1988 TABLE OF CONTENTS

SECTION NAME 1 SECT.

GENERAL INFORMATION
OA. General lnformation
SER OB. Maintenance & Lubrication
HEATING AND AIR CONDITIONING
1A. Heating and Ventilation
1B. Air Conditioning
1D1. R-4 AIC Com~ressorOverhaul
FRAME AND BUMPERS
2B. Bumpers
2C. Chassis Sheet Metal
STEERING, SUSPENSION, WHEELS
AND TIRES
3. Diagnosis
3A. Wheel Alignment
3B5. Steering Wheels and Columns
3B6. Steering Linkage
3B7. Power Steering Gear and Pump
3C. Front Suspension
3D. Rear Suspension
3E. Tires and Wheels
FINAL DRIVE
4A. Propeller Shaft
4B. Rear Axle
4B1. Bora-Warner Axle
BRAKES
5. Brakes
5A3. Comoosite Master Cvlinder
This manual applies t o the 1988 Pontiac Firebird Models. 5B1. Disc r rake Caliper ~ s s e m b l y-
It contains the latest product information available at the 300013100 Series
time of publication approval. lnformation pertaining to 5B6. Disc Brake Caliper Assembly - 3548
the operation of the vehicle is contained in the Owner's Series
Manual which accompanies each vehicle. The right is 5C3. Direct Torque Drum Brake Assembly
reserved to make changes at any time without notice. 5D2. Power Head Assembly - Tandem
Diaohraam
Any references to brand names in this manual is intended 5F. ~~ecification and
s Special Tools
merely as an example of the types of lubricant% tools, ENGINE
materials, etc, recommended for use in servicing 1988 6. Engine General lnformation
Pontiac Models. In all cases, an equivalent may be used. 6A2. 2.8L
6A3. 5.OL & 5.7L
6B. Engine Cooling
6C. E n ~ i n eFuel
6D. ~ n g i n eElectrical
6D1. Battery
6D2. Cranking System
6D3. Charging System
6D4. Ignition System
6D5. Engine Wiring
6E. Driveabilitv and Emissions
6E2. ~missions'
6E3. Emissions - PFI
6F. Engine Exhaust
TRANSMISSION
7A. Automatic Transmission - General
lnformation
7A1. Automatic Transmission - On-Car
Service
700R4. Automatic Transmission
Hydraulic Diagnosis
PONTIAC DIVISION 700R4. Automatic Transmission
Unit Repair
GENERAL MOTORS CORPORATION 76. 5-Speed Manual Transmission
PONTIAC, MICHIGAN 48053 7C. Clutch
CHASSIS ELECTRICAL
1987 General Motors Corp. All Rights Reserved. 8A. Electrical Diagnosis
8B. Lighting and Horns
No part of this publication may be reproduced, stored in any 8C. Instrument Panel, Gages & Console
retrieval system or transmitted i n any form or by any means, 8E. Windshield Wiper &Washer System
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 ACCESSORIES
permission of General Motors Corp. This includes all text, 9A. Radio Systems and Antennas
illustrations, tables and charts. 9B. Cruise Control
9G. Miscellaneous Accessories

S-881OF 9-87 Printed i n Canada I 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 design-
e d for the purpose.

Accordingly, anyone w h o intends t o use a replacement part, ser-

vice 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 replace-
ment 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 fail-
ure t o follow these instructions.
 GENERAL INFORMATION OA-1

SECTION (DA
GENERAL NFORMAT
CONTENTS
General Description ................................... OA- 1 Prevailing Torque Fasteners ......................... OA-2
Body Number Plate ...................................... OA- 1 Recommendations For Fastener Reuse ........ OA-2
Vehicle Identification Number ..................... OA- 1 Vehicle Lifting Procedures ............ .,............. OA-2
Metric Fasteners ......................................... OA- 1 Precautions Against Tipping ........................ OA-7
Fastener Strength Identification ................... OA-2 Automotive Abbreviations ...................
.... 0.4- 1 1

GENERAL DESCRIPTION
Only general information appears in this section. left of the windshield, see Figure 2. Refer to Figure 3
Detailed specifications on major units are given at the for detailed "VIN" code information. For Engine V.I.
end of each respective section of this manual. N. Location, refer to Figure 4.

BODY NUMBER PLATE METRIC FASTENERS

The Body Number Plate (Fig. 1) is attached to Pontiac models are primarily dimensioned in the
the front tie bar behind either the right or left headlamp metric system, Most fasteners are metric and are very
in the engine On The close in dimension to well-known customary fasteners
Number Plate identifies numerous items as outlined in in the inch system. It is most important that
Figure 1. re~lacement fasteners be of the correct nominal
d&meter, thread pitch and strength.
VEHICLE IDENTIFICATION NUMBER
Original equipment metric fasteners (except
The Vehicle Identification Number (VIN) Plate "beauty" bolts, such as exposed bumper bolts, and
is located on top of the instrument panel at the lower cross recess head screws) are identified by a number

1 -- BODY STYLE
2 ASSEMBLY P U N T
3 -- UNIT NUMBER
4 -- PAINT TYPE
5 - ROOF OPTION
6 -- SEAT OPTION
7 - TRIM COMBINATION
8 - UPPER BODY
9 - UPPER COLOR
10 -- LOWER BODY
11 - REMAINING LINES
-AVAILABLE FOR
--PLANT USE
12 - LOWER COLOR
13 - MODEL YEAR
14 -- TIME BUILD CODE
15 - DIVISION
16 - BODY TvPE
6200224A
Fig. 1 Body Number Plate
OA-2 GENERAL INFORMATION

the numbered head marking system. The metric

VIN NUMBER PLATE fasteners used on GM products are designed to new,
LOCATION 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

A prevailing torque nut is designed to develop an
interference between the nut and bolt threads. This is
Fig. 2 Vehicle Identification Number Plate Location
most often accomplished by distortion of the top of an
all-metal nut or by using a nylon patch on the threads
marking indicating the strength of the material in the in the middle of the hex flat. A nylon insert may also
fastener as outlined below. Metric cross recess screws be used as a method of interference between nut and
are identified by a Posidriv or Type 1A cross recess as bolt threads (Fig. 11).
shown in Figure 8. Either a Phillips head or Type 1A A prevailing torque bolt is designed to develop an
cross recess screwdriver can be used in Posidriv recess interference between bolt and nut threads, or the
screw heads, but Type 1A cross recess screwdrivers threads of a tapped hole. This is accomplished by
will perform better. distorting some of the threads or by using a nylon patch
or adhesive (Fig. 11).
NOTICE: Most metric fasteners have a blue color
coating. However, this should not be used as a RECOMMENDATIONS FOR FASTENER REUSE: I

