Service Repair Procedures

The 1986 Fiero Service Manual provides updated information with regards to fluid leak detection/correction and other procedures and should be used for the purpose of this campaign service.


CAUTION: PROPER SERVICE PROCEDURES AND SAFETY PRACTICES, AS DESCRIBED IN THE REFERENCED SERVICE MANUAL, MUST BE FOLLOWED. FAILURE TO FOLLOW PROPER SERVICE PROCEDURES, INCLUDING ALL SAFETY PRECAUTIONS, COULD CREATE CONDITIONS THAT MAY LEAD TO ENGINE COMPARTMENT FIRES, POSSIBLY CAUSING INJURY TO PERSONS SERVICING AND/OR OPERATING THE VEHICLE.


1. If a connecting rod knock is evident, see Engine Repair Procedure section in this bulletin (Page 10) otherwise proceed to Step 2.

2. Check for significant fluid leaks and correct as required. This should include the following:

NOTE: Fluorescent oil and coolant additive can be ordered through Kent-Moore by calling 1-800-345-2233.

A. ENGINE COOLANT LEAK DETECTION/CORRECTION:

NOTE: Prior to performing coolant leak detection, refer to service bulletins 86-6(Gasoline)-39 and 84-6(Gasoline)-73.

NOTE: Slight coolant leakage from the head gasket may occur initially when performing a pressurized leak test on a "Cold" new engine which has not been previously started. Normally, this initial leakage will stop once the engine has been operated at normal temperatures for approximately ten (10) minutes.

1. Inspect all coolant and heater hoses for leakage and/or deterioration, correct/replace as required.

2. With engine cold perform a pressurized leak test as described in 1986 Fiero Service Manual Section 6B-14, 15. Correct leaks found. If a coolant leak is evident but cannot be located, a special flourescent coolant additive and a "high intensity" ultraviolet black light may be used to determine leak location.
3. With engine cold, remove radiator cap and add 1 oz. container flourescent coolant additive (Kent-Moore P/N J-29545 or equivalent) to coolant system.

4. Install new radiator cap P/N 10036879.

5. Check for correct operation of the engine cooling fan system per 1986 Fiero Service Manual Section 8A-31-1 through 8A-31-15. Correct irregularities.

6. Start engine and allow it to reach normal operating temperature. One on-off cycle of electric coolant fan signifies engine is at normal operation temperature.

7. Inspect for external leaks by using a black light. Correct as necessary.

FIGURE 1:

8. If no external evidence of a leak is found, remove cover from valve lifter area and inspect per Pontiac Dealer Service Management Bulletin 84-SM-34C (refer to Figure 1). With engine warm and pressure applied, coolant should be visible using a black light. If condition is evident, see Cracked Block Information section in this bulletin.
B. ENGINE OIL LEAK DETECTION/CORRECTION:

1. If visual inspection of engine does not reveal source of oil leak, use a black light with fluorescent oil additive (one 1-oz. container Kent-Moore P/N J28431-B or equivalent), refer to 1986 Fiero Service Manual, Section 6-5.

2. To correct oil leaks from sheet metal covers, replace necessary covers with latest available service parts (refer to appropriate parts book). Use RTV sealant P/N 1052915 and ensure mating surfaces are thoroughly cleaned and free of any dirt, grease, oil, etc. before applying sealant.

NOTE: Refer to service bulletins 86-6(Gasoline)-49 and 86-6 (gasoline)-35 for proper removal procedures of rocker arm cover and push rod cover, respectively.

C. TRANSMISSION FLUID LEAK DETECTION/CORRECTION:

Inspect for automatic or manual transmission fluid leaks per 1986 Fiero Service Manual, Section 7A-3. For manual transmission fluid leak detection the "Powder Method", as described in 1986 Fiero Service Manual, Section 7A-3, is recommended.

FIGURE 2 - HEAT SHIELD LOCATIONS:

SERVICE REPAIR PROCEDURES - CONTINUED FROM PAGE 4

3. Check for proper locations of heat shields and condition of fasteners (See Figure 2). Repair or replace as required.
4. Check and correct improperly routed hoses or wiring or combustible materials on or near exhaust system/manifold.

5. Check and correct thermostatic air cleaner system, including duct work, per 1986 Fiero Service Manual, section 6E2-C14. Clean system and install new air cleaner element P/N 25043317 (AC Type A913C With Foam Wrap - NO SUBSTITUTES!). Secure air cleaner with washer faced nuts torqued 18-35 in.lbs. (2-4 N-m); DO NOT OVERTIGHTEN!

6. Check for presence and legibility of "Coolant System Fill Procedure" label. There should be two (2) labels; one located on engine compartment deck lid and one by radiator cap. Replace or clean as required. Install new labels only on a clean dry surface.

NOTE: If an engine kit, short block was installed, or connecting rod knock repair procedure used proceed to Step 8 (as Step 7 would have been previously performed.

7. Change oil and oil filter. Install AC type PF-51 oil filter P/N 25010908 or equivalent. Install 4.0 quarts SF grade 5W-30 engine oil. Replace old dipstick with new recalibrated dipstick P/N 10101497.

8. Install "Check Engine Oil At Each Fuel Fill" Label (NPN). Install on lower inside surface of fuel filler door below existing "Unleaded Fuel Only" label. Apply label only on a clean, dry surface.

9. Apply updates P/N 10077794 & 10077795 to pages 5-8 and 6-4 respectively of owners manual.

10. Ensure that owner has a copy of the revised maintenance schedule booklet. Provide copies to owners as required.

11. Install Campaign Identification Label.