque converter bolts........... 27
EGR valve mounting bolts.......................... 15
Engine mounting bracket bolts.................... 80
Engine strut bracket................................. 35
Exhaust manifold mounting bolts................. 25
Flywheel mounting bolts............................. 50
Front Cover mounting bolts (small)............... 15
Front cover mounting bolts (large)............... 25
Fuel pump mounting bolts........................... 15
Intake manifold to cylinder head bolts
--2.8L..................................................... 23
--3.1L..................................................... 19
Main bearing cap bolts............................... 70
Oil filter bolt............................................. 15
Oil filter connector bolt............................... 29
Oil pan mounting bolts (small)...................... 84 inch pounds
Oil pan mounting bolts (large)...................... 18
Oil pump mounting bolt............................... 30
Oil pump cover bolts.................................. 96 inch pounds
Oil pressure switch.................................... 60 inch pounds
Oil drain plug............................................ 18
Rear lifting bracket bolt.............................. 25
Rocker arm cover bolts............................... 96 inch pounds
Rocker arm stud to cylinder head................. 45
Spark plugs.............................................. 12
Starter motor mounting bolts....................... 32
Strut bracket assembly nut and bolt............. 35
Timing chain tensioner bolts........................ 15
Water outlet housing bolts.......................... 25
Water pump mounting bolts (small) .............. 84 inch pounds
Water pump mounting bolts (medium)............ 15
Water pump mounting bolts (large)............... 25
Water pump pulley bolt............................... 15
V8 Engine
Oil Pressure.............................................. 15 PSI minimum at 2000 RPM
Compression pressure................................. 100 to 150 PSI
Maximum variation between cylinders............ 20%
Firing Order.............................................. 1-8-4-3-6-5-7-2
Valves and Related Components
Valve face angle....................................... 45 Degrees
Valve seat angle....................................... 46 Degrees
Valve Seat width
--Intake.................................................. 1/32 to 1/16 inch
--Exhaust................................................ 1/16 to 3/32 inch
Valve seat runout..................................... 0.002 inch max
Stem-to-Guide clearance
--Standard.............................................. 0.001 to 0.0027 inch
--Service Limit
----Intake............................................... 0.0037 inch max
----Exhaust............................................. 0.0047 inch max
Valve spring height.................................... 1 23/32 inch
Valve spring free length
--1984 and eariler..................................... 1.86 inch
--1985 and later....................................... 2.03 inch
Crankshaft and Connecting Rods
Main journal diameter
--Journal 1.............................................. 2.4484 to 2.4493 inches
--Journals 2,3 and 4.................................. 2.4481 to 2.4490 inches
--Journal 5.............................................. 2.4479 to 2.4488 inches
Journal Taper
--Standard.............................................. 0.0002 inch
--Service limit.......................................... 0.0010 inch max
Journal out of round
--Standard.............................................. 0.0002 inch
--Serice limit........................................... 0.0010 max
Main Bearing oil clearance
--Journal 1.............................................. 0.0008 to 0.0020 inch
--Journal 2,3, and 4.................................. 0.0011 to 0.0023 inch
--Journal 5.............................................. 0.0017 to 0.0032 inch
Crankshaft Endplay................................... 0.002 to 0.006 inch
Connecting rod journal diameter.................. 2.0986 to 2.0998
Connecting rod journal taper
--standard.............................................. 0.0005 inch
--service limit.......................................... 0.001 inch max
Connecting rod journal out of round.............
