1988 pontiac firebird service repair manual by kjsmfmmf

1988

TABLE OF CONTENTS SECTION NAME

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

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

3 4

-- BODY STYLE ASSEMBLY P U N T

-- UNIT NUMBER

-- PAINT TYPE

- ROOF OPTION 6 -- SEAT OPTION

7 8 9 10

- TRIM COMBINATION - UPPER BODY

- UPPER COLOR -- LOWER BODY

- REMAINING LINES

-- 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

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:

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

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

IOU DAY OF THE YEAR1

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

V I N LOCATION

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

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

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

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

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 ,

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

to get equivalent nurnber of:

Multiply

ACCELERATION

LENGTH Inch Foot Yard Mile

to get equivalent number ol:

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

OA-12 GENERAL INFORMATION

DECIMAL AND METRIC EQUIVALENTS Fractions

Decimal In

Metric MM

Fractions

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

Decimal

Metric

In .

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 EMR EOS ESC -

Electromotive Force Electronic M o d u l e Retard Exhaust Oxygen Sensor Electronic Spark Control

APT - Adjustable Part Throttle AT - Automatic Transmission ATC - Automatic Temperature Control ATDC - After Top Dead Center BAR0 Bat.

FMVSS

- Federal Motor Vehicle Safety

Barometric Absolute Pressure Sensor

- Positive Terminal

BHP - Brake Horsepower BP - Back Pressure BTDC - Before Top D e a d Center

Ft. Lb. - Foot Pounds (Torque) FWD - Front Wheel Drive - Four Wheel Drive 4 x 4 - Four Wheel Drive 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

CCOT - Cycling Clutch (Orifice) Tube CCP - Controlled Canister Purge C.E. - Check Engine CEAB - Cold Engine A i r b l e e d CEMF - Counter Electromotive Force CID - Cubic Inch Displacement CLOOp - Closed Loop CLCC - Closed Loop Carburetor Control

CP - Canister Purge Cu. In. - Cubic Inch CV - Constant Velocity Cyl. - Cylinder(s)

IAC - l d l e Air Control IC - Integrated Circuit I D - Identification - Inside Diameter ILC - I d l e Load Compensator I/P- Instrument Panel ISC - I d l e Speed Control

- Kilometers

kmiL - Kilometers Liter (mpg) kPa - Kilopascals

L-4

- Four Cylinder In-Line (Engine)

L-6

DBB - Dual Bed Bead DBM - Dual Bed Monolith DEFl - Digital Electronic Fuel Injection DFI - D i g i t a l Fuel Injection D i f f . Differential Distr. - Distributor

Man. Vac. - M a n i f o l d Vacuum 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 ECC Electronic Comfort Control ECM - Electronic Control M o d u l e

MPG - Miles Per G a l l o n MPH - Miles Per Hour MT - M a n u a l Transmission

LF LR

Six Cylinder In-Line (Engine)

- Left Front - Left Rear

N.m

- Newton Metres (Torque)

Emission Control

Fig. 014-15 -- Common Abbreviations

PAIR - Pulse Air Injection Reaction System P B - Power Brakes PCV - Positive Crankcase Ventilation PECV - Power Enrichment Control Valve

0.4-14 GENERAL INFORMATION

SERVICE P A R E SlDENTlFlGATlON LABEL The Service Parts Identification Label provides identification of vehicle equipment to assist in servicing and determining replacement parts, Included on this label will be regular production options (RPO's) as well as standard and mandatory options. The label will be af-

VEHICLE

fixed to the inside of each passenger car vehicle at the assembly plant. For additional information on the Service Parts Identification Label, see a GM Parts Catalog.

---f lGlAZ3799ER157148

IDENTIFICATION NUMBER

1JD69

A R L A02 A65 BGY B9A B9K C60 D l 0 D35 E5Z E6E E9Z F L T GU1 JM7 <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

EXAMPLE -

BBPBBBBPPB

DIS. LACQUER

WA-L8240

P A I N T TECHNOLO(IY SOLUTION LACOUEH DlSPEHSlON L A C O U E H H I G H SOLIDS E N 4 M E L \VA CERBORNE ENAI.ICL BASECOAT C L C A l 3 C 0 4 T

U8240

A4721

VINYL FOP CCIl.Oli I l F AI'I'LICAHLZI

I'AINT L O U L S APd[J L O L A T I O N S L LfJIVEIi L:C)UY C O L O I I U UPI'CH f!O[IY (,OLCJII 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

I 1lilP.1 ~ , l J P . l l ~ l P l l/O ~ 'J',

BODY TYPE STYLE OPTION CONTENT

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 The maintenance services contained in Schedules I and 11 are based on the assumption that your car will be used as designed: @ To carry passengers and cargo within the limits shown on the Tire Placard located on the edge of the driver's door. @ On reasonable road surfaces within legal driving limits. @ On unleaded gasoline.

