Pontiac Firebird 1988, Trans Am 1988 User Manual

1988

SER

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.

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.

PONTIAC DIVISION

GENERAL MOTORS CORPORATION

PONTIAC, MICHIGAN 48053

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 electronic, 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 in Canada

TABLE OF CONTENTS

SECTION NAME

GENERAL INFORMATION

OA. General lnformation

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
5B1.	Disc r rake Caliper ~ s s e m b l y-
	300013100 Series
5B6.	Disc Brake Caliper Assembly - 3548
	Series
5C3.	Direct Torque Drum Brake Assembly
5D2.	Power Head Assembly - Tandem
	Diaohraam
5F.	~ ~ e c i f i c a t i o ands Special Tools
ENGINE
6.	Engine General lnformation
6A2.	2.8L
6A3.	5.OL & 5.7L
6B.	Engine Cooling
6C.	E n ~ i n Fuel
6D.	~ n g i n Electrical
6D1.	Battery
6D2.	Cranking System
6D3.	Charging System
6D4.	Ignition System
6D5.	Engine Wiring
6E.	Driveabilitv and Emissions
6E2.	~ m i s s i o n s '
6E3.	Emissions - PFI
6F.	Engine Exhaust

TRANSMISSION

7A. 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

CHASSIS ELECTRICAL

8A. Electrical Diagnosis

8B. Lighting and Horns

8C. Instrument Panel, Gages & Console

8E. Windshield Wiper &Washer System

ACCESSORIES

9A. Radio Systems and Antennas

9B. Cruise Control

9G. Miscellaneous Accessories

I BODY SERVICE MANUAL

1 SECT.

END OF MANUAL

CAUTION

To reduce the 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 with one of the same part number or with an equivalent part. Do not use a replacement part of lesser quality.

The service procedures recommended and described in this service manual are effective methods of performing service and repair. Some of these procedures require the use of tools specially designed for the purpose.

Accordingly, anyone w h o intends t o use a replacement part, service procedure or tool, which is not recommended by the vehicle manufacturer, must first determine that neither his safety nor the safe operation of the vehicle will be jeopardized by the replacement part, service procedure or tool selected.

It is important t o note that this manual contains various 'Cautions' and 'Notices'that must be carefully observed in 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' arenot exhaustive, because it is impossible t o warn of all the 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	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. Detailed specifications on major units are given at the end of each respective section of this manual.

BODY NUMBER PLATE

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.

VEHICLE IDENTIFICATION NUMBER

The Vehicle Identification Number (VIN) Plate is located on top of the instrument panel at the lower

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.

METRIC FASTENERS

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

1 -- BODY STYLE

2ASSEMBLY 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

VIN NUMBER PLATE

LOCATION

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

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 1 4 x 2

PREVAILING TORQUE FASTENERS

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

I

I

6 0 0 0	S I E
6 0 0 0	STE
T r a n s	Am
G r a n d	P r l x
G r a n d	P r l x LE

G . P . B r o u g h a m

B o n n e v l i l e

B o n n e v l l l e L E

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

S e d , i n	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 Nott'I~L, . ~ck
c'<jupc	2	1101)r Nuti.Ill,.ick
S t a t l o n		W ~ q u n 4		Uc,or
C o u p e	1	l > t i ~ >Nr o t c h b d c k			S p r c l d l
C o u p e	2	D o o r C o n v e r t ~ b l r
S c d . l n	4	D o o r	b W ~ n d o w P l a l l i B a c k
S c d . j n	4	Uui,r	4	Wl,idir,r	N u t c h b d c k

M a n u a l	B e l t s
M a n u d i B e l t s		W l t h B u l l t - I n S d f r t y

b l a i i u a l B e l t s V l t l i B u l l t - I n S a f e t y ( D r l v r r O n l y )

GENERAL INFORMATION OA-3

PLANT CODE

GM	PLANT CODES
LV . 1 . N .	POSITION $ 1 1 )
	L a k r w o o d
	L a n s l n q	B
	N o r w o o d
	P o n t l a c
	T a r r y t o w n
	W1:low	Run

S t . T h e r e s e

L o r d s t o w n

( V . I . N . POSITION $ 8 )

CARBURETION	I

MPFI T u r b o

Fig. 3 Vehicle Identification Number Data

OA-4 GENERAL INFORMATION

VEHICLE COMPONENT IDEN"IIFICA"T0N NUMBER LOCATION

Refer to 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

ISHIFT BUILT	1
1A & B = FIRST SHIFT
C 5 H - SECOND SHIFT

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

V I N LOCATION

I

OPTIONAL V I N LOCATION --I

Fig. OA-6 --Transmission VIN Location

LUBRICATION POINTS

ENGINE COMPARTMENT

CHASSIS - SEE

MAINTENANCE SCHEDULE ENGINE OIL AND FILTER COOLING SYSTEM

WHEEL BEARINGS

AUTO TRANSMISSION FLUID

I

LOWER CONTROL ARM BALL JOINTS

I I

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'sManual.

