Camaro, Firebird, Z28 1999-2002

Routine Maintenance & Tune-Up

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Accessory Drive Belts



Accessory Belt Routing


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Fig. Serpentine drive belt routing-3.8L engine



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Fig. Serpentine drive belt routing-5.7L engine



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Fig. A/C drive belt routing-5.7L engine

Adjusting

Serpentine belt tension is maintained by a spring-loaded automatic tensioner. No adjustments are necessary.

Inspection

Inspect the drive belt for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. All worn or damaged drive belts should be replaced immediately.

Removal & Installation
3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  4.  
  5. Position a hex-head socket on the belt tensioner pulley bolt.
  6.  
  7. Rotate the drive belt tensioner clockwise to relieve the tension on the drive belt.
  8.  
  9. Remove the drive belt from the tensioner and pulleys.
  10.  
  11. Clean and inspect the belt surfaces of all the pulleys.

    Click image to see an enlarged view

    Fig. Serpentine belt and tensioner detail view-3.8L engine

  12.  

To install:

  1. Route the drive belt around the pulleys.
  2.  
  3. Position a hex-head socket on the belt tensioner pulley bolt.
  4.  
  5. Rotate the drive belt tensioner clockwise to relieve the tension.
  6.  
  7. Install the drive belt onto the drive belt tensioner.
  8.  
  9. Inspect the drive belt to ensure that the belt is properly aligned into the grooves of the pulleys.
  10.  
  11. Reconnect negative battery cable.
  12.  

5.7L Engine
Air Conditioner Belt
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  4.  
  5. Remove the serpentine accessory drive belt.
  6.  
  7. Install a breaker bar with hex-head socket to the air conditioning (A/C) belt tensioner bolt.
  8.  
  9. Rotate the A/C belt tensioner clockwise in order to relieve tension on the belt.
  10.  
  11. Remove the A/C belt from the pulleys.
  12.  
  13. Slowly release the tension on the A/C belt tensioner.
  14.  
  15. Remove the breaker bar and socket from the A/C belt tensioner bolt.
  16.  
  17. Clean and inspect the belt surfaces of all the pulleys.

    Click image to see an enlarged view

    Fig. A/C belt detail view-5.7L engine

  18.  

To install:

  1. Install the A/C belt around the crankshaft balancer.
  2.  
  3. Install a breaker bar with hex-head socket to the A/C belt tensioner bolt.
  4.  
  5. Rotate the A/C belt tensioner clockwise in order to relieve tension on the tensioner.
  6.  
  7. Install the A/C belt under the idler pulley.
  8.  
  9. Install the A/C belt over the A/C compressor pulley.
  10.  
  11. Slowly release the tension on the A/C belt tensioner.
  12.  
  13. Remove the breaker bar and socket from the A/C belt tensioner bolt.
  14.  
  15. Inspect the A/C belt for proper alignment.
  16.  
  17. Install the serpentine accessory drive belt.
  18.  
  19. Reconnect negative battery cable.
  20.  

Serpentine Accessory Drive Belt
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  4.  
  5. Disconnect the following electrical connectors:

    Intake air temperature (IAT) sensor
     
    Mass airflow (MAF) sensor
     

  6.  
  7. Remove the air intake duct from the following:

    Throttle body
     
    Air cleaner box
     

  8.  
  9. Install a breaker bar with hex-head socket to the drive belt tensioner bolt.
  10.  
  11. Rotate the drive belt tensioner clockwise in order to relieve tension on the belt.
  12.  
  13. Remove the belt from the pulleys and the drive belt tensioner.
  14.  
  15. Slowly release the tension on the drive belt tensioner.
  16.  
  17. Remove the breaker bar and socket from the drive belt tensioner bolt.
  18.  
  19. Clean and inspect the belt surfaces of all the pulleys.

    Click image to see an enlarged view

    Fig. Serpentine belt detail view-5.7L engine

  20.  