EXPLANATION OF SCHEDULED MAINTENANCE SERVICES The services listed in Maintenance Scheduies I and 11 are further explained below. When the following maintenance services are performed, make sure all parts are replaced and all necessary repairs are done before driving your car. Be sure to use the proper fluid and lubricants as shown in Figure OB-2.

ITEM 1 Engine Oil and Oil Filter Change* ALWAYS USE SFICC OR SF/CD ENERGY CONSERVING OILS O F PROPER VISCOSITY - Also. always change oil and filter as soon as possible after driving in a dust storm. See your Owner's Manual for further details.

ITEM 2 Chassis Lubrication Lubricate all grease fittings in suspension and steering linkage. Lubricate transmissionltransaxle shift linkage, parking brake cable guides, underbody contact points and linkage. Also lubricate clutch cross shaft lever every 30,000 miles (50 000 km) on rear-wheel-drive cars only.

ITEM 3 Carburetor Choke and Hoses* If your car is equipped with a carburetor, verify that choke and vacuum break work properly and are within 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.

ITEM 4 Carburetor or Throttle Body Mounting Bolt Torque* Check torque of mounting bolts and/or nuts.

ITEM5 Engine Idle Speed Adjustment* (Engines without Idle Speed Control or Idle Air Control) - Adjust to specifications shown on the underhood label. If no specifications are shown on the label, no adjustment is necessary. Calibrated test equipment must be used.

ITEM 6 ~i~~and wheel aotation To equalize wear and obtain maximum tire life, rotate in accordance with patterns shown in Owner's Manual.

Vacuum or A.I.R. Pump Drive Belt Inspection* When a separate belt is used to drive the vacuum or A.I.R. pump, inspect i t for cracks, fraying, wear and proper tension. Adjust or replace as needed.

ITEM 8 Cooling System Service* Drain, flush and refill system with new coolant. See your Owner's Manual for further details.

ITEM 9 Wheel Bearing Repack (Rear-Wheel-Drive Cars Only Except Corvette) Clean and repack front wheel bearings at each brake relining or 15,000 miles ( 2 5 000 km), whichever comes 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 service, clean and repack bearings at each brake relining or 30,000 miles (50 000 km), whichever comes first. Corvette models do not require wheel bearing repack.

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 conditions: @ When most trips are less than 4 miles (6 kilometers). When most trips are less than 10 miles (16 kilometers) and outside temperatures remain below freezing.

Idling andlor low speed operation in stop-and-go traffic. Towing a trailer. Operating in dusty areas. Schedule I should also be followed if the car is used for delivery service, 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:

*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 maintenance 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 TransmissionRransaxle Service

ITEM 16 Engine Timing Check*

The manual transmission or transaxle fluid does not require changing. (Corvette only.) Change fluid in overdrive unit every 30,000 miles (50 000 km). For automatic transmissions or transaxles, change both the fluid and filter every 15,000 miles (25 000 km) if the car is mainly driven under one or more of these conditions: @ In heavy city traffic where the outside temperature regularly reaches 90Â°F (32Â°C) or higher. @ In hilly or mountainous terrain. @ Frequent trailer pulling. @ Uses such as found in taxi, police car or delivery service. If you do not use your car under any of these conditions, change both the fluid and filter every 100,000 miles (160 000 km). See you Owner's Manual for further details.

Adjust timing to underhood label specifications. If no specifications are shown, no adjustment is needed.

ITEM 11 Spark Plug Service* Replace spark plugs with type listed in your Owner's Manual.

ITEM 12 Spark Plug W i r e Inspection* Clean wires and inspect for burns, cracks or other damage. Check the wire boot fit at distributor and at spark plugs. Replace wires as needed.

ITEM 13 Positive Crankcase Ventilation (PCV) Valve Inspection* Inspect valve for proper function. Replace valve if necessary as well as any worn, plugged or collapsed hoses.

ITEM 14 EGR System Service* Conduct EGR System Service as referenced in the EGR System Chart shown in the appropriate 6E Section. Also, refer to your GM maintenance schedule booklet for specific applications.