positive way of identifying as some metric fasteners

are not color coated. Clean, unrusted prevailing torque nuts and bolts
may be reused as follows:
General Motors Engineering Standards, along a. Clean dirt and other foreign material off nut
with other North American Industries, have adopted or bolt.
a portion of the standard metric fastener sizes defined b. Inspect nut or bolt to insure there are no
by I S 0 (International Standards Organization). This cracks, elongation, or other signs of abuse
was done to reduce the number of fastener sizes used or overtightening. (If there is any doubt,
and yet retain the best strength qualities in each thread replace with a new prevailing torque
size. For example, the customary 1/4-20 and 1/4-28 fastener of equal or greater strength.)
screws are replaced by the metric M6.0 X 1 screw c. Lightly coat bolt & nut with engine oil.
which has nearly the same diameter and 25.4 threads Assemble parts and hand start nut or bolt.
per inch. The thread pitch is in between the customary d. Observe that before fastener seats, it
coarse and fine thread pitches. develops torque per the chart in Figure 10.
Metric and customary thread notation differ (If there is any doubt, replace with a new
slightly. The difference is shown in Figure 9. prevailing torque fastener of equal or
greater strength.)
FASTENER STRENGTH ODENTIFIGATION e. Tighten fastener to torque specified in
Most commonly used metric fastener strength appropriate section of this manual.
property classes are 9.8 and 10.9 with the class Bolts and nuts which are rusty or damaged
identification embossed on the head of each bolt. should be replaced with new parts of equal or
Customary (inch) strength classes range from grade 2 greater strength.
to 8 with radial line identification embossed on each VEHICLE LIF"TING PROCEDURES
bolt head (i.e., grade 7 bolt will exhibit 5 embossed
radial lines on the bolt head). Some metric nuts will be NOTICE: When jacking or lifting vehicle from
marked with single digit strength identification frame side rails, be certain lift pads do not contact
numbers on the nut face. Figure 12 shows the different catalytic converter as damage to converter will
strength markings. result.
When replacing metric fasteners, be careful to use
bolts and nuts of the same strength or greater than the Many dealer service facilities and service stations
original fasteners (the same number marking or higher) are equipped with a type of automotive hoist which
.It is also important to select replacement fasteners of must bear upon some part of the frame in order to lift
the correct size. Correct replacement bolts and nuts are the vehicle. Figures 14 and 15 indicate the
available through the parts division. Many metric recommended areas for hoist contact for Pontiac
fasteners available in the after-market parts channels Sunbird models.
were designed to metric standards of countries other If any other hoist methods are used, special care
than the United States. These fasteners may be of a must be used not to damage the fuel tank, filler neck, I
I
lower strength, different thread pitch and may not have exhaust system or underbody.
 GENERAL INFORMATION OA-3

PLANT CODE

GM PLANT CODES
LV.1.N. POSITION $ 1 1 )

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 7 D~,i,r P l a l n Lia~.k l I l . ~ t ~ ' l ~ l i . ~ c k ~

Seci.in 4 Utnir 6 \$lndi,w N o t t ' I ~ L , . ~ c k
c'<jupc 2 1101)r Nuti.Ill,.ick
Statlon W ~ q u n 4 Uc,or
Coupe 1 l > t i ~ >Nr o t c h b d c k S p r c l d l
Coupe 2 Door C o n v e r t ~ b l r
Scd.ln 4 Door b W ~ n d o w P l a l l i Back
Scd.jn 4 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

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 IOU DAY OF THE YEAR1

-
T H M 700-R4 TRANSMISSION I.D. LOCATION
1
ISHIFT BUILT
-
A & B = FIRST SHIFT
C5H SECOND SHIFT

T H M 700-R4 TRANSMISSION I D E N T I F I C A T I O N NUMBER

11

V I N LOCATION

I OPTIONAL V I N LOCATION --I 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 USING FRAME CONTACT HOIST

REARWARD OF FRONT TIRE ' FORWARD OF REAR TIRE

USING SUSPENSION CONTACT HOIST USING SUSPENSION CONTACT HOIST

LIFTING ON REAR AXLE 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

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 cus-
tomary (Inch) type nuts, bolt5 and screws. Many are metnc and some are very close in d ~ m e n s ~ oton custom-
ary 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
strength character~st~cs
In each thtead size. For example. the customary 114-20 and 1/4-28 screws are replaced
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 AND BOLT

WASHER NYLON STRIP OR PATC

I 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.
I
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 ,
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 NUT STRENGTH

IDENTIFICATION IDENTI FlCATlON
POSlDRlV

Fig. OA-12 -- Metric Information, Chart C

 SI METRIC-CUSTOMARYCONVERSION TABLE

to get equivalent to get equivalent

Multiply by nurnber of: Multiply by number ol:
LENGTH ACCELERATION

Inch millimeters ( m m )
Foot meters ( m )
Yard meters
Mile kilometers (km) TORQUE

AREA newton-meters (N-m)

newton-meters
millimeters2 (mm2)
centimeters2 (cm2 ) POWER
meters' (m2)
meters2 Horsepower

VOLUME PRESSURE OR STRESS

mm3 kilopascals (kPa)
Inches of mercury 3.377
cm3 Poundslsq. in. 6.895 kilopascals
liters (I)
Quart liters ENERGY OR WORK
Gallon liters
Yard3 meters3 (ma) BTU joules (J)
Foot-pound joules
MASS Kilowatt-hour joules (J = one W's)

Pound kilograms (kg)

Ton kilograms (kg)
Ton tonne (t)
Foot candle
FORCE
FUEL PERFORMANCE
Kilogram newtons (N)
Ounce newtons Mileslgal kilometerslliter (km/l)
Pound newtons Gallmile literslkilometer ( I l k m )
TEMPERATURE VELOCITY

Degree Fahrenheit degree Celsius (C) Mileslhour 1.609

OA-12 GENERAL INFORMATION

DECIMAL AND METRIC EQUIVALENTS

Fractions Decimal Metric Fractions Decimal Metric

In . MM . In . MM .

Fig. OA-14 ..Metric Information, Chart E

 - -

GENERAL INFORMATION OA-13

LIST OF AUTOMOTIVE ABBREVIATIONS

WHICH MAY BE USED IN THIS MANUAL

A-6 - A x i a l 6 Cyl. A C Compressor

AIC - A i r Conditioning
ACC - Auto'matic Climate Control
EMF - Electromotive Force PAIR - Pulse Air Injection Reaction System
EMR - Electronic M o d u l e Retard P B - Power Brakes
EOS - Exhaust Oxygen Sensor PCV - Positive Crankcase Ventilation
ESC - Electronic Spark Control PECV - Power Enrichment Control Valve

APT - Adjustable Part Throttle

AT - Automatic Transmission
ATC - Automatic Temperature Control
ATDC - After Top Dead Center
FMVSS - Federal Motor Vehicle Safety
BAR0 - Barometric Absolute Pressure Sensor
Ft. Lb. - Foot Pounds (Torque)
Bat. + - Positive Terminal FWD - Front Wheel Drive
- Four Wheel Drive
BHP - Brake Horsepower 4 x 4 - Four Wheel Drive
BP - Back Pressure
BTDC - Before Top D e a d Center H D - Heavy Duty
HE1 - H i g h Energy Ignition
Cat. Conv. - Catalytic Converter
CC - Catalytic Converter
- Cubic Centimeter
- Converter Clutch
CCC - Computer Command Control
HVM - Heater-Vent-Module

IAC - l d l e Air Control

CCOT - Cycling Clutch (Orifice) Tube IC - Integrated Circuit
CCP - Controlled Canister Purge I D - Identification
C.E. - Check Engine - Inside Diameter
CEAB - Cold Engine A i r b l e e d ILC - I d l e Load Compensator
CEMF - Counter Electromotive Force I/P- Instrument Panel
CID - Cubic Inch Displacement ISC - I d l e Speed Control
CLOOp - Closed Loop
CLCC - Closed Loop Carburetor Control km - Kilometers

CP - Canister Purge kmiL - Kilometers Liter (mpg)

Cu. In. - Cubic Inch kPa - Kilopascals
CV - Constant Velocity
Cyl. - Cylinder(s)
L-4 - Four Cylinder In-Line (Engine)
DBB - Dual Bed Bead L-6 - Six Cylinder In-Line (Engine)
DBM - Dual Bed Monolith LF - Left Front
DEFl - Digital Electronic Fuel Injection LR - Left Rear
DFI - D i g i t a l Fuel Injection
-
D i f f . Differential Man. Vac. - M a n i f o l d Vacuum
Distr. - Distributor MAP - M a n i f o l d Absolute Pressure

EAC - Electric A i r Control Valve

EAS - Electric A i r Switching Valve MPG - Miles Per G a l l o n
-
ECC Electronic Comfort Control MPH - Miles Per Hour
ECM - Electronic Control M o d u l e MT - M a n u a l Transmission

N.m - Newton Metres (Torque)

Emission Control

Fig. 014-15 -- Common Abbreviations

0.4-14 GENERAL INFORMATION

SERVICE P A R E SlDENTlFlGATlON LABEL

The Service Parts Identification Label provides identifi- fixed to the inside of each passenger car vehicle at the
cation of vehicle equipment to assist in servicing and assembly plant.
determining replacement parts, Included on this label
will be regular production options (RPO's) as well as For additional information on the Service Parts Identifi-
standard and mandatory options. The label will be af- cation Label, see a GM Parts Catalog.

