PONTIAC FIERO 1988 Service Repair Manual

7C.4 CLUTCH
CLUTCH DIAGNOSIS
CONDITION PROBABLE CAUSE CORRECTION
Fails to Release
(Pedal pressed to
floor shift lever a. Faulty pilot bearing. a. Replace bearing.
does not move freely b.
Faulty driven disc. b.
Replace disc.
in and out of
re- c. Fork off ball stud. c.
Install properly and*
verse gear) lubricate
fingers at
re-
lease bearing and ball stud.
d. Clutch disc hub
bind- d. Repair or replace
ing on clutch gear clutch
gear and/or disc.
spline.
e. Clutch disc warped e.
Replace disc (run-out
or bent. should
not exceed
.020").
* Very lightly lubricate
fingers.
a. Oil soaked driven a. Install new disc and
disc. correct
leak at its source.
b. Worn facing or
fac- b. Replace disc.
ing torn from disc.
c. Warped pressure c. Replace pressure plate
plate or flywheel. or flywheel.
d. Weak diaphragm
d. Replace pressure plate
spring. e. Driven plate not e. Make
30 to 40 normal
seated in. starts. CAUTION:
Do
not overheat.
f. Driven plate over- f. Allow to cool.
Slipping

CLUTCH 7C-5
Grabbing (Chattering)
Rattling
- Transmission
Click
Release Bearing Noise
with Clutch Fully
Engaged
Noisy
Pedal Stays on Floor
When Disengaged heated.
a. Oil
on facing. Burned
or glazed facings.
b. Worn splines
on
clutch gear.
c. Warped pressure
plate or flywheel.
d. Burned or smeared
resin on flywheel or
pressure plate.
a. Weak retracting
springs.
b. Release fork loose
on ball stud or in bear-
ing groove.
c. Oil in driven plate
damper.
d. Driven plate damper
spring failure.
a. Release bearing bind-
ing on transmission
bearing retainer.
b. Fork improperly in-
stalled. a. Worn release bearing.
b. Fork off ball stud
(heavy clicking).
c. Pilot bearing loose
in crankshaft.
a. Bind in release
bearing.
b. Springs weak in
pressure plate. a.
Install new disc and
correct leak.
b. Replace transmission
clutch gear.
c. Replace pressure plate
or flywheel.
d. Sand off if superficial,
replace burned or heat
checked parts.
a. Replace pressure plate.
b. Check ball stud and
retaining.
c. Replace driven disc.
d. Replace driven disc.
a. Clean, relubricate,
check for burrs, nicks,
etc.
b. Install properly.
a. Replace bearing.
b. Install properly and
lubricate fork fingers
and bearing.
c. See Section
6 for
bearing fits.
Lubricate and free-up
release bearing.
b. Replace pressure
plate.
ON-VEHICLE SERVICE
CLUTCH HYDRAULIC SYSTEM 7. Remove the clutch fluid reservoir from bracket.
NOTICE: The clutch hydraul~c 4ystern is serviced 8. Pull brake niaster cylinder forward for access to
as a complete unit, it has been bled
of air and filled clutch master cylinder.
with fluid. Individual components of the system 9. Remove the clutch master cylinder from cowl.
are
not available separately. 10. Hoist vehicle.
1 1. Remove the slave cvlinder heat shield.
Prior to any vehicle service that requires removal of
the slave cylinder
(i.e., transmission and clutch housing
removal), the
master cylinder push rod must be
disconnected from the clutch pedal. If not discon-
nected, permanent damage to the slave cylinder will
occur if the clutch pedal is depressed while the slave
cylinder is disconnected.
Removal
1. Disconnect negative battery cable.
2. Remove the steering column trim cover.
3. Remove the hush panel.
4. Discoonect the master cylinder push rod from
clutch pedal.
5. Remove the clutch master cylinder to cowl nuts.
6. Remove the brake booster to cowl nuts.
12. Remove the slave cylinder from bell housing.
13. Lower vehicle.
14. Remove the clutch hydraulic system from engine
compartment.
Installation
1. Position
hydraulic clutch master cylinder at cowl
and feed slave cylinder drown to bell housing
area.
2. Pilot clutch master cylinder push rod through
cowl and position master cylinder to cowl with
U
bolt.
3. Connect brake booster to cowl.
4. Pilot clutch master cylinder
U bolt through
clutch braces and torque nuts.
5. Torque brake master cylinder to cowl nuts.