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~duel 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 custom-

ary nuts. bolts and screws in the Inch system M~smatchedo r Incorect nut5, bolt5 and screu s 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 ~ was done to reduce the number of srzes used and yet retarn the best

strength character~st~cInseach thtead size. For example. the customary 114-20and 1/4-28screws are replaced by the metrlc M6.3 x I screw w h ~ c hhas nearly the same d~amete rand 25.4 threads per inch. The thread p ~ t c h

I S 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~amete r
~n inches	rn M~ll~meter s

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~na lparts 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

I

WASHER

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'FFASTENER OF

EQUAL OR GREATER STRENGTH).

5 . TIGHTEN TO TORQUE SPECIFIED IN SERVl('kMANl'AL ,

I

OA-10 GENERAL INFORMATION

METRIC BOLT AND NUT IDENTIFICATION

Common metric fastener strength property classss are 9.8 and 10.9 with the clers idsntifica$ion embossed on the haad of each bolt. Customary (inch) strength clases range from grade 2 to 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 (~nch)bolts - ldent~f~cat~onmarks correspond to bolt strength - lncreas~ngnumbers represent lncreaslng strength.

Metr~cBolts - ldent~f~cat~onclass numbers correspond to bolt strength - lncreas~ngnumbers represent lncreaslng strength.

MANUFACTURERS	NUT STRENGTH
IDENTIFICATION	IDENTI FlCATlON

POSlDRlV

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

Multiply

Inch

Foot

Yard

Mile

Quart

Gallon

Yard3

Pound

Ton

Ton

Kilogram

Ounce

Pound

Degree Fahrenheit

SI METRIC-CUSTOMARYCONVERSION TABLE

	to get equivalent
by	nurnber of:
LENGTH
	millimeters (mm)
	meters (m)
	meters
	kilometers (km)
AREA
	millimeters2 (mm2)
	centimeters2 (cm2)
	meters' (m2)
	meters2
VOLUME
	mm3
	cm3
	liters (I)
	liters
	liters
	meters3 (ma)
MASS
	kilograms (kg)
	kilograms (kg)
	tonne (t)
FORCE
	newtons (N)
	newtons
	newtons
TEMPERATURE
	degree Celsius (C)

		to get equivalent
Multiply	by	number ol:
	ACCELERATION
	TORQUE
		newton-meters (N-m)
		newton-meters
	POWER
Horsepower
	PRESSUREOR STRESS
Inches of mercury	3.377	kilopascals (kPa)
Poundslsq. in.	6.895	kilopascals
	ENERGY OR WORK
BTU		joules (J)
Foot-pound		joules
Kilowatt-hour		joules (J = one W's)
Foot candle
	FUEL PERFORMANCE
Mileslgal		kilometerslliter (km/l)
Gallmile		literslkilometer (Ilkm)
	VELOCITY
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 - Axial 6 Cyl. A C Compressor

AIC - Air Conditioning

ACC - Auto'matic Climate Control

				EMF -		Electromotive Force
				EMR - Electronic Module Retard
				EOS - Exhaust Oxygen Sensor
				ESC - Electronic Spark Control
	APT - Adjustable Part Throttle
	AT -	Automatic Transmission
	ATC - Automatic Temperature Control
	ATDC -		After Top Dead Center
	BAR0 - Barometric Absolute Pressure Sensor			FMVSS - Federal Motor Vehicle Safety
				Ft. Lb. - Foot Pounds (Torque)
	Bat. + - Positive Terminal
				FWD -		Front Wheel Drive
	BHP - Brake Horsepower				-	Four Wheel Drive
				4 x 4 -		Four Wheel Drive
	BP -	Back Pressure
	BTDC -		Before Top Dead Center	HD -	Heavy Duty
	Cat. Conv. - Catalytic Converter			HE1 - High Energy Ignition
	CC -	Catalytic Converter
	-	Cubic Centimeter
	-	Converter Clutch
	CCC -		Computer Command Control
				HVM - Heater-Vent-Module
	CCOT - Cycling Clutch (Orifice) Tube			IAC - l d l e Air Control
				IC -	Integrated Circuit
	CCP - Controlled Canister Purge			I D -	Identification
	C.E. - Check Engine			-	Inside Diameter
	CEAB - Cold Engine Airbleed			ILC - Idle Load Compensator
	CEMF - Counter Electromotive Force			I/P-	Instrument Panel
	CID - Cubic Inch Displacement			ISC - Idle 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 - Digital Fuel Injection
	Diff. -		Differential	Man. Vac. - Manifold Vacuum
	Distr.	-	Distributor	MAP -		Manifold Absolute Pressure
	EAC - Electric Air Control Valve
	EAS - Electric Air Switching Valve			MPG - Miles Per Gallon
	ECC - Electronic Comfort Control			MPH - Miles Per Hour
	ECM -		Electronic Control Module	MT -	Manual Transmission
				N . m -		Newton Metres (Torque)
			Emission Control