---f lGlAZ3799ER157148 1JD69

i
VEHICLE BODY TYPE STYLE
IDENTIFICATION A R L A02 A65 BGY B9A B9K C60 D l 0 D35 E5Z E6E E9Z F L T GU1 JM7
NUMBER OPTION CONTENT
<19 KG4 LC3 M X 1 M31 N A 5 NB1 OMX V K 3 VC2 V Y 1 VY4 V73 Y19 ZJ7
GBJ 6 2 L 62U 67D 671 679 7BJ 8HJ 9HJ

BBPBBBBPPB EXAMPLE -
DIS. LACQUER WA-L8240 U8240 A4721

VINYL
P A I N T TECHNOLO(IY
FOP CCIl.Oli
SOLUTION LACOUEH
I l F AI'I'LICAHLZI
DlSPEHSlON L A C O U E H
H I G H SOLIDS E N 4 M E L
\VA CERBORNE ENAI.ICL I'AINT L O U L S APd[J L O L A T I O N S I
BASECOAT C L C A l 3 C 0 4 T L LfJIVEIi L:C)UY C O L O I I 1lilP.1
U UPI'CH f!O[IY (,OLCJII ~ , l J P . l l ~ l P l l/O
~ 'J',
A h l l I 1 U L f L!O[)Y O I I ACCCNT
COLOF? ISTHIPINO CTC. I

LABEL LOCATION

Fig. OA-16 Service Parts Idcnt~frcationLabel

 MAINTENANCE AND LUBRICATION OB-1

SECTION OB
NTENANCE AND LUBR
CONTENTS
Maintenance Schedule, Gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OB-l
Maintenance Schedules I and 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OB-2
Owner Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OB-3
Recommended Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OB-6

PASSENGER CAR MAINTENANCE SCHEDULE

VEHICLES WITH GASOLINE ENGINE
NORMAL CAR USE ITEM 4
The maintenance services contained in Schedules I Carburetor or Throttle Body Mounting Bolt
and 11 are based on the assumption that your car will be Torque*
used as designed:
Check torque of mounting bolts and/or nuts.
@ To carry passengers and cargo within the limits
shown on the Tire Placard located on the edge of the ITEM5
driver's door.
Engine Idle Speed Adjustment*
@ On reasonable road surfaces within legal driving
limits. (Engines without Idle Speed Control or Idle Air
Control) - Adjust to specifications shown on the under-
@ On unleaded gasoline.
hood label. If no specifications are shown on the label, no
adjustment is necessary. Calibrated test equipment must
EXPLANATION OF SCHEDULED MAINTENANCE be used.
SERVICES
The services listed in Maintenance Scheduies I and ITEM 6
11 are further explained below. When the following main- ~i~~and wheel aotation
tenance services are performed, make sure all parts are
replaced and all necessary repairs are done before driving To equalize wear and obtain maximum tire life,
your car. Be sure to use the proper fluid and lubricants as rotate in accordance with patterns shown in Owner's
shown in Figure OB-2. Manual.

ITEM 1
Engine Oil and Oil Filter Change* Vacuum or A.I.R. Pump Drive Belt Inspection*
ALWAYS USE SFICC OR SF/CD ENERGY CON- When a separate belt is used to drive the vacuum or
SERVING OILS O F PROPER VISCOSITY - Also. A.I.R. pump, inspect i t for cracks, fraying, wear and
always change oil and filter as soon as possible after proper tension. Adjust or replace as needed.
driving in a dust storm. See your Owner's Manual for
further details. ITEM 8
Cooling System Service*
ITEM 2
Drain, flush and refill system with new coolant. See
Chassis Lubrication your Owner's Manual for further details.
Lubricate all grease fittings in suspension and steer-
ing linkage. Lubricate transmissionltransaxle shift ITEM 9
linkage, parking brake cable guides, underbody contact Wheel Bearing Repack (Rear-Wheel-Drive Cars
points and linkage. Also lubricate clutch cross shaft lever
every 30,000 miles (50 000 km) on rear-wheel-drive cars Only Except Corvette)
only. Clean and repack front wheel bearings at each brake
relining or 15,000 miles ( 2 5 000 km), whichever comes
ITEM 3 first, when car is used in such service as police, taxi or
door-to-door delivery. If you do not use your car in such
Carburetor Choke and Hoses* service, clean and repack bearings at each brake relining
If your car is equipped with a carburetor, verify that or 30,000 miles (50 000 km), whichever comes first.
choke and vacuum break work properly and are within Corvette models do not require wheel bearing repack.
specifications. Correct any binding caused by damage or
gum on the choke shaft. Inspect hoses for proper hookup,
cracks, chafing or decay. Correct as necessary.
OB-2 MAINTENANCE AND LUBRICATION

Select and follow Schedule I or Schedule I1 based on how you use your car:

SCHEDULE I
Follow Schedule I if your car is mainly operated under one or moreof the following Idling andlor low speed operation in stop-and-go traffic.
conditions: Towing a trailer.
@ When most trips are less than 4 miles (6 kilometers). Operating in dusty areas.
When most trips are less than 10 miles (16 kilometers) and outside temperatures Schedule I should also be followed if the car is used for delivery service,
remain below freezing. police, taxi or other commercial applications.

TO BE SERVICED

Every 30.000 miles I50 000 km)

Every 30,000 miles I50 000 km) or 36 months

Every 30,000 miles 150 000 km)

SCHEDULE ll
Follow Schedule II only if none of the driving conditions specified in Schedule I apply.

TO BE SERVICED

At 7 500 miles 12 500 km on1

FOOTNOTES:

I *An Emission Control Service

t t T h e U.S. Environmental Protection Agency has determined that the failure to perform this
maintenance item will not nullifv the emission warrantv or limit recall liabilitv orior to the
completion of vehicle useful life. General Motors, however, urges that all recommended main-
tenance services be performed at the indicated intervals and the maintenance be recorded in
section C of the owner's ma~ntenanceschedule.

Figure OB-1 Maintenance Schedules I and I1 - Gasoline Vehicles

F CARLINE MAINTENANCE AND LUBRICATION 08-3

ITEM 10 ITEM 16
TransmissionRransaxle Service Engine Timing Check*
The manual transmission or transaxle fluid does not Adjust timing to underhood label specifications. If
require changing. (Corvette only.) Change fluid in over- no specifications are shown, no adjustment is needed.
drive unit every 30,000 miles (50 000 km).
For automatic transmissions or transaxles, change ITEM 17
both the fluid and filter every 15,000 miles (25 000 km) if
the car is mainly driven under one or more of these Fuel Tank, Cap and Lines Inspection*
conditions: Inspect fuel tank, cap and lines (including fuel rails
@ In heavy city traffic where the outside temperature and injection assembly, if so equipped) for damage or
regularly reaches 90F (32C) or higher. leaks. Inspect fuel cap gasket for an even filler neck
@ In hilly or mountainous terrain.
imprint or any damage. Replace parts as needed.
@ Frequent trailer pulling.
ITEM 18
@ Uses such as found in taxi, police car or delivery
service. Thermostatically Controlled Air Cleaner
If you do not use your car under any of these condi- Inspection*
tions, change both the fluid and filter every 100,000 miles If your car is equipped, inspect all hoses and ducts
(160 000 km). See you Owner's Manual for further for proper hookup. Make sure valve works properly.
details.