ITEM 15 Air Cleaner and PCV Filter Replacement* On 1.6 and 2.0 liter engines, replace every 50,000 miles (80 000 km). On all other engines, replace every 30,000 miles (50 000 km). Replace more often under dusty conditions. Ask your dealer for the proper replacement interval for your driving conditions. *An Emission Control Service

ITEM 17 Fuel Tank, Cap and Lines Inspection* Inspect fuel tank, cap and lines (including fuel rails and injection assembly, if so equipped) for damage or leaks. Inspect fuel cap gasket for an even filler neck imprint or any damage. Replace parts as needed.

ITEM 18 Thermostatically Controlled Air Cleaner Inspection* If your car is equipped, inspect all hoses and ducts for proper hookup. Make sure valve works properly.

OWNER INSPECTIONS AND SERVICES Listed below are inspections and services which should be made by either you or a qualified technician at the intervals shown to help ensure proper safety, emission performance and dependability of your car. Take any problems promptly to your dealer or another qualified technician for service advice. Whenever repairs are necessary, have them completed at once. For your safety and 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. Be sure to use the proper fluids and lubricants as shown in Figure OB-2.

WHILE OPERATING YOUR VEHICLE Automatic transmissionltransaxle shift indicator operation -Make sure the indicator points to the gear chosen. Horn operation - Blow the horn occasionally to make sure it works. Check all button locations. I

Brake system operation -- Be alert to abnormal sounds, increased brake pedal travel or repeated pulling to one side when braking. Also, if a brake warning light comes on or flashes, or the anti-lock warning light (if equipped) comes on or remains on, something may be wrong with part of the brake system. Have it inspected and repaired at once. Exhaust system operation - Be alert to any changes in the sound of the system or any smell of fumes. These are signs the system may be leaking or overheating. . Have it inspected and repaired at once. Also see "Engine Exhaust Gas Caution (Carbon Monoxide)" and "Catalytic Converter" in your Owner's Manual.

OB-4MAINTENANCE AND LUBRICATION Tire and wheel operation - Be alert to a vibration of the steering wheel or seat at normal highway speeds. This may mean a wheel balance is needed. Also, a pull right or left on a straight, level road may show the need for a tire pressure adjustment or wheel alignment. Steering system operation - Be alert to changes in steering action. An inspection is needed when the steering wheel is harder to turn or has too much free play or if unusual sounds are noted when turning or parking. Headlight aim operation - Take note of light pattern occasionally. If beam aim doesn't look right, headlights should be adjusted.

AT EACH FUEL FILL Engine oil level check - Check engine oil level and add if necessary. See your Owner's Manual for further details. NOTICE: A large loss in this system may indicate a problem. Have it inspected and repaired at once. Engine coolant level and condition - Check engine coolant level in coolant reservoir tank and add if necessary. Replace if dirty or rusty. See your Owner's Manual for further details. NOTICE: A large loss in this system may indicate a problem. Have it inspected and repaired at once. Windshield washer fluid level check -- Check washer fluid level in container and add if necessary. 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 opening all the way when primary latch is released. Make sure that hood closes firmly.

AT LEAST MONTI-ILY Tire and wheel inspection and pressure check-- Check tires for abnormal wear or damage. Also, check for damaged wheels. Keep pressures as shown on 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. Light operation check - Check operation of license plate light, side-marker lights, headlights including high beams, parking lights, taillights, brake lights. turn signals, backup lights, instrument panel and interior lights and hazard warning flashers. Fluid leak check - After the car has been parked for a while, inspect the surface beneath the car for water, oil, fuel or other fluids. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, the cause should be found and corrected at once.

AT LEAST TWICE A YEAR (FOR EXAMPLE, EVERY SPRING AND FALL) Power steering pump fluid level check -Check power steering pump fluid level in accordance with Owner's Manual instructions and keep at proper level.

NOTICE: A large loss in this system may indicate a problem. Have it inspected and repaired at once. Brake master cylinder reservoir fluid level check ----Check fluid and keep at proper level. Note: It is normal for the brake fluid level to go down slightly as the brake pads wear - so be sure to keep reservoir filled. NOTICE: A large loss in this system may indicate a problem. Have it inspected and repaired at once. Clutch system service --- manual transmissionltransaxle --- For cars equipped with hydraulic clutch system, check the reservoir fluid level and add fluid as required. All others, check clutch pedal free travel and adjust as necessary. See your Owner's Manual for further details. NOTICE: A large loss in this system may indicate a problem. Have it inspected and repaired at once. Weatherstrip Lubrication - Clean surface and then apply a thin film of silicone grease with a clean cloth.