7C-6 CLUTCH
6. Clutch master cylinder push rod to clutch pedal.
7. Install brake switch.
8. Install hush panel.
9. Install steering column trim cover.
10. Install clutch reservoir to bracket.
1 1. Hoist vehicle.
12. Pilot slave cylinder into clutch fork.
NOTICE: With a new system, the slave cylinder
contains a shipping strap that pre-positions the
push rod for installation, and also provides a
bearing insert.
Follojving installation of the slave
cylinder, the first actuation of the clutch pedal will
break the shipping strap and give
normal system
operation.
13. Install slave cylinder and heat shield to bell
housing.
14.
Lojver vehicle.
15. Connect negative battery cable.
CLUTCH ASSEMBLY
Removal
1. Remove the transmission as outlined in
transmission section.
2. Remove the slave cylinder heat shield and slave
cylinder
from flywheel housing.
3. Reniove the flywheel housing.
4. Slide clutch fork from ball stud and remove fork
from dust boot. Ball stud is threaded into clutch
housing and is easily replaced, if necessary.
5. Install Tool 5-33169 to support the clutch
assen~bly during removal. Look for mark or white
painted letter on clutch cover and
"X" mark on
flywheel. If
"Xu or letter is not evident, mark
flywheel and clutch cover for indexing purposes
during installation.
6. Loosen clutch-to-flywheel attaching bolts evenly
1 turn at a time until spring pressure is released.
7. Remove clutch and pressure plate assembly.
lnspection
Inspect the flywheel for cracks, heat checking or
other defects. Replace or repair as required.
Installation
Pressure plate and flywheel face, (They should be
free of oil, grease, metal deposits or burned spots.)
Installation
1. Position clutch disc and pressure plate in relative
installed position and support them with
alignment Tool J-33169 or a drive gear.
The driven disc is installed with the damper
springs to the transmission. The flywheel side is
marked.
2. Turn clutch assembly until "X" mark or white
painted letter on cover lines up with
"X" mark on flywheel,
then align cover bolt holes to nearest
flywheel holes.
3. Install a bolt in every hole and tighten down
evenly and gradually until tight to avoid possible
clutch distortion. (Cover loads are as high as
1- 1/4 tons).
4. Remove the pilot tool.
5. Unhook clutch fork and lubricate ball socket and
fork fingers at release bearing end with a high
melting point grease such as graphite and
reinstall fork on ball stud.
6. Lubricate recess on inside of release bearing
collar and the clutch fork groove with light coat
of graphite grease. Refer to Figure 7C-6.
7. Install the clutch fork and dust boot into clutch
housing and install release bearing to fork, then
install flywheel housing.
8. Install the transmission as outlined in
transmission section.
9. Install the clutch slave cylinder and bracket.
CLUTCH PEDAL
Removal
Disconnect the negative cable at battery.
Remove the steering column trim cover.
Remove the hush panel from under dash.
If equipped, disconnect cruise control switch at
clutch pedal.
Disconnect the neutral start switch at clutch
pedal.
Renlove the turn signal and hazard flasher
mounting bracket attaching screws.
Disconnect the clutch master cylinder push rod
from pedal.
Remove the nut from clutch pedal pivot bolt. Pull
bolt out far enough for pedal removal.
Inspection
Clean and inspect all components and replace as
necessary. Do not clean bushings with a cleaning
solvent, simply wipe with a clean cloth.
Relubricate all bushings and moving parts.
Installation
1. Reverse the removal procedure.
PILOT BEARING (FIGURE 7C-7)
Replacement
The clutch pilot bearing is an oil impregnated type
bearing pressed into the crankshaft. This bearing requires
attention when the clutch is removed from the vehicle, at
which time it should be cleaned and inspected for exces-
sive wear or damage and should be replaced if necessary.
To remove, install Tool
J 23907 and remove bearing
from crankshaft, as shown in Figure
7C-7. In replacing
this bearing, use Tool
J 1522. Place bearing on pilot of
tool with radius in bore of bearing next to shoulder on tool
and drive into crankshaft. Lubricate with several drops of
machine oil.