--Standard............................................. 0.0002 inch
--Service limit......................................... 0.001 inch max
Rod bearing oil clearance........................... 0.0018 to 0.0039 inch
Connecting rod endplay (side clearance)...... 0.008 to 0.014 inch
Engine Block
Bore Diameter
--5.0L................................................... 3.7350 to 3.7385 inches
--5.7L................................................... 3.9995 to 4.0025 inches
Out of Round
--Standard............................................ 0.0010 inch
--Service limit........................................ 0.0020 inch max
Taper
--Standard............................................ 0.0005 Inch
--Service Limit....................................... 0.0015 inch max
Piston and Rings
Piston to Bore clearance
--Standard............................................ 0.0007 to 0.0017 inch
--Service limit........................................ 0.0027 inch max
Piston Ring Side Clearance
--Top Ring
----Standard.......................................... 0.0012 to 0.0032 inch
----Service limit...................................... 0.0042 inch maximum
--Second Ring
----Standard.......................................... 0.0012 to 0.0032 inch
----Service limit...................................... 0.0042 inch max
Oil ring
--Standard............................................. 0.002 to 0.007 inch
--Service limit......................................... 0.008 inch max
Piston Ring end gap
--Top Ring
----Standard.......................................... 0.010 to 0.020 inch
----Service limit...................................... 0.035 inch max
--Second ring
----Standard.......................................... 0.010 to 0.025 inch
----Service limit...................................... 0.035 inch mx
Oil ring
--Standard............................................. 0.015 to 0.055 inch
--Service limit......................................... 0.065 inch max
Camshaft
Bearing Journal diameter............................ 1.8682 to 1.8692 inches
Bearing oil clearance................................. 0.001 to 0.004 inch
camshaft endplay..................................... 0.004 to 0.012 inch
Lobe lift
--1982
----Carb
------Intake............................................ 0.238 inch
------Exhaust.......................................... 0.260 inch
-----T.B.I
------Intake............................................ 0.260 inch
------Exhaust.......................................... 0.273 inch
--1983 and 1984
----Carb
------Standard model
--------Intake......................................... 0.234 inch
--------Exhaust....................................... 0.257 inch
------High Output Model
--------Intake......................................... 0.269 inch
--------Exhaust....................................... 0.276 inch
----T.B.I
------Intake............................................ 0.257 inch
------Exhaust.......................................... 0.269 inch
--1985 -1987
----Carb
------Standard Model
--------Intake......................................... 0.234 inch
--------Exhaust....................................... 0.257 inch
------High Output
--------Intake......................................... 0.269 inch
--------Exhaust....................................... 0.276 inch
------T.P.I
(5.0)
--------Intake......................................... 0.269 inch
--------Exhaust....................................... 0.276 inch
(5.7)
--------Intake......................................... 0.273 inch
--------Exhaust....................................... 0.282 inch
--1988-1990
----5.0L
------T.B.I
--------Intake......................................... 0.234 inch
--------Exhaust....................................... 0.257 inch
------T.P.I.
--------Intake......................................... 0.269 inch
--------Exhaust....................................... 0.276 inch
----5.7L
------Intake............................................ 0.273 inch
------Exhaust.......................................... 0.282 inch
--1991-1992
----T.B.I
------Intake............................................ 0.234 inch
------Exhaust.......................................... 0.257 inch
----T.P.I
------Intake............................................ 0.275 inch
------Exhaust.......................................... 0.285 inch
Main bearing cap bolts............................... 70
Connecting rod cap nuts............................ 45
Cylinder head bolts
--1988 Earlier.......................................... 65
--1989 Later........................................... 68
Oil pump to rear main bearing cap bolt......... 65
Rear main bearing oil seal retainer bolts........ 132 inch lbs
Camshaft sprocket bolts............................ 20
Camshaft rear cover bolts.......................... 84 inch lbs
Clutch pressure plate bolts......................... 35
Crankcase front cover bolts........................ 84 inch lbs
Crankshaft pulley bolts............................... 25
Distributor clamp bolt................................. 20
Drive plate to torque converter bolts
--1984 earlier........................................... 27
--1985 later............................................. 35
Engine mounting bracket bolts..................... 80
Engine strut mounting bracket bolts.............. 35
Exhaust manifold bolts................................ 20
Flywheel to Crankshaft bolts
--1985 earlier............................................ 60
--1986 later.............................................. 74
Flywheel housing bolts
--1984 earlier............................................ 30
--1985 and later........................................ 55
Flywheel housing cover bolts........................ 84 inch lbs
Fuel pump mounting bolts............................ 15
Intake manifold bolts................................... 30
Intake manifold cover to intake (crossfire)...... 20
Oil filter bypass valve.................................. 84 inch pounds
Oil pan to crankcase bolts
--5/16" bolts............................................. 14
--1/4" bolts............................................... 84 inch pounds.