ITEM 11 OWNER INSPECTIONS AND SERVICES

Spark Plug Service* Listed below are inspections and services which
should be made by either you or a qualified technician at
Replace spark plugs with type listed in your Owner's the intervals shown to help ensure proper safety, emission
Manual. performance and dependability of your car. Take any
problems promptly to your dealer or another qualified
technician for service advice. Whenever repairs are neces-
ITEM 12 sary, have them completed at once. For your safety and
Spark Plug W i r e Inspection* that of others, any safety-related parts that could have
been damaged in an accident should be inspected and all
needed repairs should be done before operating your car.
Clean wires and inspect for burns, cracks or other dam- Be sure to use the proper fluids and lubricants as shown in
age. Check the wire boot fit at distributor and at spark plugs. Figure OB-2.
Replace wires as needed.

ITEM 13 WHILE OPERATING YOUR VEHICLE

Positive Crankcase Ventilation (PCV) Valve Automatic transmissionltransaxle shift indi-
Inspection* cator operation -Make sure the indicator points to the
gear chosen.
Inspect valve for proper function. Replace valve if
necessary as well as any worn, plugged or collapsed
hoses. Horn operation - Blow the horn occasionally to
make sure it works. Check all button locations.
ITEM 14 I
EGR System Service* Brake system operation -- Be alert to abnormal
Conduct EGR System Service as referenced in the sounds, increased brake pedal travel or repeated pulling to
EGR System Chart shown in the appropriate 6E Section. one side when braking. Also, if a brake warning light
Also, refer to your GM maintenance schedule booklet for comes on or flashes, or the anti-lock warning light (if
specific applications. equipped) comes on or remains on, something may be
wrong with part of the brake system. Have it inspected and
ITEM 15 repaired at once.
Air Cleaner and PCV Filter Replacement*
On 1.6 and 2.0 liter engines, replace every 50,000 Exhaust system operation - Be alert to any
miles (80 000 km). On all other engines, replace every changes in the sound of the system or any smell of fumes.
30,000 miles (50 000 km). Replace more often under These are signs the system may be leaking or overheating. .
dusty conditions. Ask your dealer for the proper replace- Have it inspected and repaired at once. Also see "Engine
ment interval for your driving conditions. Exhaust Gas Caution (Carbon Monoxide)" and "Catalytic
Converter" in your Owner's Manual.
*An Emission Control Service
OB-4MAINTENANCE AND LUBRICATION
Tire and wheel operation - Be alert to a vibra- NOTICE: A large loss in this system may indicate a
tion of the steering wheel or seat at normal highway problem. Have it inspected and repaired at once.
speeds. This may mean a wheel balance is needed. Also, a
pull right or left on a straight, level road may show the Brake master cylinder reservoir fluid level
need for a tire pressure adjustment or wheel alignment. check ----Check fluid and keep at proper level. Note: It is
normal for the brake fluid level to go down slightly as the
Steering system operation - Be alert to brake pads wear - so be sure to keep reservoir filled.
changes in steering action. An inspection is needed when
the steering wheel is harder to turn or has too much free NOTICE: A large loss in this system may indicate a
play or if unusual sounds are noted when turning or problem. Have it inspected and repaired at once.
parking. Clutch system service --- manual transmis-
Headlight aim operation - Take note of light sionltransaxle --- For cars equipped with hydraulic
pattern occasionally. If beam aim doesn't look right, clutch system, check the reservoir fluid level and add fluid
headlights should be adjusted. as required. All others, check clutch pedal free travel and

AT EACH FUEL FILL

adjust as necessary. See your Owner's Manual for further
details.
NOTICE: A large loss in this system may indicate a
~
Engine oil level check - Check engine oil level
and add if necessary. See your Owner's Manual for further problem. Have it inspected and repaired at once.
details. Weatherstrip Lubrication - Clean surface and
NOTICE: A large loss in this system may indicate a then apply a thin film of silicone grease with a clean cloth.
problem. Have it inspected and repaired at once.
Engine coolant level and condition - Check
engine coolant level in coolant reservoir tank and add if EACH TIME OIL IS CHANGED
necessary. Replace if dirty or rusty. See your Owner's Automatic and manual transmissionltrans-
Manual for further details. axle fluid level check - Check transmission/transaxle
NOTICE: A large loss in this system may indicate a fluid level and add as required. (Corvette only) if equipped
problem. Have it inspected and repaired at once. with manual transmission - check fluid in the overdrive
unit and add as required.
Windshield washer fluid level check -- Check
washer fluid level in container and add if necessary. NOTICE: A large loss in this system may indicate a
problem. Have i t inspected and repaired at once.
Hood latch operation - When opening hood on
cars equipped with hoods that open from the front, note
the operation of secondary latch. It should keep hood from Brake systems inspection - For convenience,
opening all the way when primary latch is released. Make the following should be done when wheels are removed
sure that hood closes firmly. for rotation: Inspect lines and hoses for proper hookup,
binding, leaks, cracks, chafing, etc. Inspect disc brake
AT LEAST MONTI-ILY pads for wear and rotors for surface condition. Also in-
spect drum brake linings for wear and cracks. Inspect
Tire and wheel inspection and pressure other brake parts, including drums, wheel cylinders, park-
check-- Check tires for abnormal wear or damage. Also, ing brake, etc. at the same time. Check parking brake
check for damaged wheels. Keep pressures as shown on adjustment.
Tire Placard on the driver's door (include spare unless it is
a stowaway). Pressure should b\: checked when tires are
"cold". See "Tires" in Owner's Manual for further
infomation. INSPECT BRAKES MORE OFTEN IF DRIVING
HABITS OR CONDITIONS RESULT I N FREQUENT
Light operation check - Check operation of BRAKING.
license plate light, side-marker lights, headlights includ-
ing high beams, parking lights, taillights, brake lights. Steering, suspension and front drive axle
turn signals, backup lights, instrument panel and interior boot and seal inspection - Inspect front and rear
lights and hazard warning flashers. suspension and steering system for damaged, loose or
missing parts, signs of wear or lack of lubrication. Inspect
Fluid leak check - After the car has been parked power steering lines and hoses for proper hookup, bind-
for a while, inspect the surface beneath the car for water, ing, leaks, cracks, chafing, etc. (On cars equipped with
oil, fuel or other fluids. Water dripping from the air manual steering gear, check for seal leakage.) On front-
conditioning system after use is normal. If you notice fuel wheel-drive cars, clean then inspect drive axle boot seals
leaks or fumes, the cause should be found and corrected at for damage, tears or leakage. Replace seals if necessary.
once.
Exhaust system inspection - Inspect complete
system. Inspect body near the exhaust system. Look for
AT LEAST TWICE A YEAR (FOR EXAMPLE, broken, damaged, missing or out-of-position parts as well
EVERY SPRING AND FALL) as open seams, holes, loose connections or other condi-
Power steering pump fluid level check -- tions which could cause a heat buildup in the tloor pan or
Check power steering pump fluid level in accordance with could let exhaust fumes seep into the trunk or passenger
Owner's Manual instructions and keep at proper level. compartment.
 MAINTENANCE AND LUBRICATION OB-5