EACH TIME OIL IS CHANGED Automatic and manual transmissionltransaxle fluid level check - Check transmission/transaxle fluid level and add as required. (Corvette only) if equipped with manual transmission - check fluid in the overdrive unit and add as required. NOTICE: A large loss in this system may indicate a problem. Have i t inspected and repaired at once. Brake systems inspection - For convenience, the following should be done when wheels are removed for rotation: Inspect lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc. Inspect disc brake pads for wear and rotors for surface condition. Also inspect drum brake linings for wear and cracks. Inspect other brake parts, including drums, wheel cylinders, parking brake, etc. at the same time. Check parking brake adjustment. INSPECT BRAKES MORE OFTEN IF DRIVING HABITS OR CONDITIONS RESULT I N FREQUENT BRAKING. Steering, suspension and front drive axle boot and seal inspection - Inspect front and rear suspension and steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect power steering lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc. (On cars equipped with manual steering gear, check for seal leakage.) On frontwheel-drive cars, clean then inspect drive axle boot seals for damage, tears or leakage. Replace seals if necessary. Exhaust system inspection - Inspect complete system. Inspect body near the exhaust system. Look for broken, damaged, missing or out-of-position parts as well as open seams, holes, loose connections or other conditions which could cause a heat buildup in the tloor pan or could let exhaust fumes seep into the trunk or passenger compartment.

MAINTENANCE AND LUBRICATION OB-5

Throttle linkage inspection -- Inspect for interference, binding, damaged or missing parts. Engine drive belts inspection - Inspect all belts for cracks, fraying and wear. Adjust or replace as needed. Rear axle service (if equipped) - Check gear lubricant level and add if needed. For cars equipped with a limited slip rear axle, fluid does not require changing (except Caprice and Corvette -change fluid and required additive at first 7,500 miles (12 500 km). See your Owner's Manual or "Recommended Fluids & Lubricants Chart" in this section. IF YOU USE YOUR GAR TO PULL A TRAILER, CHANGE GEAR LUBRICANT EVERY 7,500 MILES (12 500 KM). NOTICE: A large loss in this system may indicate a problem. Have it inspected and repaired at once. Power antenna -Clean and then lubricate power antenna mast. The proper lubricant as shown in Figure OB-2 should be used.

AT LEAST ONCE A YEAR Lap and shoulder belts condition and operation - Inspect belt system, including webbing, buckles, latch plates, retractors, guide loops and anchors. Moveable head restraint operation -On cars with moveable restraints, make sure restraints stay in the desired position. (See adjustment instructions in your Owner's Manual.) Seatback latch and recliner operation o n cars equipped with recliner seat --- Be sure seatbacks latch on those cars with folding seats using mechanical latches. Make sure the recliner is holding by pushing and pulling on the top of the seatback while it is reclined. See your Owner's Manual for seat operating information. Spare tire and jack storage- Be alert to rattles in rear of car. Make sure the space tire, all jacking equipment, any tire inflator and any covers or doors are securely stowed at all times. Oil jack ratchet or screw mechanism after each use. Key lock service - Lubricate key lock cylinder at least annually. Body lubrication service - Lubricate all body door hinges including the tailgate or hatchback lid (if equipped). Also lubricate the body hood, fuel door and rear compartment hinges and latches including interior glove box and counsel doors, and any folding seat hardware. "Fansmissionltransaxle n e u t r a l o r c l u t c h starl switch operation CAUnON: Before pedorming t h e following safety switch check, b e sure t o have enough r o o m around t h e car. Then, firmly apply b o t h t h e parking brake (see your Owner's Manual for procedure) and t h e regular brakes. Do n o t use t h e accelerator