To install:

  1. Route the drive belt around all pulleys except the water pump and belt tensioner.
  2.  
  3. Install the breaker bar with hex-head socket to the belt tensioner bolt.
  4.  
  5. Rotate the belt tensioner clockwise in order to relieve the tension on the tensioner.
  6.  
  7. Install the drive belt under the water pump pulley.
  8.  
  9. Install the drive belt onto the belt tensioner.
  10.  
  11. Slowly release the tension on the belt tensioner.
  12.  
  13. Remove the breaker bar and socket from the belt tensioner bolt.
  14.  
  15. Inspect the drive belt for proper alignment.
  16.  
  17. Install the air intake duct to the following:

    Throttle body
     
    Air cleaner box
     

  18.  
  19. Connect the following electrical connectors:

    MAF sensor
     
    IAT sensor
     

  20.  
  21. Reconnect negative battery cable.
  22.  

Firing Orders





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Fig. 3.8L (VIN K) Engine Firing Order: 1-6-5-4-3-2 Distributorless ignition system



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Fig. 5.7L (VIN G) Engine Firing Order: 1-8-7-2-6-5-4-3 Distributorless ignition system (one coil on each cylinder)

Fuel Filter



Removal & Installation

The inline fuel filter is located on the fuel feed pipe before the fuel injection system and mounted directly in front of the rear axle. The filter housing is constructed of steel with quick-connect inlet and threaded outlet fittings. The threaded fitting is sealed with an O-ring. In order to disengage quick-connect fittings, a fuel line quick-connect separator tool set, such as J-37088-A or equivalent, is required. There is no manufacturer set service interval for fuel filter replacement. We suggest replacing the filter every 30-40 thousand miles.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Clean both the inlet and the outlet fittings on the fuel filter.

    Click image to see an enlarged view

    Fig. The inline fuel filter is mounted in a bracket located under the vehicle, directly in front of the rear axle

  6.  
  7. Disengage the quick-connect fittings at the fuel filter inlet as follows:
    1. Slide the dust covers from the quick-connect fittings.
    2.  
    3. Grasp both sides of the fitting. Twist the female connector 1 / 4 turn in each direction to loosen any dirt within the fitting. Using compressed air and safety glasses, blow any accumulated dirt out of the fitting.
    4.  
    5. If equipped with the plastic hand releasable fitting, squeeze the plastic retainer release tabs and pull the connection apart.
    6.  
    7. If equipped with metal fittings, choose the correct size quick release tool and insert the tool into the female connector, then push inward to release the locking tabs. Pull the connector apart.
    8.  
    9. Use a clean lint free rag to clean male pipe ends. Inspect both ends of the fitting for dirt and burrs. Clean or replace components as required. If it is necessary to remove rust or burrs from the fuel pipe, use emery cloth in a radial motion with the pipe end to prevent damage to the O-ring sealing surface.
    10.  

  8.  
  9. Remove the threaded outlet fitting from the chassis fuel pipe. Slide the fuel filter from the bracket.
  10.  
  11. Inspect the fuel pipe O-ring for cuts, nicks, swelling or distortion. Replace if necessary.
  12.  

To install:

  1. Slide the fuel filter into the bracket.
  2.  
  3. Tighten the outlet fitting to the chassis fuel pipe. Torque the fitting to 22 ft. lbs. (30 Nm).
  4.  
  5. Engage the quick-connect inlet fitting as follows:
    1. Apply a few drops of clean engine oil to the male pipe end. This will ensure proper reconnection and prevent a possible fuel leak.
    2.  
    3. Push both sides of the fitting together to cause the retainer tabs to snap in place. Once installed, pull on both sides of the fitting to ensure connection is secure.
    4.  
    5. Reposition dust cover over the quick-connect fitting.
    6.  

  6.  
  7. Tighten the fuel filler cap.
  8.  
  9. Confirm that the ignition is in the OFF position. Connect the negative battery cable.
  10.  
  11. Pressurize the fuel system by cycling the ignition without attempting to start the engine. Turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Again, turn to the ON position and check for fuel leaks.
  12.  