Throttle linkage inspection -- Inspect for inter- pedal. If t h e engine starls, b e ready t o t u r n
ference, binding, damaged or missing parts. off t h e ignition promptly. Take these pre-
Engine drive belts inspection - Inspect all c a u t i o n s because t h e car c o u l d m o v e
belts for cracks, fraying and wear. Adjust or replace as w i t h o u t warning and possibly cause per-
needed. sonal injury or properly damage. O n auto-
matic transmissionltransaxle cars, t r y t o
Rear axle service (if equipped) - Check gear s t a r l t h e engine in each gear. The starler
lubricant level and add if needed. For cars equipped with a should crank only i n "Park" or "Neutral."
limited slip rear axle, fluid does not require changing O n manual transmissionltransaxle cars,
(except Caprice and Corvette -change fluid and required place t h e shiR lever in "Neutral," push t h e
additive at first 7,500 miles (12 500 km). See your clutch halfway and t r y t o starl. The starler
Owner's Manual or "Recommended Fluids & Lubricants should crank only w h e n t h e clutch is fully
Chart" in this section. depressed.
IF YOU USE YOUR GAR TO PULL A TRAILER, Steering c o l u m n lock operation - While
CHANGE GEAR LUBRICANT EVERY 7,500 MILES parked, try to turn key to "Lock" in each gear range. The
(12 500 KM). key should turn to "Lock" only when gear is in "Park" on
NOTICE: A large loss in this system may indicate a automatic or "Reverse" on manual transmissionltransax-
problem. Have it inspected and repaired at once. le. On cars with key release lever, try to turn key toULock"
Power antenna -Clean and then lubricate power without depressing the lever. The key should turn to
antenna mast. The proper lubricant as shown in Figure "Lock" only with the key lever depressed. On all vehicles,
OB-2 should be used. the key should come out only in "Lock."
Parking brake and transmissionltransaxle
AT LEAST ONCE A YEAR "Park" mechanism operation
Lap and shoulder belts condition and opera- CAUT1ON:Before checking t h e holding
tion - Inspect belt system, including webbing, buckles, ability of t h e parking brake and automatic
latch plates, retractors, guide loops and anchors. transmissionltransaxle "Park" mecha-
Moveable head restraint operation -On cars nism, p a r k o n a f a i r l y steep h i l l w i t h
with moveable restraints, make sure restraints stay in the enough r o o m for movement i n the d o w n -
desired position. (See adjustment instructions in your hill direction. To reduce t h e risk of person-
Owner's Manual.) al injury or property damage, b e prepared
t o apply t h e regular brakes promptly if the
Seatback latch and recliner operation o n car begins t o move.
cars equipped with recliner seat --- Be sure seat-
backs latch on those cars with folding seats using mechan- To check the parking brake, with the engine running and
ical latches. Make sure the recliner is holding by pushing transmission/transaxle in "Neutral." slowly remove foot
and pulling on the top of the seatback while it is reclined. pressure from the regular brake pedal (until the car is held
See your Owner's Manual for seat operating information. by only the parking brake).
Spare tire and jack storage- Be alert to rattles To check the automatic transmissionltransaxle "Park"
in rear of car. Make sure the space tire, all jacking equip- mechanism holding ability, release all brakes after shift-
ment, any tire inflator and any covers or doors are securely ing the transmissionltransaxle to "Park."
stowed at all times. Oil jack ratchet or screw mechanism ljnderbody flushing - At least every spring,
after each use. tlush from the underbody with plain water any corrosive
Key lock service - Lubricate key lock cylinder at materials used for ice and snow removal and dust control.
least annually. Take care to thoroughly clean any areas where mud and
Body lubrication service - Lubricate all body other debris can collect. Sediment packed in closed areas
door hinges including the tailgate or hatchback lid (if of the vehicle should be loosened before being flushed.
equipped). Also lubricate the body hood, fuel door and Engine cooling system service - Inspect
rear compartment hinges and latches including interior coolant and freeze protection. If dirty or rusty, drain, flush
glove box and counsel doors, and any folding seat and refill with new coolant. Keep coolant at the proper
hardware. mixture as specified in your Owner's Manual. This pro-
"Fansmissionltransaxle n e u t r a l o r c l u t c h vides proper freeze protection. corrosion inhibitor level
starl switch operation and engine operating temperature. Inspect hoses and re-
place if cracked. swollen or deteriorated. Tighten hose
CAUnON: Before pedorming t h e follow- clamps. Clean outside of radiator and air conditioning
ing safety switch check, b e sure t o have condensor. Wash radiator filler cap and neck. To help
enough r o o m around t h e car. Then, firmly ensure proper operation. a pressure test of both the cooling
apply b o t h t h e parking brake (see your system and cap is also recommended. (See maintenance
Owner's Manual for procedure) and t h e schedule charts in Figure OB-l for the recommended
regular brakes. Do n o t use t h e accelerator coolant change interval.)
NOTE: Fluids and lubricants identified below by name, part number or specification may be obtained from your GM dealer.

USAGE FLUlDlLUBRlCANT
Engine Oil GM Goodwrench Motor 011or equivalent for API S e ~ l c e SFICC
, or SFICD of the
recommended v~scos~ty
Engine Coolant M~xtureof water and good qual~tyethylene glycol base antllreeze conforming to GM spec
1825M (GM Part No 1052753)
Brake and Hydraul~cClutch Systems Delco Supreme 11 Fluld (GM Part No 1052535) or DOT-3 Fluld
Parking Brake Cables Chass~sgrease meetlng requirements of GM-6031M (GM Part No 1052497)
Power Steering System GM power steerlng flu~d,Part No 1052884 or equivalent
Manual Steerlng Gear (reclrculat~ngball) Use lubricant meetlng requirements of GM-4673M (GM Part No 1052182)
Automatic Transrn~ssionRransaxleand 5 Speed Manual Transm~ss~ons DEXR0N'-II Automat~cTransm~ss~on
Flu~d(GM Part No 1051855) Camaro and Flreblrd
(5 Speed)

Manual Transm~ssion(rear-wheel-drive) 4 Speed Corvette overdr~veunlt - DEXRON a.II All others SAE-80W-90 GL-5 gear lubr~cant
(GM Part No 1052271)
Shin Linkage
Manual Transm~ss~onRransaxle Chass~sgrease meetlng requirements of GM-6031M (GM Part No 1052497)
Key Lock Cylinders Black Key Lock Cyl~nders- light oil (GM Par1 No. 1052949)
All other Key Lock Cyl~nders- sllicone lubrlcant (GM Part No 1052277)
Automatic Transmlss~onfrransaxle Shlft Llnkage Eng~ne011
Clutch Llnkage Plvot Po~nts Eng~ne011
Floor Sh~nL~nkage Eng~ne011
Power Antenna Mast (3-mast sect~on-typeonly) Llght 011(GM Part No 1052949)
Chass~sLubr~cation Chass~sgrease meetlng requirements of GM-6031M (GM Part No 1052497)
Standard D~fferent~al
Rear Axle SAE 80W or SAE 80W-90 GL-5 (SAE 80W GL-5 In Canada) gear lubricant (GM Part No
1052271)
L~m~ted-Sl~p
D~flerent~al
Rear Axle For Camaro only - Use SAE BOW190 GL-5+ Hypold 011(GM Part No 1050010), 11equ~pped
wl5 7L (L98) Englne or 5 OL (LB9) engine w m p e e d manual transm~ss~on
and disc brakes
All other applications - Use SAE 80W or SAE 80W-90 GL-5 Gear Lubr~cant(GM Part No
1052271)
W~ndsh~eld.Washer
Solvent GM Opt~kleenWasher Solvent (GM Part No 1051515) or equ~valent
Hood Latch Assembly
a) Plvots and Sprlng Anchor a) Eng~ne011
b) Release Pawl b) Chass~sgrease meet~ngrequirements of GM.6031M (GM Part No 1052497)
Front Wheel Bearings (rearqwheel-drive) Lubricant GM Part No 1051344 grease or equivalent
Hood and door hlnges, statlon wagon tailgate hlnge or hatchback Ild and Eng~ne011
Ilnkage, headl~ghtdoor assembl~es,statlon wagon rear foldrng seat, fuel door
hlnge, rear compartment Ihd hlnges
Weatherstr~ps S~l~cone
Grease (GM Part No 1052863) or equivalent