pedal. If t h e engine starls, b e ready t o t u r n off t h e ignition promptly. Take these prec a u t i o n s because t h e car c o u l d m o v e w i t h o u t warning and possibly cause personal injury or properly damage. O n automatic transmissionltransaxle cars, t r y t o s t a r l t h e engine in each gear. The starler should crank only i n "Park" or "Neutral." O n manual transmissionltransaxle cars, place t h e shiR lever in "Neutral," push t h e clutch halfway and t r y t o starl. The starler should crank only w h e n t h e clutch is fully depressed. Steering c o l u m n lock operation - While parked, try to turn key to "Lock" in each gear range. The key should turn to "Lock" only when gear is in "Park" on automatic or "Reverse" on manual transmissionltransaxle. On cars with key release lever, try to turn key toULock" without depressing the lever. The key should turn to "Lock" only with the key lever depressed. On all vehicles, the key should come out only in "Lock." Parking brake and transmissionltransaxle "Park" mechanism operation CAUT1ON:Before checking t h e holding ability of t h e parking brake and automatic transmissionltransaxle "Park" mechanism, p a r k o n a f a i r l y steep h i l l w i t h enough r o o m for movement i n the d o w n hill direction. To reduce t h e risk of personal injury or property damage, b e prepared t o apply t h e regular brakes promptly if the car begins t o move. To check the parking brake, with the engine running and transmission/transaxle in "Neutral." slowly remove foot pressure from the regular brake pedal (until the car is held by only the parking brake). To check the automatic transmissionltransaxle "Park" mechanism holding ability, release all brakes after shifting the transmissionltransaxle to "Park." ljnderbody flushing - At least every spring, tlush from the underbody with plain water any corrosive materials used for ice and snow removal and dust control. Take care to thoroughly clean any areas where mud and other debris can collect. Sediment packed in closed areas of the vehicle should be loosened before being flushed. Engine cooling system service - Inspect coolant and freeze protection. If dirty or rusty, drain, flush and refill with new coolant. Keep coolant at the proper mixture as specified in your Owner's Manual. This provides proper freeze protection. corrosion inhibitor level and engine operating temperature. Inspect hoses and replace if cracked. swollen or deteriorated. Tighten hose clamps. Clean outside of radiator and air conditioning condensor. Wash radiator filler cap and neck. To help ensure proper operation. a pressure test of both the cooling system and cap is also recommended. (See maintenance schedule charts in Figure OB-l for the recommended coolant change interval.)

NOTE: Fluids and lubricants identified below by name, part number or specification may be obtained from your GM dealer.

FLUlDlLUBRlCANT

USAGE 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) Automatic Transrn~ssionRransaxleand 5 Speed Manual Transm~ss~ons

Use lubricant meetlng requirements of GM-4673M (GM Part No 1052182)

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 Power Antenna Mast (3-mast sect~on-typeonly)

Eng~ne011

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 b) Release Pawl

DEXR0N'-II Automat~cTransm~ss~on Flu~d(GM Part No 1051855) Camaro and Flreblrd (5 Speed)

Llght 011(GM Part No 1052949)

a) Eng~ne011 b) Chass~sgrease meet~ngrequirements of GM.6031M (GM Part No 1052497)

Front Wheel Bearings (rearqwheel-drive) Hood and door hlnges, statlon wagon tailgate hlnge or hatchback Ild and Ilnkage, headl~ghtdoor assembl~es,statlon wagon rear foldrng seat, fuel door hlnge, rear compartment Ihd hlnges

Lubricant GM Part No 1051344 grease or equivalent

Weatherstr~ps

S~l~cone Grease (GM Part No 1052863) or equivalent

Eng~ne011

Figure 00-2Recommended Fluids and Lubricants

HEATING AND VENTILATION 1A-1

SECTION

NG AND VENT CONTENTS General Description ................................. 1A-1 Diagnosis - Heater Trouble ...................... 1A-5 Insufficient Heating or Defrosting .............. 1A-5 Blower Electrical ......................................... 1A-7 Improper Air DeliveryINo Mode Shift ....... 1 A-8 Too Much Heat .......................................... 1A-9 Controls ....................................................... 1A-10 Blower Noise ............................................... 1A-11

On-Vehicle Sewice ....................................... 1A-13 Heater Control Assembly ..........................1A- 13 Blower Switch .......................................1A-13 Temperature Cable ..................................1A- 13 Heater Core ..........................................1A- 13 Vent Control Cable .................................1A- 13 Lower Heater Outlet ................................1A-14 Blower Motor ........................................1A-14

GENERAL DESCRIPTION The base heater system is designed to provide heating, ventilation, windshield defrosting and on some cars, side window defogging. Ram air ventilation is provided on some cars by two (2) outboard vent valves installed in the plenum. These vent valves are controlled by push-pull controls mounted in the instrument panel. When either of these valves are opened, air will enter the passenger compartment from the pressurized plenum and be directed to the floor of the vehicle.

& /

VENTILATION

1-FRONT INLET GRILLE 2-BODY LOCK PILLAR EXHAUST VALVE

Fig. 2 Interior Body Air & Exit - Typical Hatchback Models

The power-vent, heat, and defrost provisions of the base system are controlled within the heater module. The module itself is composed of two (2) components - a blower air inlet and a heater defroster. The blower air inlet is mounted to the front of the cowl and the heater defroster assembly is mounted to the rear of the cowl. A gasket is used between the two to prevent air, water and noise entrance into the passenger compartment. Air distribution is through a 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 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 control head is cycled through its full range of travel, the cable clip will assume a position assuring that the temperature valve will seat in both extreme positions. The vent and/or defrost cables also have the