CLUTCH 7C-7
1-CLUTCH MASTER CYLINDER
2-RESERVOIR MOUNTING BRACKET
3-5 Nem (30 IN.
LBS.)
4-RESERVOIR
5-BRAKE PEDAL
BRACKET ASSEMBLY
6-BUSHING
8-35 Nem (25 FT
LBS.)
9-13 Nem (10 FT LBS.)
10-SPACE R
11-CLUTCH MASTER CYLINDER
12-U-BOLT
13-CLUTCH HOUSING
14-CLUTCH FORK
15-SLAVE CYLINDER
16-HEAT SHIELD
17-21
Nom (15 FT. LBS
Figure 7C-5 Clutch System Components

7C-8 CLUTCH
1. J5824 CLUTCH PILOT TOOL
2. J23907 CLUTCH PILOT BEARING REMOVER
J 10264-7C-Y
SPECIFICATIONS 1
N-m (Ft.Lb.) (In,Lb.)
Clutch Reservoir to
Mounting Bracket 5
- 30
Clutch Master
Cylinder to Cowl 13 10
Heat Shield to
Bell Housing 2
1 15
Slave Cylinder
to Bell Housing 21 15
Clutch Pedal to
Mounting Bracket 35 25
Neutral Start Switch 3
- 26
Pressure Plate
to Flywheel
V6 21 15
V8 40 30
Flywheel to
- Crankshaft V6 70 50
Flywheel to
- Crankshaft V8 100 75
Bell Housing to
Engine
V6 75 55
V8 92 68

CONTENTS
ELECTRICAL DIAGNOSIS
Cell
1
2
3
4 5
10
11
12 14
20
21
22
23
30
31
33
34
40
4
1
60
61
62
63
64
65
66
67
68
Index
Introduction
Symbols
Troubleshooting Procedures Repair Procedures
Power Distribution
Fuse Block Details
Light Switch Details
Ground Distribution
Engine:
V6 VIN S
Engine: V8 VIN
F
Engine: V8 VIN E
Engine:
V8 VIN 8
Starter and Charging System
Coolant Fans
Vehicle Speed Sensor
Cruise Control Horns
Brake Warning System
Heater
Defogger
Air Conditioning: System Check
Air Conditioning: Blower Controls
Air Conditioning: Compressor Controls
Air Conditioning: Air Delivery
Air Conditioning: Blower Controls
Air Conditioning: Compressor Controls
Air Conditioning: Air Delivery Cell
77
8
1
82
86 90
9
1
100
102
103
110
111
112
114
117
120
130
133
134
135
141
143
145
150
151
201 202
203
Warnings and Alarms: Chime
Instrument Panel: Gages Cluster
Instrument Panel:
Digital Cluster
Driver Information Center
(DIC)
WiperlWasher
WiperlWasher: Pulse
Headlights
Headlight Doors
Headlights with Lamp Monitor
Exterior Lights
Exterior Lights with Lamp Monitor
Back Up Lights
Interior Lights
Interior Lights Dimming
Power Windows
Power Door Locks
Theft Deterrent
Hatch Release
Hatch Pull-Down
Power Mirrors
Automatic Day-Night Mirror
Lumbar Support
Radio Power Antenna
Component Location Views
Harness Connector Faces
Harness Routing Views

