1988
TABLE OF CONTENTS SECTION NAME
1
SECT.
GENERAL INFORMATION OA. OB.
SER
General lnformation Maintenance & Lubrication
HEATING AND AIR CONDITIONING 1A. 1B. 1D1.
Heating and Ventilation Air Conditioning R-4 AIC Com~ressorOverhaul
FRAME AND BUMPERS 2B. 2C.
Bumpers Chassis Sheet Metal
STEERING, SUSPENSION, WHEELS AND TIRES 3. 3A. 3B5. 3B6. 3B7. 3C. 3D. 3E.
Diagnosis Wheel Alignment Steering Wheels and Columns Steering Linkage Power Steering Gear and Pump Front Suspension Rear Suspension Tires and Wheels
FINAL DRIVE 4A. 4B. 4B1.
Propeller Shaft Rear Axle Bora-Warner Axle
BRAKES 5. 5A3. 5B1.
This manual applies t o the 1988 Pontiac Firebird Models. It contains the latest product information available at the time of publication approval. lnformation pertaining to the operation of the vehicle is contained in the Owner's Manual which accompanies each vehicle. The right is reserved to make changes at any time without notice.
5B6. 5C3. 5D2. 5F.
Any references to brand names in this manual is intended merely as an example of the types of lubricant% tools, materials, etc, recommended for use in servicing 1988 Pontiac Models. In all cases, an equivalent may be used.
Brakes Comoosite Master Cvlinder Disc r rake Caliper ~ s s e m b l y300013100 Series Disc Brake Caliper Assembly - 3548 Series Direct Torque Drum Brake Assembly Power Head Assembly - Tandem Diaohraam ~~ecification and s Special Tools
ENGINE 6. 6A2. 6A3. 6B. 6C. 6D. 6D1. 6D2. 6D3. 6D4. 6D5. 6E. 6E2. 6E3. 6F.
Engine General lnformation 2.8L 5.OL & 5.7L Engine Cooling E n ~ i n eFuel ~ n g i n eElectrical Battery Cranking System Charging System Ignition System Engine Wiring Driveabilitv and Emissions ~missions' Emissions - PFI Engine Exhaust
TRANSMISSION Automatic Transmission - General lnformation 7A1. Automatic Transmission - On-Car Service 700R4. Automatic Transmission Hydraulic Diagnosis 700R4. Automatic Transmission Unit Repair 76. 5-Speed Manual Transmission 7C. Clutch 7A.
PONTIAC DIVISION GENERAL MOTORS CORPORATION PONTIAC, MICHIGAN 48053
CHASSIS ELECTRICAL 8A. 8B. 8C. 8E.
1987 General Motors Corp. All Rights Reserved. No part of this publication may be reproduced, stored in any retrieval system or transmitted i n any form or by any means, i n c l u d i n g b u t n o t l i m i t e d t o e l e c t r o n i c , mechanical, photocopying, recording or otherwise, without the prior written permission of General Motors Corp. This includes all text, illustrations, tables and charts.
S-881OF
9-87
Printed i n Canada
Electrical Diagnosis Lighting and Horns Instrument Panel, Gages & Console Windshield Wiper &Washer System
ACCESSORIES
I
9A. 9B. 9G.
Radio Systems and Antennas Cruise Control Miscellaneous Accessories
BODY SERVICE MANUAL
END OF MANUAL
CAUTION T o reduce t h e chance of personal injury and/or property damage, the following instructions must be carefully observed: Proper service and repair are important t o the safety of the service technician and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced w i t h one of t h e same part number or w i t h an equivalent part. Do not use a replacement part of lesser quality. The service procedures recommended and described i n this service manual are effective methods of performing service and repair. Some of these procedures require the use of tools specially designe d for the purpose. Accordingly, anyone w h o intends t o use a replacement part, service procedure or tool, which is n o t recommended b y the vehicle manufacturer, must first determine that neither his safety nor t h e safe operation of the vehicle will be jeopardized b y the replacement part, service procedure or t o o l selected.