Rocker Arm cover bolts
--1984 earlier............................................ 48 inch lbs
--1985..................................................... 60 inch lbs
--1986-1989............................................. 75 inch lbs
--1990 and later........................................ 89 inch lbs
Spark plugs............................................... 22
Harmonic Balancer...................................... 60
Oil Pressure......................................... 15 PSI minimum at 2000 RPM
Compression Pressure............................ 100 to 150 PSI
Maximum variation between cylinders....... 20%
Firing Order......................................... 1-2-3-4-5-6
Valves and Related Components
Valve face angle................................... 45 Degrees
Valve seat angle................................... 46 Degrees
Valve seat width
--Intake.............................................. 0.049 to 0.059 inch
--Exhaust............................................ 0.063 to 0.075 inch
Valve seat run out................................. 0.002 inch maximum
Stem to guide clearance......................... 0.001 to 0.0028 inch
Valve spring height................................ 1.57 inches
Valve Spring free length.......................... 1.91 inches
Crankshaft and Connecting Rods
Crankshaft endplay................................ 0.002 to 0.007 inch
Connecting rod endplay (side clearance).... 0.006 to 0.017 inch
Main bearing journal diameter
--1982 (all).......................................... 2.4937 to 2.4946 inches
--1983 and 1984
----Journals 1, 2 and 4 .......................... 2.4937 to 2.4946 inches
----Journal 3........................................ 2.4932 to 2.4941 inches
--1985 and later.................................... 2.647 to 2.648 inches
Main bearing oil clearance
--1982 (all).......................................... 0.0017 to 0.0030 inch
--1983 and 1984
----Journals 1,2, and 4........................... 0.0016 to 0.0032 inch
----Journal 3........................................ 0.0021 to 0.0033 inch
--1985 and later................................... 0.0012 to 0.0030 inch
Connecting rod bearing journal diameter .... 1.9983 to 1.9994 inches
Connecting rod bearing oil clearance......... 0.0012 to 0.0037 inch
Crankshaft Journal taper/out-of-round limit. 0.0002 inch
Engine Block
Cylinder bore diameter............................ 3.504 to 3.507 inches
Out-of-round limit.................................. 0.0005 inch
Taper limit............................................ 0.0005 inch
Pistons and Rings
Piston-to-bore clearance......................... 0.0012 to 0.0026 inch
Compression Ring side clearance
--1989 and earlier
----Top Ring......................................... 0.0012 to 0.0027 inch
----Second Ring.................................... 0.0016 to 0.0037 inch
--1990 and later.................................... 0.0020 to 0.0035 inch
Oil ring side clearance............................. 0.0080 inch maximum
Piston ring end gap
--Compression rings................................ 0.0010 to 0.0020 inch
--Oil ring.............................................. 0.055 inch maximum
Camshaft
Bearing journal diameter.......................... 1.868 to 1.870 inches
Bearing oil clearance............................... 0.001 to 0.004 inches
Lobe lift
--1984 and earlier
----Intake............................................ 0.231 inch
----Exhaust.......................................... 0.262 inch
--1985 and later
----Intake............................................ 0.231 inch
----Exhaust.......................................... 0.273 inch
Torque Specs Ft-lbs
Rocker arm stude to cylinder head............. 45
Main bearing cap bolts............................. 73
Connecting rod cap bolts......................... 39
Cylinder head bolts
--1989 and eariler................................... 70
--1990 and later
----Step 1............................................. 40
----Step 2............................................. Tighten and turn additional 90*
Camshaft rear cover bolts......................... 84 inch pounds
Camshaft sprocket bolts........................... 18
Clutch cover to flywheel bolts.................... 15
Connecting rod cap nuts........................... 37
Crankshaft Pulley bolts............................. 25
Crankshaft pulley hub bolt......................... 75
Cylinder Head Bolts
--2.8L................................................... 70
--3.1L
