PONTIAC FIERO 1988 Service Repair Manual

2C-14 CHASSIS SHEET METAL
J10259-2C-F
Figure 5 Concealed Headlights

CHASSIS SHEET METAL 26-15
Figure 6 Actuator Assembly
Figure
7 Door Lower Air Deflector

2C-16 CHASSIS SHEET METAL
Figure 9 Rear Bumper Fascia Extension

CHASSIS SHEET METAL 2C-17
DRILL FOUR (4) .I25 INCH DIA. HOLES
AT EXISTING DRILL DIMPLES IN FASCIA.
Figure 10 License Plate Bracket Mounting

STEERING, SUSPENSION, f IRES AND WHEELS DIAGNOSIS 3.1
SECVION 3
STEER NG, SUSPENS
WHEELS
AGNOS
CONTENTS
........................................... General Information 3- 1 ............................................ General Diagnosis 3- 1
Power Recirculating Ball .................................. 3-3
................. Steering Linkage ........................ .. 3-3
Power Steering Pump ................... ... ............ 3-4
Steering Column
Lock System
........................... ... ................ 3-4
Column ............................................................ 3-5
........................................ Turn Signal Switch 3-6
Ignition Switch .............................................. 3-7
Key Reminder .............................................. 3-7
Dimmer Switch .................... ... ................ 3-10
Pivot and Switch Assembly ............................ 3-10
Steering Gear and Pump Leaks .......................... 3- 10
Seal Replacement Recommendations ................. 3- 10
Power Steering System Test Procedure .............. 3-12
................ Strut Dampener and Shock Absorber 3- 12
Tires ........................ .. ..................................... 3- 13
Vibrations .......................... .............. .................... 3- 14
.......................... Tapered Roller Bearings .. .... 3- 14
Trim Height .............................................. 3-14
GENERAL INFORMATION Abnormal or Excessive Tire Wear
Since the problems in steering, suspension, tires
and wheels involve several systems, they must all be
considered when diagnosing a complaint. To avoid
e Front-wheel or rear-wheel alignment
using the wrong symptom, always road test the car
o Sagging or broken springs
first. Proceed with the following preliminary checks
Tire out of balance and correct any substandard conditions which are worn strut dampener or shock absorber found. o Hard driving
--
e Tires for wrong pressure and uneven wear
o Joints from the column to the steering gear for
loose connectors or wear
o Front and rear suspension, and the steering gear
or linkage for loose or damaged parts
Out-of-round or out-of-balance tires, bent wheels,
and loose and/or rough wheel bearings
@ Power steering system for leaks. Also check the
power steering fluid level and the pump drive belt
tension
GENERAL DIAGNOSIS
Car Pulls (Leads)
Inspect
Mismatched or uneven tires
Broken or sagging springs
Radial tire lateral force
Front-wheel or rear-wheel alignment
o Steering gear valve off center (unbalanced)
e Front brakes dragging
a Overloaded car
e Not rotating tires
Scuffed Tires
o Toe incorrect
e Excessive speed on turns
o Suspension arm bent or twisted
Wheel Tramp
Inspect
o Blister or bump on tire
o Improper strut dampener or shock absorber
action
Shimmy, Shake or Vibration
inspect
e Tire or wheel out of balance
e Worn wheel bearings
a Worn tie rod ends
o Worn lower ball joints

3-2 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
o Excessive wheel runout
e Blister or bump on tire
e Excessive loaded radial runout of tire and wheel
assembly
Hard Steering (Power)
lnspect
e Hydraulic system - Make test with gage J 5176
or J 25323
e Steering gear adjustment
e Bind or catch in steering gear
e Loose steering gear mounting
e Steering gear pressure port check valve (800
series)
Too Much Play In Steering
a lnspect
e Wheel bearings worn
e Loose steering gear mounting
e Joints from column to steering gear loose or worn
e Steering gear adjustment
Poor Returnability (Power)
Inspect
e Lack of lubrication - ball joints and tie rod ends
o Bind in ball joints
o Rind in steering column
e Front-wheel alignment
e Steering gear adjustment
e Sticking valve
o Steering gear adjustment
e Lower coupling binding on steering gear
Abnormal Noise, Front End
lnspect
Lubrication - ball joints and tie rod ends
Damaged suspension components
Worn control arm bushings or tie rod ends
Imose stabilizer shaft
Loose wheel nuts
Loose suspension bolts
Wheel covers
Steering gear adjustment
Worn strut dampener, shock absorbers or
n~ountings
Spring improperly positioned
Wander or Poor Steering Stability
Inspect
o Mismatched or uneven tires
e Lubrication - ball joints and tie rod ends
e Worn strut dampeners or shock absorbers
e Loose stabilizer shaft Broken
or sagging springs
e Steering gear adjustment
e Front-wheel or rear-wheel alignment
Erratic Steering When Braking
lnspect
e Wheel bearings worn
e Broken or sagging springs
e Leaking wheel cylinder or caliper
Warped rotors
e Incorrect or uneven caster
Low Or Uneven Trim Height
e Broken or sagging springs
@ Overloaded car
e Incorrect or weak springs
Ride Too Soft
Inspect
e Worn strut dampeners or shock absorbers
e Incorrect or sagging springs
Ride Too Harsh
lnspect -
e Incorrect strut dampeners or shock absorbers
e Incorrect springs
Body Leans Or Sways In Corners
lnspect
e Loose stabilizer shaft
e Worn strut dampeners, shock absorbers or
mounting
a Broken or sagging springs
e Overloaded car
Suspension Bottoms
lnspect
a Overloaded car
e Worn strut dampeners or shock absorbers
e Incorrect, broken or sagging spring
"Dog" Tracking
lnspect
e Damaged rear suspension arm or worn bushings
e Bent rear axle
e Frame or underbody alignment incorrect