Page
Air Conditioning
Air Delivery
Electronic
.................... 68-0
Manual
....................... 65-0
Blower Controls
Electronic
.................... 66-0
Manual
....................... 63-0
Compressor Controls Electronic
.................... 67-0
Manual
....................... 64-0
................... System Check 62-0
Alarms (Audible)
Chime
......................... 77-0
Antenna(Power) ................... 151-0
Brakes
................. Warning System 41-0
................... Charging system 30-7
...................... Cigar Lighter 114-0
Circuit Breaker Details
PWR ACC Circuit
.......... Breaker 10.1.10.3.10.5.1 1.3
WDO Circuit Breaker
10.1. 10.3. 10.5. 11-4
.......... Component Location Views 201-0
Connectors (Harness Connector Faces) 202-0
el00 .......................... 202-0
............... Junction Block ((2238) 202-2
Coolant Fan
....................... 31-0
Cruise Control
..................... 34-0
Defogger
......................... 61-0
Digital Clock
...................... 150-0
Displays Digital Cluster
.................. 82-0
Coolant Temperature
........... 82-2
Page
......................... Fuel 82-3
................... Oil Pressure 82-2
.................. Speedometer 82-3
................. Door Locks (Power) 130-0
...... Driver Information Center (DIC) 86-0
Engines
... Multi-Port Fuel Injection (VIN S) 20-0
.... Multi-Port Fuel Injection (VIN 8) 23-0
.... Throttle
Body Injection (VIN E) 22-0
...... Tuned
Port Injection (VIN F) 21-0
................. Fuse Block Details 11-0
Fuse Details
........... INST LP 10.0.10.2.10.4.1 1.1
.............. TAIL 10.0.10.2.10.4.1 1.2
................ CRANK 10.0.10.2.1 0.4
.............. CTSY 10~0.10.2.10.4.1 1.2
......... STOP HAZ 10.1.10.3.10.5.1 1.3
............ RADIO 10.1.10.3.10.5.1 1.4
............ WIPER 10.1.10.3.10.5.1 1.4
.................... HATCH 10.2.1 0.4
........... HTR AlC 10.1.10.3.10.5.1 1.4
........... CIH.FAN 10.1.10.3.10.5.1 1.4
......... TURN BIU 10.1.10.3.10.5.1 1.4
............ GAGES 10.1.10.3.10.5.1 1.4
ECM-IGN
(V6 VIN S. V8 VIN F.
........ V8 VIN 8. V8 VIN E) 10.1.1 1.7
............ INJ 1 (V6 VIN S) 10.1.1 1.10
......... FPIINJ 2 (V6 VIN S) 10.1.1 1.10
... INJ 1 (V8 VIN F. V8 VIN 8) 10.3.1 1.11
FPIINJ 2 (V8 VIN F. V8 VIN 8) 10.3.1 1.11
............ CLSTR 10.1.10.3.10.5.1 1.13
............. FPIINJ 2 (V8 VIN E) 11-12
Page
Gages
................... Gages Cluster 81-0
........... Coolant Temperature 81-2
......................... Fuel 81-3
................... Oil Pressure 81-2
.................. Speedometer 81-3
................ Ground Distribution 14-0
Harness Routing Views
............. 203-0
........................... Heater 60-0
............................ Horns 40-0
Indicators
.................. Digital Cluster 82-0
................ Brake Warning 82-4
.................. Fasten Belts 82-1
...................... Hi Beam 82-1
...................... Security 82-1
............ Service Engine Soon 82-4
......................... Shift 82-5
......................... Turn 82-1
................... Gages Cluster 81-0
................ Brake Warning 81-0
.................. Fasten Belts 81-0
...................... Hi Beam 81-0
............ Service Engine Soon 81-0
......................... Shift 81-1
......................... Turn 81-0
Instrument Panel
Digital Cluster
.................. 82-0
Gages Cluster
................... 81-0
............ Interior Lights Dimming 117-0
...................... Introduction 2-0
Lights (Exterior)
........................ Back Up 112-0
...................... Fog 100.3,10 3.0

INDEX
Page
................... Front Marker 110-0
...................... Frontpark 110-0
......................... Hazard 110-0
........ Hazard with Lamp Monitor 111-0
..................... Headlights 100-0
........................ Doors 102-0
............ With Lamp Monitor 103-0
................. Nigh Level Stop 110-0
................... License 110.3,11 0.4
Park
........................... 110-0
............... Rear Marker 110.3,11 0.4
stop
........................... 110-1
...................... Tail 110.3,11 0.4
................ Tail with Monitor 111-2
Turn ........................... 110-0
Lights (Interior)
.............. Cargo Compartment 114-1
....................... Courtesy 114-0
.......................... Dome 114-0
...................... Glove Box 114-0
................. Lights Dimming 117-0
........................ Reading 114-0
................ Light Switch Details 12-0
.................... Mirrors (Power) 141-0
Automatic
DayINight ............ 143-0
................. Power Distribution 10-0
Radio
...................... With UK3 150-0
With
UK3 and Subwoofer
..................... Amplifier 15 0-2
Without Subwoofer Amplifier and
with
UK3 ..................... 150-5 With
Subwoofer Amplifier and
without UK3
..................
.................. Repair Procedures
Seats (Power)
Lumbar Support
.................
Starter ............................
........................... Symbols
........... Theft Deterlent (Passkey)
......... Troubleshooting Procedures
.................. Hatch Pull-Down
..................... Hatch Release
............... Vehicle Speed Sensor
Warnings (Audible)
Chime
.........................
................... Windows (Power)
WiperIWasher
With Pulse .....................
................... Without Pulse
Page