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 all modes (VENT, HEAT, DEFROST) by the switch on the control head. The power-vent ventilation feature is available in the vent mode. Outside air enters the plenum and is driven by the blower to the temperature valve. In the cold position of the temperature valve, air bypasses the heater core to the vent valve opening and enters the passenger compartment through the vent duct and outlets in the center of the instrument panel. If some heated air is desired, the temperature valve may be opened. This allows mixed (tempered) air to flow out the center vent opening. Blending air between modes can be done by varying the mode selector. Varying the selector between "Heat" and "Defrost" will allow more air or less air to be directed out either the defroster outlet or the heater outlet. The closer the mode selector is positioned to the "Heater" position, the larger the amount of air coming out the heater outlet. The closer the mode selector is positioned to "Defrost," the larger the amount of air going to the windshield. The temperature of this air is governed by the temperature lever position.

Side window defogging, if so equipped, is provided via ducts in the outboard corners of the instrument panel. Maximum air flow from these vents will be in "Heater" mode with reduced air flow in "Defrost" mode. Varying the mode selector between "Heater" and "Vent" positions varies the proportion of air coming out the heater outlet and the center vent outlets. With the selector in some midway position, air coming out the center vent outlets will be ambient temperature, while air out the heater outlet will be mixed warm air, its temperature depending on temperature lever position. In the heat and defrost mode, outside air is driven by the blower to the temperature valve which, depending upon its position as controlled by the operator, distributes all or some portion of the inlet air through the heater core. The vent valve will prevent air entry into the vent duct and direct this ambient air to the mix portion of the heater module. The air is thus heated, mixed, and then directed into either the defroster duct or the heater outlet by the position of the mode valve and control lever. A small amount of air is bled to the side window defogger system.

HEAPING AND VENTILA"T0N 1A-3

1, LEFT AND RIGHT SIDE WINDOW DEFOG OUTLETS* 2. LEFT AND RIGHT DEFROSTER OUTLETS

3. POWER VENTIHEAT OUTLETS 4. RAM AIR VENT CONTROLS*

5. LEFT AND RIGHT RAM AIR VENT OUTLETS*

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 TO FLOOR OUTLET. ( A D D I T I O N A L VENTED AIR CAN BE DISTRIBUTED INSIDE CAR BY OPERATING VENT KNOBS.) 2-POSITION OF THIS SYSTEM SELECTOR LEVER DETERMINES AIR FLOW FROM FLOOR, INSTRUMENTPANEL OR WINDSHIELD OUTLET - I N "HEATER", FLOW IS ABOUT 80% TO FLOOR AND 20% TO WINDSHIELD OUTLETS ( A N D SlDE WINDOW DEFOGGERS).

3-THIS POSITION ALLOWS ABOUT 80% AIR FLOW TO WINDSHIELD AND 20% TO FLOOR. 4-TEMPERATURE LEVER POSITION WILL REGULATE OUTLET AIR TEMPERATURE BY BLENDING THE INCOMING OUTSIDE A I R THROUGHIAROUND THE HEATER CORE. 5-THE FAN CONTROL LEVER (OFF - H I ) PRO. VIBES SPEED CONTROL OF THE FAN.

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 2-BLENDED AIR

7-PURGE DOOR OPENS TO ALLOW AIR FLOW INTO CAR UNDER I.P. WHEN SYSTEM SELECTOR LEVER IS MOVED TO "OFF"

11-AIR DOOR CLOSES OFF HEATER AND DEFROSTER OUTLETS WHEN SYSTEM SELECTOR LEVER IS MOVED TO "OFF"

8-UNTEMPERED AIR

12-DEFROSTER DOOR MOVES BY OPERATION OF HEATER CONTROLS SYSTEM SELECTOR LEVER "ON SOME MODELS ALSO SUPPLIES SIDE WINDOW DEFOGGING DUCTS. . -.

3-HEATER CORE 4-BLOWER 9-WARMED AIR 5-DASH PANEL 6-OUTSIDE AIR FROM COWL PLENUM CHAMBER

10-TEMPERATURE DOOR MOVES BY OPERATION OF TEMPERATURE LEVER ON HEATER CONTROL

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 THERMOMETER, 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 UNDERSEAT FOR OBSTRUCTIONS.

TEN FOR DOOR SLAM PRIOR TO THE END

CHECK THE TEMPERATURE DOOR ADJUSTMENT, CABLES, LINKAGE AND ADJUST TO FULL HOT. CHECK

WITH THE TEMPERATURE DOOR FULL HOT, START THE VEHICLE. CHECK THE TEMPERATURE OF THE HEATER INLET AND OUTLET HOSES BY FEEL. THE AIR TEMPERATURE AROUND THE HOSES MUST BE AT LEAST 85OF.