It is important t o note that this manual contains various 'Cautions' and 'Notices' that must be carefully observed i n order t o reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. It is also important t o understand that these 'Cautions' and 'Notices' are n o t exhaustive, because it is impossible t o warn of all t h e possible hazardous consequences that might result from failure t o follow these instructions.
GENERAL INFORMATION OA-1
SECTION (DA
GENERAL NFORMAT CONTENTS General Description ................................... OA- 1 Body Number Plate ...................................... OA- 1 Vehicle Identification Number ..................... OA- 1 Metric Fasteners ......................................... OA- 1 Fastener Strength Identification ................... OA-2
Prevailing Torque Fasteners ......................... OA-2 Recommendations For Fastener Reuse ........ OA-2 Vehicle Lifting Procedures ............ .,............. OA-2 Precautions Against Tipping ........................ OA-7 Automotive Abbreviations ................... .... 0.4- 1 1
GENERAL DESCRIPTION Only general information appears in this section. Detailed specifications on major units are given at the end of each respective section of this manual.
left of the windshield, see Figure 2. Refer to Figure 3 for detailed "VIN" code information. For Engine V.I. N. Location, refer to Figure 4.
BODY NUMBER PLATE
METRIC FASTENERS
The Body Number Plate (Fig. 1) is attached to the front tie bar behind either the right or left headlamp in the engine On The Number Plate identifies numerous items as outlined in Figure 1.
Pontiac models are primarily dimensioned in the metric system, Most fasteners are metric and are very close in dimension to well-known customary fasteners in the inch system. It is most important that re~lacement fasteners be of the correct nominal d&meter, thread pitch and strength. Original equipment metric fasteners (except "beauty" bolts, such as exposed bumper bolts, and cross recess head screws) are identified by a number
VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number (VIN) Plate is located on top of the instrument panel at the lower
1
2
3 4
-- BODY STYLE ASSEMBLY P U N T
-- UNIT NUMBER
-- PAINT TYPE
- ROOF OPTION 6 -- SEAT OPTION
5
7 8 9 10
- TRIM COMBINATION - UPPER BODY
- UPPER COLOR -- LOWER BODY
11
- REMAINING LINES
14
-- TIME BUILD CODE
-AVAILABLE FOR --PLANT USE 12 - LOWER COLOR 13 - MODEL YEAR - DIVISION 16 - BODY TvPE 15
6200224A
Fig. 1 Body Number Plate
OA-2 GENERAL INFORMATION
VIN NUMBER PLATE LOCATION
the numbered head marking system. The metric fasteners used on GM products are designed to new, international standards that may not be used by some nondomestic bolt and nut suppliers. In general, except for special applications, the common sizes and pitches are: M 6.0 X 1 M 8 x 1.25 M 10 X 1.5 M 12 X 1.75 M 14x2
I
PREVAILING TORQUE FASTENERS Fig. 2 Vehicle Identification Number Plate Location
marking indicating the strength of the material in the fastener as outlined below. Metric cross recess screws are identified by a Posidriv or Type 1A cross recess as shown in Figure 8. Either a Phillips head or Type 1A cross recess screwdriver can be used in Posidriv recess screw heads, but Type 1A cross recess screwdrivers will perform better. NOTICE: Most metric fasteners have a blue color coating. However, this should not be used as a positive way of identifying as some metric fasteners are not color coated. General Motors Engineering Standards, along with other North American Industries, have adopted a portion of the standard metric fastener sizes defined by I S 0 (International Standards Organization). This was done to reduce the number of fastener sizes used and yet retain the best strength qualities in each thread size. For example, the customary 1/4-20 and 1/4-28 screws are replaced by the metric M6.0 X 1 screw which has nearly the same diameter and 25.4 threads per inch. The thread pitch is in between the customary coarse and fine thread pitches. Metric and customary thread notation differ slightly. The difference is shown in Figure 9.