PAIR - Pulse Air Injection Reaction System

P B - Power Brakes

PCV - Positive Crankcase Ventilation

PECV - Power Enrichment Control Valve

Fig. 014-15 -- Common Abbreviations

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-

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.

	VEHICLE ---f lGlAZ3799ER157148						1JD69	BODY TYPE STYLE
	IDENTIFICATION	A R L A02 A65	BGY B9A	B9K	C60	D l 0 D35	E5Z E6E E9Z FLT GU1 JM7	i	OPTION CONTENT
	NUMBER
		<19 KG4 LC3 MX1 M31		N A 5	NB1	OMX VK3	VC2 VY1 VY4 V73 Y19 ZJ7
		GBJ 62L 62U 67D 671 679			7BJ 8HJ 9HJ
		BBPBBBBPPB	EXAMPLE -
		DIS. LACQUER		WA-L8240		U8240	A4721

PAINT TECHNOLO(IY
SOLUTION LACOUEH
DlSPEHSlON LACOUEH
HIGH SOLIDS E N 4 M E L
\VA CERBORNE ENAI.ICL	I'AINTL O U L S APd[J LOLATIONS
BASECOAT CLCAl3C04T	L	LfJIVEIi L:C)UY COLOII
	U	UPI'CHf!O[IY	(,OLCJII
	A	h l l I 1 U L f L!O[)Y	O I I ACCCNT
		COLOF? ISTHIPINO CTC. I

V I N Y L

FOP CCIl.Oli

IlF AI'I'LICAHLZI

I

1lilP.1

~,lJP . ll~lPl/~llO'J',

LABEL LOCATION

Fig. OA-16 Service Parts Idcnt~frcationLabel

MAINTENANCE AND LUBRICATIONOB-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 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.

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.

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 MAINTENANCEAND 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 lessthan 10 miles (16kilometers)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

I	FOOTNOTES:
	*An Emission Control Service
	ttThe 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

ITEM 10 TransmissionRransaxle Service

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 90°F (32°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.

MAINTENANCE AND LUBRICATION 08-3

ITEM 16

Engine Timing Check*

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

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.

ITEM 11

Spark Plug Service*

Replace spark plugs with type listed in your Owner's Manual.

ITEM 12

Spark Plug Wir 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.

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.

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.

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.

*An Emission Control Service

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 transmis-
sionltransaxle --- 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 transmissionltrans-
axle 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 IN 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 front- wheel-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.

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 neutral or clutch starl switch operation

CAUnON: Before pedorming the following safety switch check, be sure t o have enough room around the car. Then, firmly apply both the parking brake (see your Owner'sManual for procedure) and the regular brakes. Do not use the accelerator

MAINTENANCE AND LUBRICATION OB-5

pedal. If the engine starls, b e ready t o turn off the ignition promptly. Take these precautions because t h e car could m o v e without warning and possibly cause personal injury or properly damage. On automatic transmissionltransaxle cars, try t o starl the engine in each gear. The starler should crank only i n "Park" or "Neutral."

On manual transmissionltransaxle cars, place the shiR lever in "Neutral," push the clutch halfway and t r y t o starl. The starler should crank only when the clutch is fully depressed.

Steering column 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 the parking brake and automatic transmissionltransaxle "Park" mechanism, park o n a fairly steep hill w i t h enough room for movement i n the downhill direction. To reduce the risk of personal injury or property damage, be prepared t o apply the 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.