WITH THE BLOWER ON HIGH, MOVE THE TEMPERATURE LEVER FROM FULL HOT TO FULL COLD AND LISTEN FOR AIRFLOW CHANGE.

CHECK THE TEMPERATURE DOOR ADJUSTMENT, 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-

USE THE 12 VOLT TEST LIGHT TO CHECK THE POWER FEED TERMINAL ON THE BLOWER SPEED SWITCH

REPAIR OPEN IN FEED WlRE FROM RESISTOR TO BLOWER MOTOR.

TEST LAMP DOES

Fig. 9 Blower Electrical Diagnosis

SISTOR BLOCK. CONNECT A JUMPER LEAD FROM THE BATTERY POSITIVE TERMINAL TO ANY WlRE TERMINAL IN THE CONNECTOR. USE 12 VOLT TEST LIGHT TO CHECK FOR VOLTAGE AT THE CORRESPONDING WIRE ON THE BLOWER SPEED SWITCH.

1A-8 HEATIN,G AND VENVILAVIBN

@ IMPROPER AIR DELIVERY OR NO MODE SHlFT

WITH THE VEHICLE ON AND THE ENGINE WARM, RUN THE FOLLOWING FUNCTIONAL CHECKS. CHECK CABLES FOR EXCESSIVE EFFORT OR BINDING.

MODE

POWER VENT OUTLET

HEATER OUTLET

VENT

NO AIRFLOW AMBIENT AIRFLOW NO AIRFLOW

NO AIRFLOW NO AIRFLOW COLD TO HOT AIRFLOW MINIMUM COLD TO HOT AIRFLOW

VENT

COLD

HIGH

HEATER

COLD TO HOT

HIGH

DEFROSTER

COLD TO HOT

HIGH

N0 AIRFLOW

DEFR. OUTLET

SIDE WINDOW DEFOGGER OUTLET

NO No AIRFLOW AIRFLOW NO No AIRFLOW AIRFLOW MINIMUM MINIMUM COLDTO HOT COLD TO HOT AIRFLOW AIRFLOW MINIMUM COLD TO COLD TO HOT 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 TO WARM UP. WITH

PERATURE DOOR

TEMPERATURE

HEATER DEFROSTER & 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(ยง) 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

BLOWER SPEED REDUC-

MAY OCCUR AT COLD AM-

DOOR COMBINATIONS BUT CAN

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 POSITIONS

REPAIRIREPLACE ASNECESSARY ANDRECHECK

AND REMOVE. CHECK HEATERIDEFROSTER DOOR SEALS.

MATERIALS AND REMOVE. CHECK VENT DOOR

NECESSARY AND

Fig. 14 Blower Noise Diagnosis (2 of 2)

CHECK SYSTEM FOR OBSTRUCTIONS OR FOREIGN MATERIALS BETWEEN THE FAN AND THE TEMPERATURE DOOR. REMOVE, REPAIR OR REPLACE AS NECESSARY AND RECHECK.

HEATING AND VENTILATION 1.4-13

ON-VEHICLE SERVICE HEATER ELECTRICAL WIRING The heater wiring diagrams are shown in Electrical Diagnosis, Section 8A, and should be referred to for diagnosis of electrical problems in the heater system.

7. Fully cycle controls to adjust cables and check for proper operation.

HEATER CORE Remove or Disconnect

HEATER CONTROL ASSEMBLY AND BLOWER SWITCH

Battery ground cable. Drain cooling system. Heater inlet and outlet hoses from heater core. Right lower hush panel (see Section 8C). ECM attaching screw and move aside. Right lower I.P. trim panel (see Section 8C). Lower right I.P. carrier-to-cowl screw. Four (4) heater case cover screws. Upper left screw may be reached with a long socket extension through the I.P. openings exposed by removal of the lower right I.P. trim panel. Carefully lift the lower right corner of the I.P. to align socket extension. Heater case cover. Core support plate and baffle screws. Heater core, support plate and baffle from case.

Remove or Disconnect

1. Negative battery cable. 2. Control/radio console trim plate. 3. Three (3) controller retaining screws and pull controller out from console. 4. Control cables and electrical connections. 5 . Blower switch from controller if either switch or controller requires replacement. If controller is being replaced, transfer blower switch to new controller. Install or Connect 1. When installing controller, install lower right screw first to properly align controller in console. 2. Blower switch to controller. 3. Control cables and electrical connections. 4. Three (3) controller retaining screws and controller to console. 5. Control/radio console trim plate. 6. Negative battery cable.