Figure 00-2Recommended Fluids and Lubricants

 HEATING AND VENTILATION 1A-1

SECTION 1A
NG AND VENT
CONTENTS
General Description ................................. 1A-1 On-Vehicle Sewice ....................................... 1A-13
Diagnosis - Heater Trouble ...................... 1A-5 Heater Control Assembly ..........................1A- 13
Insufficient Heating or Defrosting .............. 1A-5 Blower Switch .......................................1A-13
Blower Electrical ......................................... 1A-7 Temperature Cable ..................................1A- 13
Improper Air DeliveryINo Mode Shift ....... 1 A-8 Heater Core ..........................................1A- 13
Too Much Heat .......................................... 1A-9 Vent Control Cable .................................1A- 13
Controls ....................................................... 1A-10 Lower Heater Outlet ................................1A-14
Blower Noise ............................................... 1A-11 Blower Motor ........................................1A-14

GENERAL DESCRIPTION
The base heater system is designed to provide The power-vent, heat, and defrost provisions of
heating, ventilation, windshield defrosting and on some the base system are controlled within the heater
cars, side window defogging. Ram air ventilation is module. The module itself is composed of two (2)
provided on some cars by two (2) outboard vent valves components - a blower air inlet and a heater defroster.
installed in the plenum. These vent valves are The blower air inlet is mounted to the front of the cowl
controlled by push-pull controls mounted in the and the heater defroster assembly is mounted to the
instrument panel. When either of these valves are rear of the cowl. A gasket is used between the two to
opened, air will enter the passenger compartment from prevent air, water and noise entrance into the
the pressurized plenum and be directed to the floor of passenger compartment. Air distribution is through a
the vehicle. heater outlet, defroster duct, power-vent duct work
and outlets.
The three modes of the base heater system (vent,
heat, defrost) are controlled by the functional

&
/ VENTILATION
assemblies within the heater module. These assemblies
are defined below:
1. Motor & Fan Assembly (Blower).
Provides and regulates air flow from the air inlet
for further processing and/or distribution.
2. Heater Core.
Transfers heat from engine coolant to inlet air,
heating the inlet air.
3. Temperature Valve.
Regulates the amount of air passing through the
heater core, controlling the temperature and mix
of heated and ambient air.
4. Mode (Defroster) Valve.
Regulates the flow and distribution of processed
air to the distribution (heater or defroster) ducts.
5. Vent Valve.
Regulates the flow of non-processed (outside) air
into the passenger compartment.
The operation of these assemblies is controlled by
the levers and switch on the control head. Depending
on model application, two (2) or three (3) indexed
snap-in cables are attached to the module and control
levers.
The temperature cable has the slider-type,
self-adjust feature. As the temperature lever of the
1-FRONT INLET GRILLE
control head is cycled through its full range of travel,
2-BODY LOCK PILLAR EXHAUST VALVE the cable clip will assume a position assuring that the
temperature valve will seat in both extreme positions.
Fig. 2 Interior Body Air & Exit - Typical Hatchback
The vent and/or defrost cables also have the
Models
1A-2 HEATING AND VENTILATION

520003-1A
Fig. 3 Interior Body Air & Exit - Typical Sedan, Station Wagon

self-adjusting feature. Blower speeds are controllable in Side window defogging, if so equipped, is
all modes (VENT, HEAT, DEFROST) by the switch provided via ducts in the outboard corners of the
on the control head. instrument panel. Maximum air flow from these vents
The power-vent ventilation feature is available in will be in "Heater" mode with reduced air flow in
the vent mode. Outside air enters the plenum and is "Defrost" mode.
driven by the blower to the temperature valve. In the Varying the mode selector between "Heater" and
cold position of the temperature valve, air bypasses the "Vent" positions varies the proportion of air coming
heater core to the vent valve opening and enters the out the heater outlet and the center vent outlets. With
passenger compartment through the vent duct and the selector in some midway position, air coming out
outlets in the center of the instrument panel. If some the center vent outlets will be ambient temperature,
heated air is desired, the temperature valve may be while air out the heater outlet will be mixed warm air,
opened. This allows mixed (tempered) air to flow out its temperature depending on temperature lever
the center vent opening. Blending air between modes position.
can be done by varying the mode selector. In the heat and defrost mode, outside air is driven by
Varying the selector between "Heat" and the blower to the temperature valve which, depending
"Defrost" will allow more air or less air to be directed upon its position as controlled by the operator, distributes
out either the defroster outlet or the heater outlet. The all or some portion of the inlet air through the heater core.
closer the mode selector is positioned to the "Heater" The vent valve will prevent air entry into the vent duct and
position, the larger the amount of air coming out the direct this ambient air to the mix portion of the heater
heater outlet. The closer the mode selector is module. The air is thus heated, mixed, and then directed
positioned to "Defrost," the larger the amount of air into either the defroster duct or the heater outlet by the
going to the windshield. The temperature of this air is position of the mode valve and control lever. A small
governed by the temperature lever position. amount of air is bled to the side window defogger system.
 HEAPING AND VENTILA"T0N 1A-3

1, LEFT AND RIGHT SIDE WINDOW 3. POWER VENTIHEAT 5. LEFT AND RIGHT RAM AIR
DEFOG OUTLETS* OUTLETS VENT OUTLETS*
2. LEFT AND RIGHT DEFROSTER 4. RAM AIR VENT
OUTLETS CONTROLS* * NOT ON ALL MODELS
J10001-1A-F

Fig. 4 Heater V e n t i l a t i o n S y s t e m - T y p i c a l

1-THIS POSITION ALLOWS OUTSIDE AIR FLOW 3-THIS POSITION ALLOWS ABOUT 80% AIR
TO FLOOR OUTLET. ( A D D I T I O N A L VENTED FLOW TO WINDSHIELD AND 20% TO FLOOR.
AIR CAN BE DISTRIBUTED INSIDE CAR BY
OPERATING VENT KNOBS.) 4-TEMPERATURE LEVER POSITION WILL
REGULATE OUTLET AIR TEMPERATURE BY
2-POSITION OF THIS SYSTEM SELECTOR BLENDING THE INCOMING OUTSIDE A I R
LEVER DETERMINES AIR FLOW FROM THROUGHIAROUND THE HEATER CORE.
FLOOR, INSTRUMENTPANEL OR WIND-
SHIELD OUTLET - I N "HEATER", FLOW IS 5-THE FAN CONTROL LEVER (OFF - H I ) PRO.
ABOUT 80% TO FLOOR AND 20% TO WIND- VIBES SPEED CONTROL OF THE FAN.
SHIELD OUTLETS ( A N D SlDE WINDOW DE-
FOGGERS).