----Step 1............................................. 40
----Step 2............................................. Tighten Additional 90*
Distributor Hold down............................... 25
Driveplate-to-torque converter bolts........... 27
EGR valve mounting bolts.......................... 15
Engine mounting bracket bolts.................... 80
Engine strut bracket................................. 35
Exhaust manifold mounting bolts................. 25
Flywheel mounting bolts............................. 50
Front Cover mounting bolts (small)............... 15
Front cover mounting bolts (large)............... 25
Fuel pump mounting bolts........................... 15
Intake manifold to cylinder head bolts
--2.8L..................................................... 23
--3.1L..................................................... 19
Main bearing cap bolts............................... 70
Oil filter bolt............................................. 15
Oil filter connector bolt............................... 29
Oil pan mounting bolts (small)...................... 84 inch pounds
Oil pan mounting bolts (large)...................... 18
Oil pump mounting bolt............................... 30
Oil pump cover bolts.................................. 96 inch pounds
Oil pressure switch.................................... 60 inch pounds
Oil drain plug............................................ 18
Rear lifting bracket bolt.............................. 25
Rocker arm cover bolts............................... 96 inch pounds
Rocker arm stud to cylinder head................. 45
Spark plugs.............................................. 12
Starter motor mounting bolts....................... 32
Strut bracket assembly nut and bolt............. 35
Timing chain tensioner bolts........................ 15
Water outlet housing bolts.......................... 25
Water pump mounting bolts (small) .............. 84 inch pounds
Water pump mounting bolts (medium)............ 15
Water pump mounting bolts (large)............... 25
Water pump pulley bolt............................... 15
V8 Engine
Oil Pressure.............................................. 15 PSI minimum at 2000 RPM
Compression pressure................................. 100 to 150 PSI
Maximum variation between cylinders............ 20%
Firing Order.............................................. 1-8-4-3-6-5-7-2
Valves and Related Components
Valve face angle....................................... 45 Degrees
Valve seat angle....................................... 46 Degrees
Valve Seat width
--Intake.................................................. 1/32 to 1/16 inch
--Exhaust................................................ 1/16 to 3/32 inch
Valve seat runout..................................... 0.002 inch max
Stem-to-Guide clearance
--Standard.............................................. 0.001 to 0.0027 inch
--Service Limit
----Intake............................................... 0.0037 inch max
----Exhaust............................................. 0.0047 inch max
Valve spring height.................................... 1 23/32 inch
Valve spring free length
--1984 and eariler..................................... 1.86 inch
--1985 and later....................................... 2.03 inch
Crankshaft and Connecting Rods
Main journal diameter
--Journal 1.............................................. 2.4484 to 2.4493 inches
--Journals 2,3 and 4.................................. 2.4481 to 2.4490 inches
--Journal 5.............................................. 2.4479 to 2.4488 inches
Journal Taper
--Standard.............................................. 0.0002 inch
--Service limit.......................................... 0.0010 inch max
Journal out of round
--Standard.............................................. 0.0002 inch
--Serice limit........................................... 0.0010 max
Main Bearing oil clearance
--Journal 1.............................................. 0.0008 to 0.0020 inch
--Journal 2,3, and 4.................................. 0.0011 to 0.0023 inch
--Journal 5.............................................. 0.0017 to 0.0032 inch
Crankshaft Endplay................................... 0.002 to 0.006 inch
Connecting rod journal diameter.................. 2.0986 to 2.0998
Connecting rod journal taper
--standard.............................................. 0.0005 inch
--service limit.......................................... 0.001 inch max
Connecting rod journal out of round.............