STEERING, SUSPENSION, VIBES AND WHEELS DIAGNOSIS 3-3
Steering Wheel Kick-Back (Power)
Inspect
e Air in system
e Loose steering gear mounting
e Joints from column to steering gear loose or worn
e Tie rod ends loose
Worn or missing check valve
(800 series)
e Wheel bearings worn
e See "Too Much Play In Steering" for other
possible causes.
Steering Wheel Surges Or Jerks (Power)
Inspect
Hydraulic system - Make pressure test with gage
J 5176-D or
J 25323
e Sluggish steering gear valve
Loose pump drive belt
Cupped Tires
Inspect
Front-wheel or rear-wheel alignment
e Strut dampeners or shock absorbers weak
e Wheel bearing worn
e Excessive tire or wheel runout
e Worn ball joint
a Loose steering gear adjustment
POWER RECIRCULATING BALL
SEERING GEAR DIAGNOSIS
Hissing Noise
There is some noise in all power steering systems.
One of the most common is a hissing sound when the
steering wheel is turned and the car is not moving. This
noise will be most evident when turning the wheel
while the brakes are applied. There is no relationship
between this noise and steering performance. Do not
replace the valve unless the "hissing" noise is extremely
objectionable. A replacement valve will also have a
slight noise, and is not always a cure for the condition.
Check that the intermediate shaft joints are not loose.
Rattle or Chucking Noise
Inspect -
Pressure hose grounding out
e Tie rod ends loose
e Steering gear attachment loose
a Loose pitman shaft "over-center" adjustment.
A slight rattle may occur on turns because of
increased clearance off the "high point". This is
normal and clearance must not be reduced below
specified limits to eliminate this slight rattle.
Poor Return of Steering Wheel to Center
Front-wheel alignment
Wheel bearing worn
Tie rod end binding
Ball joint binding
Steering wheel rubbing against turn signal
housing
Steering gear adjustments
Tight or frozen intermediate steering shaft
Sticky or plugged spool valve
Momentary Increase in Effort Whsn Turning
Wheel Fast to Right or Left
Inspect
High internal leakage
Steering Wheel Surges or Jerks When Turning
With
Engine Running Especially During Parking
ln8pe~t
e Insufficient pump pressure
Sticky flow control valve
Excessive Wheel Kickback or Loose Steering
Air in system
Steering gear attachment loose
Tie rod ends loose
Wheel bearings worn
Steering gear flexible coupling loose on shaft or
rubber disc mounting nuts loose
Loose thrust bearing preload adjustment
Excessive "over-center" lash
Worn pressure port check valve
Hard Steering or Lack of Assist
(Especially During Parking)
-
Brakes applied while turning steering wheel
Intermediate shaft damaged or worn
e Sticky flow control valve
Insufficient pump pressure
Excessive internal pump leakage
Excessive internal steering gear leakage
STEERING LINKAGE DIAGNOSIS
Excessive Play or Looseness in Steering Systern
inspect
r, Worn upper ball joints
e Steering gear worm bearings loosely adjusted