Fig. 5 Heater C o n t r o l - T y p i c a l
1A-4 HEATING AND VENTILATION

1-DEFROSTER OUTLET 7-PURGE DOOR OPENS TO ALLOW 11-AIR DOOR CLOSES OFF HEATER
AIR FLOW INTO CAR UNDER I.P. AND DEFROSTER OUTLETS WHEN
2-BLENDED AIR WHEN SYSTEM SELECTOR LEVER SYSTEM SELECTOR LEVER IS
IS MOVED TO "OFF" MOVED TO "OFF"
3-HEATER CORE
8-UNTEMPERED AIR 12-DEFROSTER DOOR MOVES BY
4-BLOWER OPERATION OF HEATER
9-WARMED AIR CONTROLS SYSTEM SELECTOR
5-DASH PANEL LEVER
10-TEMPERATURE DOOR MOVES BY "ON SOME MODELS ALSO
6-OUTSIDE AIR FROM COWL OPERATION OF TEMPERATURE SUPPLIES SIDE WINDOW
PLENUM CHAMBER LEVER ON HEATER CONTROL DEFOGGING DUCTS. . -.

Fig. 6 Typical Heater System Air Flow

 HEATING AND VENTILATION 1A-5

@ INSUFFICIENT HEATING OR DEFROSTlNG

OF THE HEATER

IF PROBLEM NOT RESOLVED THEN

HECK FOR AIRFLOW OUT DEFROSTER

VENT OUTLETS

INSTALL THE RADIATOR CAP. WITH ENGINE WARM,

DRIVE THE VEHICLE AT 48 KPH(3OMPH).WITH A THER-
MOMETER, CHECK THE AMBIENT AIR TEMPERATURE

CONTINUED AT TOP OF NEXT PAGE

Fig. 7 Insufficient Heating o r Defrosting Diagnosis Procedure ( 7 of 2)

1A-6 HEATING AND VENTILATION

w
CHECK VEHICLE FOR
COLD AIR LEAKS AT DASH,
HEATER CASES AND FROM
VENTS. CHECK TEN FOR DOOR SLAM PRIOR TO THE END
UNDERSEAT FOR
OBSTRUCTIONS.
I

WITH THE BLOWER ON

HIGH, MOVE THE TEMP-
ERATURE LEVER FROM
I FULL HOT TO FULL
CHECK THE TEMPERA- WITH THE TEMPERATURE COLD AND LISTEN FOR
TURE DOOR ADJUSTMENT, DOOR FULL HOT, START THE AIRFLOW CHANGE.
CABLES, LINKAGE AND AD- VEHICLE. CHECK THE TEMPER-
JUST TO FULL HOT. CHECK ATURE OF THE HEATER INLET
AND OUTLET HOSES BY FEEL.
THE AIR TEMPERATURE
AROUND THE HOSES MUST BE
AT LEAST 85OF.

CHECK THE TEMPER-

ATURE DOOR AD-
JUSTMENT, CABLES,
CONTROL, LINKAGE &

BETWEEN THE

COOLANT REPLACE.

Fig. 8 Insufficient Heating or Defrosting Diagnosis Procedure (2 of 2)

 HEATING AND VENTILATION 1A-7

@ BLOWER ELECTRICAL

LOCATE SHORT IN THE

FOLLOWING WIRES:
1. FROM THE FUSE PANEL

2. FROM THE BLOWER

SPEED SWITCH TO THE
HEATER RESISTOR BLOCK.
3. FROM THE HEATER RE-

SISTOR BLOCK. CONNECT A

JUMPER LEAD FROM THE BAT-
TERY POSITIVE TERMINAL TO
ANY WlRE TERMINAL IN THE
CONNECTOR. USE 12 VOLT
TEST LIGHT TO CHECK FOR
VOLTAGE AT THE CORRES-
PONDING WIRE ON THE
BLOWER SPEED SWITCH.
USE THE 12 VOLT REPAIR OPEN IN FEED
TEST LIGHT TO WlRE FROM RESISTOR TO
CHECK THE POWER BLOWER MOTOR.
FEED TERMINAL ON
THE BLOWER
SPEED SWITCH

TEST LAMP DOES

Fig. 9 Blower Electrical Diagnosis

1A-8 HEATIN,G AND VENVILAVIBN

@ IMPROPER AIR DELIVERY OR NO MODE SHlFT

I WITH THE VEHICLE ON AND THE ENGINE WARM, RUN THE FOLLOWING FUNC-
TIONAL CHECKS. CHECK CABLES FOR EXCESSIVE EFFORT OR BINDING.

MODE POWER HEATER DEFR. SIDE

VENT OUTLET OUTLET WINDOW
OUTLET DEFOGGER
OUTLET
VENT
I I
NO
AIRFLOW
NO
AIRFLOW
NO
AIRFLOW No
AIRFLOW I
VENT

HEATER
COLD

COLD
HIGH

HIGH
HIGH

HIGH
AMBIENT
AIRFLOW
NO
NO
AIRFLOW
COLD TO
NO
AIRFLOW
MINIMUM
No
AIRFLOW
MINIMUM
I
TO HOT AIRFLOW HOT COLDTO HOT COLD TO HOT
AIRFLOW AIRFLOW AIRFLOW
DEFROSTER COLD HIGH HIGH N0 MINIMUM COLD TO MINIMUM
TO HOT AIRFLOW COLD TO HOT COLD TO
HOT AIRFLOW
AIRFLOW AIRFLOW

CONNECTED & CABLE SHEATH RETAINED

G20025.1A
Fig. 10 Improper Air Delivery Or No Mode Shift Diagnosis
 HEATING AND VENTILATION 1A-9

@TOO MUCH HEAT

TEMPERATURE LEVER

TO CONTROL END OF

LOW THE ENGINE

PERATURE DOOR TO WARM UP. WITH

TEMPERATURE HEATER DEFROST-

ER & VENT DOOR
BLOWER INLET & REPAIR

Fig. 1 1 Too Much Heat Diagnosis.

 ----

1A-10 HEATING AND VENTILATION

@ CONTROLS
MOVES ON HIGH BLOWER

CHECK CABLES FOR ROUTING, KINKEC CABLES,

WIRING INTERFERENCE OR OTHER INSTRUMENT
PANEL INTERFERENCE. WlTH A LONGER CABLE AND
ADD A LOOP TO THE CABLE
ROUTING TO INCREASE CONTROL
EFFORT, CHECK INSTRUMENT
PANEL INTERFERENCES WlTH
NEW CABLE ROUTING TO INSURE
PROPER OPERATI

REMOVE CABLE
FROM DOOR(S)
CAUSING BINDING
AND CYCLE DOOR()
MANUALLY. CHECK
FOR DOOR BINDING

INSTALLATION

I
SEAL OK

SHAFT ALIGNMENT, BENT

Fig. 12 Heater Controls Diagnosis

 HEATING AND VENTILATION 1A-1 1

~ @ BLOWER NOISE

SIT IN THE VEHICLE WlTH THE DOORS AND WINDOWS CLOSED. WlTH THE IGNITION ON
AND THE ENGINE OFF, START WITH THE BLOWER ON HIGH, IN VENT MODE AND THE
TEMPERATURE LEVER ON FULL COLD. CYCLE THROUGH BLOWER SPEEDS, MODES AND
TEMPERATURE DOOR POSITIONS TO FIND WHERE THE NOISE OCCURS AND WHERE THE

SYSTEMS AND MODES (USUALLY DEFROSTER) MAY BE WORSE THAN OTHERS. CHECK
ANOTHER VEHICLE IF POSSIBLE (SAME MODEL) TO DETERMINE IF THE NOISE IS
TYPICAL OF THE SYSTEM AS DESIGNED.