--Standard............................................. 0.0002 inch
--Service limit......................................... 0.001 inch max
Rod bearing oil clearance........................... 0.0018 to 0.0039 inch
Connecting rod endplay (side clearance)...... 0.008 to 0.014 inch
Engine Block
Bore Diameter
--5.0L................................................... 3.7350 to 3.7385 inches
--5.7L................................................... 3.9995 to 4.0025 inches
Out of Round
--Standard............................................ 0.0010 inch
--Service limit........................................ 0.0020 inch max
Taper
--Standard............................................ 0.0005 Inch
--Service Limit....................................... 0.0015 inch max
Piston and Rings
Piston to Bore clearance
--Standard............................................ 0.0007 to 0.0017 inch
--Service limit........................................ 0.0027 inch max
Piston Ring Side Clearance
--Top Ring
----Standard.......................................... 0.0012 to 0.0032 inch
----Service limit...................................... 0.0042 inch maximum
--Second Ring
----Standard.......................................... 0.0012 to 0.0032 inch
----Service limit...................................... 0.0042 inch max
Oil ring
--Standard............................................. 0.002 to 0.007 inch
--Service limit......................................... 0.008 inch max
Piston Ring end gap
--Top Ring
----Standard.......................................... 0.010 to 0.020 inch
----Service limit...................................... 0.035 inch max
--Second ring
----Standard.......................................... 0.010 to 0.025 inch
----Service limit...................................... 0.035 inch mx
Oil ring
--Standard............................................. 0.015 to 0.055 inch
--Service limit......................................... 0.065 inch max
Camshaft
Bearing Journal diameter............................ 1.8682 to 1.8692 inches
Bearing oil clearance................................. 0.001 to 0.004 inch
camshaft endplay..................................... 0.004 to 0.012 inch
Lobe lift
--1982
----Carb
------Intake............................................ 0.238 inch
------Exhaust.......................................... 0.260 inch
-----T.B.I
------Intake............................................ 0.260 inch
------Exhaust.......................................... 0.273 inch
--1983 and 1984
----Carb
------Standard model
--------Intake......................................... 0.234 inch
--------Exhaust....................................... 0.257 inch
------High Output Model
--------Intake......................................... 0.269 inch
--------Exhaust....................................... 0.276 inch
----T.B.I
------Intake............................................ 0.257 inch
------Exhaust.......................................... 0.269 inch
--1985 -1987
----Carb
------Standard Model
--------Intake......................................... 0.234 inch
--------Exhaust....................................... 0.257 inch
------High Output
--------Intake......................................... 0.269 inch
--------Exhaust....................................... 0.276 inch
------T.P.I
(5.0)
--------Intake......................................... 0.269 inch
--------Exhaust....................................... 0.276 inch
(5.7)
--------Intake......................................... 0.273 inch
--------Exhaust....................................... 0.282 inch
--1988-1990
----5.0L
------T.B.I
--------Intake......................................... 0.234 inch
--------Exhaust....................................... 0.257 inch
------T.P.I.
--------Intake......................................... 0.269 inch
--------Exhaust....................................... 0.276 inch
----5.7L
------Intake............................................ 0.273 inch
------Exhaust.......................................... 0.282 inch
--1991-1992
----T.B.I
------Intake............................................ 0.234 inch
------Exhaust.......................................... 0.257 inch
----T.P.I
------Intake............................................ 0.275 inch
------Exhaust.......................................... 0.285 inch
Main bearing cap bolts............................... 70
Connecting rod cap nuts............................ 45
Cylinder head bolts
--1988 Earlier.......................................... 65
--1989 Later........................................... 68
Oil pump to rear main bearing cap bolt......... 65
Rear main bearing oil seal retainer bolts........ 132 inch lbs
Camshaft sprocket bolts............................ 20
Camshaft rear cover bolts.......................... 84 inch lbs
Clutch pressure plate bolts......................... 35
Crankcase front cover bolts........................ 84 inch lbs
Crankshaft pulley bolts............................... 25
Distributor clamp bolt................................. 20
Drive plate to torque converter bolts
--1984 earlier........................................... 27
--1985 later............................................. 35
Engine mounting bracket bolts..................... 80
Engine strut mounting bracket bolts.............. 35
Exhaust manifold bolts................................ 20
Flywheel to Crankshaft bolts
--1985 earlier............................................ 60
--1986 later.............................................. 74
Flywheel housing bolts
--1984 earlier............................................ 30
--1985 and later........................................ 55
Flywheel housing cover bolts........................ 84 inch lbs
Fuel pump mounting bolts............................ 15
Intake manifold bolts................................... 30
Intake manifold cover to intake (crossfire)...... 20
Oil filter bypass valve.................................. 84 inch pounds
Oil pan to crankcase bolts
--5/16" bolts............................................. 14
--1/4" bolts............................................... 84 inch pounds.
Rocker Arm cover bolts
--1984 earlier............................................ 48 inch lbs
--1985..................................................... 60 inch lbs
--1986-1989............................................. 75 inch lbs
--1990 and later........................................ 89 inch lbs
Spark plugs............................................... 22
Harmonic Balancer...................................... 60