3.4 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
e Excessive pitman shaft to ball nut lash in steering
gear
e Worn intermediate rod or tie rod sockets
Excessive Looseness in Tie Rod or Intermediate
Rod Pivots, or Excessive Vertical Lash in
Idler
Support
Inspect -
e Seal damage and leakage resulting in loss of
lubricant, corrosion and excessive wear
Hard Steering
0 Inspect
e Tight or frozen intermediate rod, tie rod or idler
socket
e Steering gear adjusted too tight
POWER STEERING PUMP DIAGNOSIS
Foarning, Milky Power Steering Fluid, Low Fluid
Level, and Possible Low Pressure
This can be caused by air in the fluid, and loss of
fluid due to internal pump leakage causing overflow.
Check for leak and correct. Bleed the system.
Extremely cold temperatures will cause air bubbles in
the system if the fluid level is low. If the fluid level is
correct and pump still foams, remove pump from car
and separate reservoir from housing. Check soft plug
and housing for cracks. If housing is cracked, replace
housing.
Low Pressure Due to Steering Pump
Inspect
e Flow control valve stuck or inoperative
e Pressure plate not flat against cam ring
e Extreme wear of cam ring
e Scored pressure plate, thrust plate or rotor
e Vanes sticking in rotor slots
Q Cracked or broken thrust or pressure plate
e High internal leakage
Low Pressure Due To Steering Gear
Inspect
e Scored housing bore
Q Leakage at valve rings or seals
Growling Noise in Steering Pump
Inspect
e Excessive back pressure in hoses or steering gear
caused by restriction
e Scored pressure plates, thrust plate or rotor
e Worn cam ring
Groaning Noise in Steering Pump
Inspect
e Air in the fluid
Low fluid level
Q Pump mounting loose
Rattling Noise in Steering Pump
Inspect - -
e Vanes sticking in rotor slots
o Vane improperly installed
o Damaged ball bearing
Swishing Noise in Steering Pump
inspect
e Damaged flow control valve
Whining Noise in Steering Pump
Inspect
Q Pump shaft bearing scored
e Scored pressure plates and vanes
STEERING COLUMN DIAGNOSIS
LOCK SYSTEM
Will Not Unlock
Inspect
o Shear flange on sector shaft collapsed
Q Damaged lock bolt
e Damaged lock cylinder
o Damaged housing
e Damaged sector
e Damaged rack
e Damaged park lock cable
Will Not Lock
Inspect
Lock bolt spring broken or worn
Damaged sector
Damaged lock cylinder
Burr on lock bolt
Damaged housing
Improper shift linkage adjustment
Damaged rack
Interference between bowl and rack coupling
Ignition switch stuck
Actuator rod restricted
Sector installed incorrectly
Park lock cable damaged

STEERING. SUSPENSION. TIRES AND WHEELS DIAGNOSIS 3-5
High Lock Effort
rn lnspect
e Lock cylinder damaged
e Ignition switch damaged
o Rack preload spring broken or deformed
e Burrs on sector, rack, housing, support or
actuator rod coupling
,
e Bent sector shaft
e Damaged rack
e Extreme misalignment of' housing to cover
e Distorted coupling slot in rack
e Bent actuator rod
e Ignition switch mounting bracket bent
e Actuator rod restricted
e Improper shift linkage adjustment
Will Stick In "Start"
rn lnspect
e Actuator rod deformed
e Check items under "High Lock Effort"
Key Cannot Be Removed in "Off-Lock"
rn lnspect
e Ignition switch is not set correctly
e Damaged lock cylinder
e Linkage mis-adjusted
Lock Cylinder Can Be Removed
Inspect
e Lock cylinder retaining screw missing
High Effort In Lock Cylinder Between "Off" and
"Off-Lock"
lnspect
o Distorted rack
Lock Bolt Hits Shaft Lock In "Off" Position and
"Park"
lnspect
e Ignition switch is not set correctly
COLUMN
Noise In Column
Inspect
e Joints from the column to the steering gear 1
e Column not correctly aligned
e Horn contact ring not lubricated
e Lack of grease on bearings
o Loose sight shields
o Lower or upper steering shaft bearing worn or
broken
e Shaft lock snap ring not seated
o Spherical joint not lubricated
High Steering Shaft Effort
e Column assembly misaligned
e Improperly installed or deformed dust seal
e Damaged upper or lower bearing
e Flash on I.D. of shift tube
e Tight intermediate steering shaft universal joint
High Shift Effort (Automatic with Column Shift)
rn lnspect
e Column not aligned correctly in car
e Wave washer with burrs
e Improperly installed dust seal
o Lack of grease on seal or bearing
e Improper screws used for ignition switch
e Burr on upper or lower end of shift tube
e Lower bowl bearing not assembled correctly
Improper Shifting (Automatic with Column
Shift)
rn lnspect
e Sheared shift tube joint or lower shift lever weld
e Improper or loose linkage adjustment
e 1,oose shift lever
e Improper gate plate
Lash In Steering Column
lnspect
e 1.P.-to-column upper and lower bracket
nlounting bolts loose
e Broken weld nuts on jacket
e I.P. upper bracket capsule sheared
e Loose shoes in housing
e Loose tilt head pivot pins
e Loose shoe lock pin in support
e Loose support screws
e Column upper and lower bracket-to-jacket bolts
loose
e Loose lower bracket-to-adapter and bearing
assembly mounting screws
e Loose 1.P.-to-jacket mounting bolts
Housing Scraping On Bowl
rn Inspect
e Bowl bent or not concentric with hub
e Cover and housing end cap not properly installed