INDICATE THE TYPE OF NOISE AND WHERE IT OCCURS:

A-WHINE, B-CLICKTTICK, C-SQUEALISCREECH, D-FLUTTER, E-RUMBLE,

F-SCRAPING, G--AIR RUSH, H-OTHER, DESCRIBE
I

BLOWER SPEED REDUC- MAY OCCUR AT COLD AM- DOOR COMBINATIONS BUT CAN

0 CONTINUED AT TOP OF NEXT PAGE

G20009-1A
Fig. 13 Blower Noise Diagnosis ( 1 of 2)
1A-12 HEATING AND VENTILATION

EXAMINE BLOWER FAN FOR WEAR

SPOTS, CRACKED BLADES OR
HUB, LOOSE FAN RETAINING
NUT AND ALIGNMENT. EXAMINE
BLOWER CASE FOR WEAR SPOTS.

ALL MODES
BUT NOT ALL
TEMPERATURE
REPAIRIREPLACE POSITIONS
ASNECESSARY
ANDRECHECK

CHECK SYSTEM
FOR OBSTRUC-
TIONS OR FOREIGN
AND REMOVE. CHECK MATERIALS AND MATERIALS BE-
HEATERIDEFROSTER REMOVE. CHECK NECESSARY AND TWEEN THE FAN
DOOR SEALS. VENT DOOR AND THE TEMPER-
ATURE DOOR.
REMOVE, REPAIR
OR REPLACE AS
NECESSARY AND
RECHECK.

Fig. 14 Blower Noise Diagnosis (2 of 2)

 HEATING AND VENTILATION 1.4-13

ON-VEHICLE SERVICE
HEATER ELECTRICAL WIRING 7. Fully cycle controls to adjust cables and check for
proper operation.
The heater wiring diagrams are shown in
Electrical Diagnosis, Section 8A, and should be HEATER CORE
referred to for diagnosis of electrical problems in the
heater system.
Remove or Disconnect
HEATER CONTROL ASSEMBLY AND BLOWER Battery ground cable.
SWITCH Drain cooling system.
Heater inlet and outlet hoses from heater core.
Remove or Disconnect Right lower hush panel (see Section 8C).
ECM attaching screw and move aside.
1. Negative battery cable. Right lower I.P. trim panel (see Section 8C).
2. Control/radio console trim plate. Lower right I.P. carrier-to-cowl screw.
3. Three (3) controller retaining screws and pull Four (4) heater case cover screws. Upper left screw
controller out from console. may be reached with a long socket extension through
4. Control cables and electrical connections. the I.P. openings exposed by removal of the lower
5 . Blower switch from controller if either switch or right I.P. trim panel. Carefully lift the lower right
controller requires replacement. If controller is corner of the I.P. to align socket extension.
being replaced, transfer blower switch to new Heater case cover.
controller. Core support plate and baffle screws.
Heater core, support plate and baffle from case.
Install or Connect
Install or Connect
1. When installing controller, install lower right
screw first to properly align controller in console. 1. Heater core, support plate and baffle to case.
2. Blower switch to controller. 2. Core support plate and baffle screws.
3. Control cables and electrical connections. 3. Heater case cover.
4. Three (3) controller retaining screws and 4. Four (4) heater case cover screws.
controller to console. 5. Lower right I.P. carrier-to-cowl screw.
5. Control/radio console trim plate. 6. Right lower I.P. trim panel (see Section 8C).
6. Negative battery cable. 7. ECM.
8. Right lower hush panel (see Section 8C).
TEMPERATURE CONTROL, POWER VENT, 9. Heater inlet and outlet hoses to heater core.
HEATER DEFROST CABLE 10. Refill cooling system and check for leaks.
11. Battery ground cable.
Remove or Disconnect VENT CONTROL CABLE (RAM VENT)
1. Hush panel(s) (see Section 8C):
a. Temperature cable - R.H. hush panel.
Remove or Disconnect 1
b. Heateddefrost cable - R.H. hush panel. 1. Hush panel(s) (see Section 8C). R.H. cable
c. Vent cable - L.H. hush panel. replacement will require removal of both L.H.
and R.H. hush panels.
2. Control/radio console trim plate.
2. Two (2) retaining screws and individual vent
3. Three (3) controller retaining screws and pull control.
controller out from console.
3. Unclip cable control clamp at vent duct and
4. Control cable requiring replacement at control disengage formed end of cable from door lever.
end.
1
5 . Cable at mode control end (temperature cable: Install or Connect
remove cable link cover at crank location).
1. Cable control clamp at vent duct and install
Install or Connect formed end of cable on door lever.
2, Two (2) retaining screws and individual vent
1. When installing controller, install right lower control.
screw first to align control in console.
3. Hush panel@) (see Section 8C).
2. Cable at mode control end (temperature cable:
install cable link cover at crank location). 4. Cycle control fully and check for proper
operation.
3. Control cable at control end.
4. Three (3) controller retaining screws and HEATER CONTROL WIRING I

contoller in console.
Remove or Disconnect
5. Control/radio console trim plate.
6. Hush panel(s) (see Section 8C). 1. Negative battery cable.
1A-14 HEATING AND VENTILATION

2. Control/radio console trim plate and hush LOWER (FLOOR) HEATER OUTLET
panels.
3. Three (3) screws holding controller in console Remove or Disconnect
and pull controller out far enough to disconnect
electrical connectors. 1. Console (see Section 8C).
2. L.H. and R.H. hush panels. (see Section 8C).
4. Blower motor and blower resistor electrical 3. Two (2) floor outlet retaining screws.
connections. 4. Floor outlet from core case.
5. Carefully pull cowl grommet from cowl and pull
wiring harness through cowl hole into engine Install or Connect
compartment.
1. Floor outlet to core case.
Install or Connect 2. Two (2) floor outlet retaining screws.
3. L.H. and R.H. hush panels.
1. When reinstalling controller, install lower right 4. Console.
screw first to align controller.
2. Cowl grommet on cowl and wiring harness. BLOWER MOTOR
3. Blower motor and blower resistor electrical
connections. Remove or Disconnect
4. Three (3) screws holding controller in console 1. Negative battery cable.
and connect electrical connectors. 2. Electrical connections at blower motor and
5. Control/radio console trim plate and hush blower resistor.
panels. 3. Blower motor cooling tube.
6. Negative battery cable. 4. Blower motor retaining screws and remove
motor/cage assembly from case.
HEATER/VENTILATION/DEFROSTER DUCTS 5. Holding blower motor cage, remove cage
retaining screw and slide cage from motor shaft.
See section 8C for removal.
Install or Connect
1. Blower motor cage and retaining screw.
2. Blower motor retaining screws and motor/cage
assembly in case.
3. Blower motor cooling tube.
4. Electrical connections at blower motor and
blower resistor.
5. Negative battery cable.
6. Reinstall radio capacitor in proper location, if so
equipped.
 CONTROL HANDLE INSTALLATION

1-UPPER DASH PANEL AND 4-INSTRUMENT PANEL ASSEMBLY 8-VENT DUCT RIGHT-HAND
PLENUM CHAMBER
5-DUCT AND VALVE ASSEMBLY 9-RIGHT-HAND VENT CONTROL
2-CONTROL CABLE ASSEMBLY
LEFT-HAND &VENT DUCT LEFT-HAND 10-LEFT-HAND VENT CONTROL

3-CONTROL CABLE ASSEMBLY 7-STEERING COLUMN COVER

RIGHT-HAND
1A-16 HEATING AND VENTILATION

1-UPPER DASH PANEL AND 6- BO LT/SCREW

PLENUM CHAMBER
7-DUCT AND VALVE ASSEMBLY
2-INSTRUMENT PANEL ASSEMBLY
8-PLENUM CHAMBER
3-EXTENSION - SIDE VENT DUCT 9-FASTENER
4-"U" NUT
10-DUCT AND BAFFLE ASSEMBLY
5-INSU LATOR ASSEMBLY
520052-1A
Fig. 602 Ram Vent System Duct Work
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