TEMPERATURE CONTROL, POWER VENT, HEATER DEFROST CABLE Remove or Disconnect 1. Hush panel(s) (see Section 8C): a. Temperature cable - R.H. hush panel. b. Heateddefrost cable - R.H. hush panel. c. Vent cable - L.H. hush panel. 2. Control/radio console trim plate. 3. Three (3) controller retaining screws and pull controller out from console. 4. Control cable requiring replacement at control end. 5 . Cable at mode control end (temperature cable: remove cable link cover at crank location).

Install or Connect

1. When installing controller, install right lower screw first to align control in console. 2. Cable at mode control end (temperature cable: install cable link cover at crank location). 3. Control cable at control end. 4. Three (3) controller retaining screws and contoller in console. 5. Control/radio console trim plate. 6. Hush panel(s) (see Section 8C).

Install or Connect 1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11.

Heater core, support plate and baffle to case. Core support plate and baffle screws. Heater case cover. Four (4) heater case cover screws. Lower right I.P. carrier-to-cowl screw. Right lower I.P. trim panel (see Section 8C). ECM. Right lower hush panel (see Section 8C). Heater inlet and outlet hoses to heater core. Refill cooling system and check for leaks. Battery ground cable.

VENT CONTROL CABLE (RAM VENT) Remove or Disconnect

1. Hush panel(s) (see Section 8C). R.H. cable replacement will require removal of both L.H. and R.H. hush panels. Two (2) retaining screws and individual vent 2. control. 3. Unclip cable control clamp at vent duct and disengage formed end of cable from door lever. Install or Connect

1. Cable control clamp at vent duct and install formed end of cable on door lever. 2, Two (2) retaining screws and individual vent control. 3. Hush panel@) (see Section 8C). 4. Cycle control fully and check for proper operation.

HEATER CONTROL WIRING Remove or Disconnect 1. Negative battery cable.

1A-14 HEATING AND VENTILATION

Control/radio console trim plate and hush panels. 3. Three (3) screws holding controller in console and pull controller out far enough to disconnect electrical connectors. 4. Blower motor and blower resistor electrical connections. 5. Carefully pull cowl grommet from cowl and pull wiring harness through cowl hole into engine compartment.

Install or Connect

1. When reinstalling controller, install lower right screw first to align controller. 2. Cowl grommet on cowl and wiring harness. 3. Blower motor and blower resistor electrical connections. 4. Three (3) screws holding controller in console and connect electrical connectors. 5. Control/radio console trim plate and hush panels. 6. Negative battery cable.

HEATER/VENTILATION/DEFROSTER DUCTS See section 8C for removal.

LOWER (FLOOR) HEATER OUTLET Remove or Disconnect

1. 2. 3. 4.

Console (see Section 8C). L.H. and R.H. hush panels. (see Section 8C). Two (2) floor outlet retaining screws. Floor outlet from core case. Install or Connect

1. Floor outlet to core case.

2. Two (2) floor outlet retaining screws. 3. 4.

L.H. and R.H. hush panels. Console.

BLOWER MOTOR Remove or Disconnect

1. Negative battery cable. 2. Electrical connections at blower motor and blower resistor. 3. Blower motor cooling tube. 4. Blower motor retaining screws and remove motor/cage assembly from case. 5. Holding blower motor cage, remove cage retaining screw and slide cage from motor shaft. 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 PLENUM CHAMBER 2-CONTROL CABLE ASSEMBLY LEFT-HAND 3-CONTROL CABLE ASSEMBLY RIGHT-HAND

4-INSTRUMENT PANEL ASSEMBLY

8-VENT DUCT RIGHT-HAND

5-DUCT AND VALVE ASSEMBLY

9-RIGHT-HAND VENT CONTROL

&VENT DUCT LEFT-HAND 7-STEERING COLUMN COVER

10-LEFT-HAND VENT CONTROL

1A-16 HEATING AND VENTILATION

1-UPPER DASH PANEL AND PLENUM CHAMBER 2-INSTRUMENT PANEL ASSEMBLY 3-EXTENSION

- SIDE VENT DUCT

4-"U" NUT

6- BO LT/SCREW

7-DUCT AND VALVE ASSEMBLY 8-PLENUM CHAMBER 9-FASTENER 10-DUCT AND BAFFLE ASSEMBLY

5-INSU LATOR ASSEMBLY 520052-1A

Fig. 602 Ram Vent System Duct Work

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