FASTENER STRENGTH ODENTIFIGATION Most commonly used metric fastener strength property classes are 9.8 and 10.9 with the class identification embossed on the head of each bolt. Customary (inch) strength classes range from grade 2 to 8 with radial line identification embossed on each bolt head (i.e., grade 7 bolt will exhibit 5 embossed radial lines on the bolt head). Some metric nuts will be marked with single digit strength identification numbers on the nut face. Figure 12 shows the different strength markings. When replacing metric fasteners, be careful to use bolts and nuts of the same strength or greater than the original fasteners (the same number marking or higher) .It is also important to select replacement fasteners of the correct size. Correct replacement bolts and nuts are available through the parts division. Many metric fasteners available in the after-market parts channels were designed to metric standards of countries other than the United States. These fasteners may be of a lower strength, different thread pitch and may not have
A prevailing torque nut is designed to develop an interference between the nut and bolt threads. This is most often accomplished by distortion of the top of an all-metal nut or by using a nylon patch on the threads in the middle of the hex flat. A nylon insert may also be used as a method of interference between nut and bolt threads (Fig. 11). A prevailing torque bolt is designed to develop an interference between bolt and nut threads, or the threads of a tapped hole. This is accomplished by distorting some of the threads or by using a nylon patch or adhesive (Fig. 11).
RECOMMENDATIONS FOR FASTENER REUSE:
I
Clean, unrusted prevailing torque nuts and bolts may be reused as follows: a. Clean dirt and other foreign material off nut or bolt. b. Inspect nut or bolt to insure there are no cracks, elongation, or other signs of abuse or overtightening. (If there is any doubt, replace with a new prevailing torque fastener of equal or greater strength.) c. Lightly coat bolt & nut with engine oil. Assemble parts and hand start nut or bolt. d. Observe that before fastener seats, it develops torque per the chart in Figure 10. (If there is any doubt, replace with a new prevailing torque fastener of equal or greater strength.) e. Tighten fastener to torque specified in appropriate section of this manual. Bolts and nuts which are rusty or damaged should be replaced with new parts of equal or greater strength.
VEHICLE LIF"TING PROCEDURES NOTICE: When jacking or lifting vehicle from frame side rails, be certain lift pads do not contact catalytic converter as damage to converter will result. Many dealer service facilities and service stations are equipped with a type of automotive hoist which must bear upon some part of the frame in order to lift the vehicle. Figures 14 and 15 indicate the recommended areas for hoist contact for Pontiac Sunbird models. If any other hoist methods are used, special care must be used not to damage the fuel tank, filler neck, exhaust system or underbody.
I I
GENERAL INFORMATION OA-3
PLANT CODE GM PLANT CODES POSITION $ 1 1 )
LV.1.N.
Lakrwood Lanslnq B Norwood Pontlac Tarrytown W1:low Run S t . Therese Lordstown
6000 SIE 6 0 0 0 STE T r a n s Am Grand P r l x G r a n d P r l x LE G.P. Brougham Bonnevlile B o n n e v l l l e LE (V.I.N.
POSITION $ 8 )
S u n b l r d GT G r a n d Am G r a n d Am LE G r ~ n dAm SE CARBURETION
MPFI T u r b o Sed,in Seci.in
7 4 c'<jupc 2 Statlon Coupe 1 Coupe 2 Scd.ln 4 Scd.jn 4
D~,i,r P l a l n Lia~.k l I l . ~ t ~ ' l ~ l i . ~ c k ~ Utnir 6 \$lndi,w N o t t ' I ~ L , . ~ c k 1101)r Nuti.Ill,.ick W ~ q u n 4 Uc,or l > t i ~ >Nr o t c h b d c k S p r c l d l Door C o n v e r t ~ b l r Door b W ~ n d o w P l a l l i Back Uui,r 4 Wl,idir,r N u t c h b d c k
Manual B e l t s Manudi B e l t s W l t h B u l l t - I n S d f r t y blaiiual B e l t s V l t l i B u l l t - I n Safety
(Drlvrr
Only)
Fig. 3 Vehicle Identification Number Data
I
OA-4 GENERAL INFORMATION
VEHICLE COMPONENT IDEN"IIFICA"T0N NUMBER LOCATION
Refer t o Fig. OA-6. 5-Speed (77mm)
metal tag attached to extension
ENGINE V.I.N.