INTRODUCTION 1:
This manual contains the following kinds of
diagnostic information:
e Electrical Schematics
Component Location Lists
@ Harness Connector Faces
@ ?koubleshooting Hints
@ System Checks
System Diagnoses
@ Circuit Operation Descriptions
@ Harness Routing Views
Using these elements together will make elec-
trical troubleshooting faster and easier. Each
element is described below.
The Electrical
Seher~latic should always be
your starting point in using this Electrical
Troubleshooting Manual. The schematic shows
the electrical current paths when a circuit is
operating properly. It is essential to under-
stand how a circuit
should work before trying to
figure out why it doesn't.
The Harness Connector Faces show the cav-
ity or terminal locations in all the multi-pin
connectors shown in the schematic. Together
with the wire colors and terminals given in the
schematic, they help you locate test points. The
drawings show the connector faces you see
after the harness connector has been discon-
nected from a component. When more than one
connector is connected to a component the con-
nectors are all shown together.
The Troubleshooting Hints offer short-cuts
or checks to help you determine the cause of
a
complaint. They are not intended to be a rigid procedure
for solving an electrical situation.
Rather, Troubleshooting Nints represent a
common-sense approach, based on an under-
standing of the circuit.
The System Check gives a summary of how
the circuit should be operated and what should
happen. This is especially important when you
are working on a new system. The System
Check will help you identify symptoms, lead
you to diagnosis and confirm the system after
repair.
The System Diagnosis provides a procedure
to follow that will locate the condition in a cir-
cuit. If your own knowledge of the system and
the Troubleshooting Hints have not produced
a
quick fix, follow the System Diagnosis. All pro-
cedures are based on symptoms to assist you in
locating the condition as fast as possible.
The Circuit Operation will help you under-
stand the circuit. It describes the components
and how the circuit works.
The Component Location List helps you find
where the parts of the circuit are in the vehicle.
A brief statement of the location is given and
also a reference to a drawing that shows the
component and its connecting wires. These
Colnponent Location Views are in cell 201.
Harness Routing Views are found in cell 203.
These views show the routing of the major wir-
ing harnesses and the in-line connectors
between the major harnesses. These views will
make troubleshooting easier when you are not
sure about harness routing.
PAGE NUMBER
This section is organized into cells with most
cells containing a circuit schematic and the text
for that circuit. This makes the section easy to
use, since the page number for a schematic will
normally stay the same year after year, and it
will also be the same in
all the GM publications
about that circuit. For example, the Cruise Con-
trol schematics will always be the first pages of
cell 34. The other information for Cruise Con-
trol follows them on pages
34-2,34-3, etc.
Some cells may have more than one circuit
schematic, such as Power Distribution, Interior
Lights, and Air Conditioning. The circuit you
want can either be located by using the index, or
by a quick look through the related cell.
All the engine circuits for a particular engine
VIN type are in the same cell. This makes that
cell easy to use, since schematics for other cars
are not in your way. The instrument panel sche-
matics are organized similarly. If you are work-
ing on a car with a Digital Cluster, only the
schematics that apply to that car's Digital
Cluster will be in the cell you use. Information
on the Indicators and Gages Clusters will be in
other cells.

These schematics break the entire electrical
system down into individual circuits. You are
not distracted by wiring which is not part of
the circuit you're working on.
It is important to realize that no attempt is
made on the schematic to represent compo-
nents and wiring as they physically appear on
the car. For example, a 4-foot length of wire is
treated no differently in a schematic from one
which is only a few inches long. The number of
cavities for each connector is listed in the Com-
ponent Location List. Similarly, switches and
other components are shown as simply as pos-
sible, with regard to function only.
The following example shows how to read a
Worn schematic, see figure
1. Locate the Horn
schematic using the Index. The circuit sche-
matic will look somewhat like the one to the
right. The schematic is read from top to bot-
tom.
Voltage is applied to the Horn Relay at all
times. When the relay coil is grounded by clos-
ing the Horn Switch, the relay contacts close.
When the relay contacts are closed, both the
LH and
RH Horns are energized.
1 HORN
SEE FUSE
I BLOCK DETAILS
Figure 1 - Typical Horn Schematic