Idle Speed & Mixture Adjustments



Idle speed is maintained by the Powertrain Control Module (PCM). No adjustment is necessary or possible.

Ignition Timing



On these vehicles, base timing is preset when the engine is manufactured. All timing changes are, then controlled directly by the Powertrain Control Module (PCM) based on information from the ignition and knock sensor systems. No adjustments are necessary or possible.

Spark Plugs & Wires



Spark Plugs
Inspection and Gapping

Chromate coated spark plugs should not be wire brushed or handled in any way once they are put in service. Chromium topcoats form a protective oxide on spark plugs that is not effective if scratched. Both coated and uncoated spark plugs will have the best chance of surviving a corrosive environment if they are left in position. Attempts to maintain spark plugs by removing them and cleaning the threads can actually create the corrosive condition that the procedure was intended to prevent.

  1. Ensure that the correct spark plug is installed. An incorrect spark plug causes drivability conditions.
  2.  
  3. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions:

    Spark plug fouling--colder plug
     
    Pre-ignition causing spark plug and/or engine damage--hotter plug
     

  4.  
  5. Inspect the terminal post for damage.

    Inspect for a bent or a broken terminal post.
     
    Test for a loose terminal post (1) by twisting and pulling the post. The terminal post should NOT move.
     

  6.  
  7. Inspect the insulator for flashover, for carbon tracking, and for soot. These conditions are caused by the electrical charge traveling across the insulator between the terminal post and the ground. Inspect for the following conditions:

    Inspect the spark plug boot for damage.
     
    Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.
     

  8.  
  9. Inspect the insulator for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes.
  10.  
  11. Inspect for evidence of improper arcing.

    Measure the gap between the center electrode and the side electrode terminals. An excessively wide electrode gap can prevent correct spark plug operation.
     
    Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator to crack.
     
    Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode.
     
    Inspect for a broken or worn side electrode.
     
    Inspect for a broken, worn, or loose center electrode by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode reduces the spark intensity.
     
    Inspect for bridged electrodes. Deposits on the electrodes reduce or eliminate the gap.
     
    Inspect for worn or missing platinum pads on the electrodes, if equipped.
     
    Inspect for excessive fouling.
     
    Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug to not seat correctly during installation.
     

  12.  
  13. Normal operation--Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
  14.  
  15. Excessive idling or slow speeds during light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
  16.  
  17. Deposit Fouling--Oil, coolant, or additives that include substances such as silicone, or very white coating, reduce the spark intensity. Most powdery deposits will not affect the spark intensity unless the substances form into a glazing over the electrode.
  18.  

Removal & Installation
3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  4.  
  5. Turn OFF the ignition switch.
  6.  
  7. Remove the spark plug wires from the spark plugs.
  8.  
  9. Remove the spark plugs from the engine.
  10.  

To install:

  1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications and correct as necessary.
  2.  
  3. Install the spark plugs to the engine and tighten to 11 ft. lbs. (15 Nm)
  4.  
  5. Connect the spark plug wires to the spark plugs.
  6.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  4.  
  5. Turn OFF the ignition switch.
  6.  
  7. Remove the spark plug wires.
  8.  
  9. Loosen each spark plug 1 or 2 turns.
  10.  
  11. Use a brush, or use compressed air in order to remove any dirt from the spark plugs.
  12.  
  13. Remove the spark plugs one at a time and place each plug in a tray marked with the corresponding cylinder numbers.
  14.  

To install:

  1. Inspect each spark plug gap. Adjust each plug as needed.
    1. Spark plug gap: 0.060 in. (1.524 mm)
    2.  

  2.  
  3. Hand start the spark plugs in the corresponding cylinders.
  4.  
  5. Tighten the spark plugs to 11 ft. lbs. (15 Nm)
  6.  
  7. Install the spark plug wires.
  8.  

 
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