ENGINE CODES: "EM, "F", "8"
OPTIONAL V.I.N. LOCATION ENGINE V.I.N. LOCATION
Fig. OA-5 -- Engine V.I.N. Location
GENERAL INFORMATION OA-5
1-1
-
T H M 700-R4 TRANSMISSION I.D. LOCATION
1
IOU DAY OF THE YEAR1
ISHIFT BUILT
-
A & B = FIRST SHIFT C5H SECOND SHIFT
11
T H M 700-R4 TRANSMISSION I D E N T I F I C A T I O N NUMBER
V I N LOCATION
I
I
OPTIONAL V I N LOCATION --I
Fig. OA-6 --Transmission VIN Location
LUBRICATION POINTS
ENGINE COMPARTMENT
CHASSIS - SEE MAINTENANCE SCHEDULE ENGINE OIL AND FILTER COOLING SYSTEM WHEEL BEARINGS AUTO TRANSMISSION FLUID
LOWER CONTROL ARM BALL JOINTS
II
STEERING LINKAGE
Fig. OA-7 Typical Lubrication Points
OA-6 GENERAL INFORMATION
USING FRAME CONTACT HOIST REARWARD OF FRONT TIRE '
USING SUSPENSION CONTACT HOIST LIFTING ON REAR AXLE
USING FRAME CONTACT HOIST FORWARD OF REAR TIRE
USING SUSPENSION CONTACT HOIST UNDER FRONT LOWER CONTROL ARM
520016-0A
Fig. 8 Vehicle Lifting Points "F" Model
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
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08-8 GENERAL INFORMATION
USE OF METRIC AND CUSTOMARY NUTS, BOLTS AND SCRERS
Some veh~clespresent spec~alservlce requ~rementsto the technrc~a~l due to the use of both metnc and customary (Inch) type nuts, bolt5 and screws. Many are metnc and some are very close in d ~ m e n s ~ oton customary nuts. bolts and screws in the Inch system M~smatchedo r Incorect nut5, bolt5 and screus can result rn damage, malfunct~onor poss~blepersonal Injury Nuts. bolts and screws removed from the veh~cle5hould be saved for re-use uhenever poscrble. If they are not re-usable. care should be taken to select a replacement that matches the ong~nal. General Motors Eng~neenngStandards have ddopted a portion of the standard metnc fastener slzes defined by S I (Systeme Internatronal) T h ~ swas done to reduce the number of srzes used and yet retarn the best In each thtead size. For example. the customary 114-20 and 1/4-28 screws are replaced strength character~st~cs by the metrlc M6.3 x I screw w h ~ c hhas nearly the same d~ameterand 25.4 threads per inch. The thread p ~ t c h IS
In between the customary coarse and fine thread prtches.
