SERVICE MANUAL UPDATE 1.6L ENGINE SPECIFICATIONS & TOOLS. Pontiac LeMans 1989

For 1990-2009 cars

# SERVICE MANUAL UPDATE 1.6L ENGINE SPECIFICATIONS & TOOLS

#### Models Affected: 1989 LEMANS SERVICE MANUAL UPDATE

This service bulletin cancels and supersedes the torque specifications, engine specifications and special tools portion of Section 6AlB in the 1989 Pontiac Le Mans Service Manual; pages 6AlB-19, 6AlB-20 and 6AlB-21.

The correct engine and torque specifications and the correct special tools pages are shown here.

SPECIFICATION FASTENER TORQUES -------------- ---------------- N-m Lb.ft. Lb.in. --- ------ ------ Camshaft Carrier and Cylinder Head Attaching 25 18 Bolts, New plus 3 turns of 60 DEG each plus 30 DEG to 50 DEG after engine warm-up (thermostat open) Camshaft Carrier Cover Bolts 9 80 Camshaft Sprocket Retaining Bolt 45 33 Camshaft Thrust Plate Bolts 8 71 Coil to Lift Bracket 25 18 Connecting Rod Cap Bolts, New 25 18 plus a 30 DEG turn Coolant Pipe to Cylinder Block 27 20 Crankshaft Pulley to Sprocket Bolts 55 41 Crankshaft Sprocket Retaining Bolt 155 114 Distributor to Cam Carrier Nuts 17 150 EGR Solenoid Assembly 6 53 EGR Valve 20 15 Engine Mount Bracket Bolts Front 40 30 Engine Mount Bracket Studs Rear 50 37 Exhaust Manifold/Cylinder Head Nuts 13 115 Exhaust Manifold/Cylinder Head Studs 13 115 Generator Bracket to Cylinder Head Studs 40 30 Heater Pipe to Intake Bolts 24 18 Intake Manifold/Cylinder Head Nuts 22 16 Main Bearing Cap Bolts, New 60 44 plus a 40 DEG to 50 DEG turn Oil Filter 15 11 Oil Pan Retaining Bolts, require Loctite 8 71 Usage Oil Plug 45 33 Oil Pressure Test Plug 23 17 Oil Pump Control Valve Plug 30 22 Oil Pump Cover Retaining Screws 6 53 Oil Pump to Cylinder Block Bolts 7 62 Pick-Up Tube to Block Bolts 7 62 Pick-Up Tube to Oil Pump Bolts 7 62 Pressure Plate to Flywheel 25 18 Spark Plugs 20 15 Thermostat Housing to Block 10 86 Throttle Body Injector Assembly 22 16 Throttle Cable Bracket and Pulley Assembly 29 21 Timing Belt Front Cover 10 89 Timing Belt Rear Cover Bolts 10 89 Timing Belt TensIoner 25 18 Water Outlet to CAM Carrier Bolts 15 133 Water Pump Retaining Bolts 8 71

#### ENGINE SPECIFICATIONS

DESCRIPTION METRIC ENGLISH ----------- ------ ------- General Data:

Engine Type 4 cylinder (In Line) Displacement 1.6 Liter 98 cu.in. Bore 79.0 mm 3.110 " Stroke 81.5 mm 3.208 " Compression Ratio 8.5:2 Firing Order 1-3-4-2

#### Cylinder Bore:

Diameter 79.0 mm 3.110" Out of Round (Max.) 0.013 mm 0.0005" Taper (Max.) 0.013 mm 0.0005" Taper-Thrust Side (Max.) 0.013 mm 0.0005"

#### Piston:

Diameter 79.0 mm 3.110" Clearance to Bore 0.02 mm 0.0008"

#### Piston Rings:

Ring, End Gap- Top Compression 0.3-0.5 mm 0.0118-0.0197" 2nd Compression 0.3-0.5 mm 0.0118-0.0197" Groove Clearance Top Impression 0.0609-0.0914 mm 0.0024-0.0036" 2nd Impression 0.0482-0.0812 mm 0.0019-0.0032"

#### Piston Pin:

Diameter 18 mm 0.72" Fit in Piston 0.007-0.01 mm 0.0003-0.0004" Fit in Rod Press

#### Camshaft:

Lift-Intake 5.61 mm 0.220" Lift-Exhaust 6.12 mm 0.241" End Play 0.09-0.21 mm 0.0035-0.0083" Journal OD #1 39.450-39.435 mm 1.5530-1.5520" #2 39.700-39.685 mm 1.5630-1.5624" #3 39.950-39.935 mm 1.5730-1.5722" #4 40.200-40.185 mm 1.5828-1.5820" #5 40.450-40.435 mm 1.5927-1.5919" Bearing ID #1 39.525-39.500 mm 1.5561-1.5551" #2 39.775-39.770 mm 1.5659-1.5650" #3 40.025-40.000 mm 1.5758-1.5748" #4 40.275-40.250 mm 1.5856-1.5846" #5 40.525-40.550 mm 1.5955-1.5965" Bearing Clearance 0.045- 0.090 mm 0.00177-0.00354"

#### Crankshaft:

Main Journal Diameter (All) 55 mm 2.1653" Taper (Max.) 0.005 mm 0.0002" Out of Round (Max.) 0.004 mm 0.00015" Main Bearing Clearance (All) 0.015-0.053 mm 0.0006-0.0020" Crankshaft End Play 0.120-0.352 mm 0.0047-0.0138" Connecting Rod Journal Diameter (All) 42.987-42.971 mm 1.6920-1.6918" Taper (Max.) 0.005 mm 0.0002" Out of Round (Max.) 0.005 mm 0.0002" Rod Bearing Clearance (All) 0.019-0.063 mm 0.0007-0.0025" Rod Side Clearance 0.070-0.242 mm 0.0028-0.0095"

#### Valve System:

Valve Lash Compensators Hydraulic Face Angle (All) 46 DEG Seat Angle (All) 46 DEG Seat Runout (Max.All) 0.05 mm 0.002" Face Runout (Max.All) 0.03 mm 0.0012" Seat Width(All) 1.270-1.780 mm 0.0500-0.0701" Valve Guide Inside Diameter (All) 7.060-7.0630 mm 0.278-0.277" Valve Stem Outside Diameter Exhaust 6.992-6.978 mm 0.2758-0.2747" Intake 7.012-6.998 mm 0.2760-0.2755" Valve Stem Guide Clearance Intake 0.02-0.05 mm 0.0008-0.002" Exhaust 0.04-0.07 mm 0.0016-0.00276" Valve Spring Loads Valve Open 618 N 140 lbs. @ 21.6mm @ 0.85" Valve Closed 275 N 62 lbs. @ 31.3 mm @ 1.24" Oil Pump:

Gear Lash 0.10-0.20 mm 0.004-0.008" Outer Gear to Body 0.11 -0.19 mm 0.0043-0.0074" Outer Gear to Crescent 0.11 -0.24 mm 0.0043-0.0090" inner Gear to Crescent 0.18-0.26 mm 0.0070-0.010" End Clearance 0.030-0.10 mm 0.001-0.004" Gear Pocket Depth 10.03-10.08 mm 0.395-0.395" Pocket Diameter Inner Gear 41.00-41.025 mm 1.614-1.615" Outer Gear 82.07-82.15 mm 3.231-3.234" Gear Diameter Inner Gear 40.95-40.975 mm 1.612-1.613" Outer Gear 81.910-81.964 mm 3.2248-3.2269"

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.