USAGE

Engine Oil

Engine Coolant

Brake and Hydraul~cClutch Systems

Parking Brake Cables

Power Steering System

Manual Steerlng Gear (reclrculat~ngball)

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

Manual Transm~ssion(rear-wheel-drive) 4 Speed

Manual Transm~ss~onRransaxleShin Linkage

Key Lock Cylinders

Automatic Transmlss~onfrransaxleShlft Llnkage

Clutch Llnkage Plvot Po~nts

Floor Sh~nL~nkage

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

Chass~sLubr~cation

Standard D~fferent~alRear Axle

L~m~ted-Sl~pD~flerent~alRear Axle

W~ndsh~eld.WasherSolvent

Hood Latch Assembly

a)Plvots and Sprlng Anchor

b)Release Pawl

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

Weatherstr~ps

FLUlDlLUBRlCANT

GM Goodwrench Motor 011or equivalent for API Se~lceSFICC, or SFICD of the recommended v~scos~ty

M~xtureof water and good qual~tyethylene glycol base antllreeze conforming to GM spec 1825M (GM Part No 1052753)

Delco Supreme 11 Fluld (GM Part No 1052535) or DOT-3 Fluld

Chass~sgrease meetlng requirements of GM-6031M (GM Part No 1052497)

GM power steerlng flu~d,Part No 1052884 or equivalent

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

DEXR0N'-IIAutomat~cTransm~ss~onFlu~d(GM Part No 1051855) Camaro and Flreblrd

(5 Speed)

Corvette overdr~veunlt - DEXRONa.II All others SAE-80W-90 GL-5 gear lubr~cant (GM Part No 1052271)

Chass~sgrease meetlng requirements of GM-6031M (GM Part No 1052497)

Black Key Lock Cyl~nders-light oil (GM Par1No. 1052949)

All other Key Lock Cyl~nders- sllicone lubrlcant (GM Part No 1052277)

Eng~ne011

Eng~ne011

Eng~ne011

Llght 011(GM Part No 1052949)

Chass~sgrease meetlng requirements of GM-6031M (GM Part No 1052497)

SAE 80W or SAE 80W-90 GL-5 (SAE 80W GL-5 In Canada) gear lubricant (GM Part No 1052271)

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 wmpee d manual transm~ss~onand disc brakes

All other applications - Use SAE 80W or SAE 80W-90 GL-5 Gear Lubr~cant(GM Part No 1052271)

GM Opt~kleenWasher Solvent (GM Part No 1051515) or equ~valent

a)Eng~ne011

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

Lubricant GM Part No 1051344 grease or equivalent

Eng~ne011

S~l~coneGrease (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 ..................................	1A13
Improper Air DeliveryINo Mode Shift .......	1A-8	Heater Core ..........................................	1A13
Too Much Heat ..........................................	1A-9	Vent Control Cable .................................	1A13
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 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	5.	LEFT AND RIGHT RAM AIR
	OUTLETS		VENT OUTLETS*
4.	RAM AIR VENT	*
	CONTROLS*		NOT ON ALL MODELS

J10001-1A-F

Fig. 4 Heater Ventilation System - Typical

1-THIS POSITION ALLOWS OUTSIDE AIR FLOW TO FLOOR OUTLET. (ADDITIONAL 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 (AND 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 AIR THROUGHIAROUND THE HEATER CORE.

5-THE FAN CONTROL LEVER (OFF - HI ) PRO. VIBES SPEED CONTROL OF THE FAN.

Fig. 5 Heater Control - Typical

1A-4 HEATING AND VENTILATION

1-DEFROSTER OUTLET

2-BLENDED AIR

3-HEATER CORE

4-BLOWER

5-DASH PANEL

6-OUTSIDE AIR FROM COWL PLENUM CHAMBER

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

8-UNTEMPERED AIR

9-WARMED AIR

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

11-AIR DOOR CLOSES OFF HEATER

AND DEFROSTER OUTLETS WHEN SYSTEM SELECTOR LEVER IS

MOVED TO "OFF"

12-DEFROSTER DOOR MOVES BY

OPERATION OF HEATER CONTROLS SYSTEM SELECTOR LEVER

"ON SOME MODELS ALSO SUPPLIES SIDE WINDOW 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 or Defrosting Diagnosis Procedure ( 7 of 2)

1A-6 HEATING AND VENTILATION

CHECK VEHICLE FOR COLD AIR LEAKS AT DASH, HEATER CASES AND FROM VENTS. CHECK UNDERSEAT FOR OBSTRUCTIONS.

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

w

TEN FOR DOOR SLAM PRIOR TO THE END

	I
	WITH THE BLOWER ON
	HIGH, MOVE THE TEMP-
	ERATURE LEVER FROM
I	FULL HOT TO FULL
WITH THE TEMPERATURE	COLD AND LISTEN FOR
DOOR FULL HOT, START THE	AIRFLOW CHANGE.
VEHICLE. CHECK THE TEMPER-
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