Metnc and customary thread notatlon d ~ f f e rsl~ghtly.The d~fferenceI S ~llustratedbelou. CUSTOMARY
METRIC
Thread Major
Thread Major
D~ameter
D~ameter
~n inches
rn M~ll~meters
Number of
D~stance
Threads
Between Threads in Mill~meters
Care should be taken when servlclng the veh~cleto guard agalnst cross thread~ngo r Improper retention due to interchanged metnc and inch nuts and bolts. When obtarn~ngmetnc o r customary nuts, bolts, and screws locally for servrcing the vehicle. care must be exerc~sedin selecting parts that are equrvalent to the ong~nalparts In dimensions. strength. and p ~ t c hof
Fig. OA-10 -- Metric Information, Chart A
GENERAL INFORMATION OA-9
REUSE OF PREVAILING "TRQUE NUT
WASHER
I
AND BOLT
NYLON STRIP OR PATC
A. CLEAN, llNRUSTFD PREVAILING TORQllF BOLTS AND NL'TS MAY Bk. REUSED AS FOLL.0WS I . CLEAN DIRT AND OTHER FORFICN MATERIAL OFF NUT AND BOLT. 2 , INSPECT BOLT AND NUT TO ASSURE THERE ARE NO CRACKS. ELONGATION OR OTHER SIGNS OF ABUSE OR OVERTIGIiTENING. LIGHTLY LUBRICATE THREADS. (IF ANY DOUBT, REPLACE WITH NEW PREVAILING TOROLE FASTENER OF EQUAL OR GREATER STRENGTH.) 3 . ASSFMBLE PARTS AND START BOLT OR NLIT. 4. OBSERVE THAT BEFORE FASTENER SkATS. I T DEVk.LOPS PREVAILING TORQUE PER CHART BELOW. ( I F ANY DOUBT, INSTALL NliW PRFVAILIN(; TORQL'F FASTENER OF EQUAL OR GREATER STRENGTH). 5 . TIGHTEN TO TORQUE SPECIFIED IN SERVl('k M A N l ' A L ,
I
OA-10 GENERAL INFORMATION
METRIC BOLT AND NUT IDENTIFICATION
Common metric fastener strength property classss are 9.8 and 10.9 with the clers idsntifica$ion embossed on the haad of each bolt. Customary (inch) strength clases range from grade 2 t o 8 wi(h line ihntificaion embosssd on each bolt head. Markings correspond to two lines lsss than the actual grade (i.e. grade 7 bolt will exhibit 5 embossd lines on the bolt head). Some metric nuts will be markd with single digit strength identification numbers on the nut face. The following figure illustr&es the different strength markings.
Customary ( ~ n c hbolts ) - l d e n t ~ f ~ c a t ~marks on correspond to bolt strength - lncreas~ngnumbers represent lncreaslng strength.
Metr~cBolts - l d e n t ~ f ~ c a t ~class o n numbers correspond to bolt strength lncreas~ngnumbers represent lncreaslng strength.
-
MANUFACTURERS IDENTIFICATION
NUT STRENGTH IDENTI FlCATlON POSlDRlV
Fig. OA-12 -- Metric Information, Chart C
SI METRIC-CUSTOMARYCONVERSION TABLE
Multiply
by
to get equivalent nurnber of:
Multiply
ACCELERATION
LENGTH Inch Foot Yard Mile
to get equivalent number ol:
by
millimeters ( m m ) meters ( m ) meters kilometers (km)
TORQUE
AREA
newton-meters (N-m) newton-meters millimeters2 (mm2) centimeters2 (cm2 ) meters' (m2) meters2
POWER Horsepower
PRESSURE OR STRESS
VOLUME mm3 cm3 liters (I) liters liters meters3 (ma)
Quart Gallon Yard3
MASS
Inches of mercury Poundslsq. in.
3.377 6.895
kilopascals (kPa) kilopascals
ENERGY OR WORK BTU Foot-pound Kilowatt-hour
joules (J) joules joules (J = one W's)
kilograms (kg) kilograms (kg) tonne (t)
Pound Ton Ton
Foot candle
FORCE FUEL PERFORMANCE Kilogram Ounce Pound
newtons (N) newtons newtons
Mileslgal Gallmile
TEMPERATURE Degree Fahrenheit
kilometerslliter (km/l) literslkilometer ( I l k m )
VELOCITY degree Celsius (C)
Mileslhour
1.609