suspension PONTIAC FIERO 1988 Service Workshop Manual

UNDERBODY-F STYLE 3H-1
SECTION 3H
UNDERBODY
CONTENTS
General Body Construction .......................................................................................................... 3H- 1
Alignment Checking ................................................................................................................ 3H- I
Floor Pan Insulators ...................... .. ........................................................................................ 3H- 1
Floor Carpets ................................................................................................................................. 3H-2
metric-to-English dimensional conversion data.
Dimensions to gage holes are measured to dead center
GENERAL BODY CONSTRUCTION of the holes and flush to adjacent surface metal unless
Information in this section pertains to unitized otherwise specified.
body construction which
incorporates integral front
and rear frame side rails. FLOOR PAN INSULATORS
Consideration must be given when checking
underbody dimensions. The engine front suspension
lower control arms are supported by a cross member.
The cross member, in turn, is bolted to the body at six
locations
-- three on each side of the engine front
compartment lower rails. Mounting provisions for the
front suspension system are shared by chassis
components (suspension lower control arms and cross
member) and body components (engine compartment
side panels). The suspension strut towers must be
dimensionally correct in relation to the remainder of
the underbody in order to maintain specified
suspension strut and
castedcamber angles.
Since the individual underbody components also
contribute directly to the overall strength of the body,
it is essential that proper welding techniques be
observed during service repair operations. The
underbody components should be properly sealed and
rustproofed whenever body repair operations destroy
or damage the original sealing and rustproofing. When
rustproofing critical underbody components, it is
essential that a good quality type of air dry primer be
used (such as corrosion resistant chromate or
equivalent material). It is not advisable to use
combination type primer-surfacers.
ALIGNMENT CHECKING
An accurate method of determining the
alignment of the underbody utilizes a measuring tram
gage. The tram gage set required to perform the
recommended measuring checks must include a
vertical pointer capable of reaching 914 mm (36").
Two types of measurements can be made with
a
tram gage: direct point-to-point measurements and
measurements calculated on a horizontal
vlane (datum
line) parallel to the underbody. In the
latter case, the
vertical pointers must be set as specified for each point
to be measured (Fig. 3-1).
Point-to-point measurements are generally taken
only on engine compartment components (Fig. 3-2)
and simply require the vertical pointers to be equally
set.
Figure #3-3 describes the alphabetically
identified points of measurement. Figure 3-4 provides Floor
pan insulators have been designed for the
higher floor pan temperatures that result from the use
of the catalytic converter in the exhaust system.
Therefore, when servicing a vehicle in the field, it is
essential that any insulators that may have been
disturbed or removed be reinstalled in the original
sequence and location. Also, if it becomes necessary to
replace an insulator, the material specified for that
particular location on the floor pan must be used. The
types of materials are listed below. Items 1 and
2 are
rolled stock and are ordered by linear foot and cut to
fit.
1. Insulator floor pan
(cerra blanket thermal) -
consists of 10 mm (3/8") thick aluminum silica
(type 1).
2. Insulator floor pan (amberlite) - consists of 10
mm
(3/8") thick resinated fibers (type 2).
3. Insulator floor pan sheet (phenolic bonded fiber
glass)
305 mm x 457 mm (12" x 18") cut to size,
(type 3).
All of the above materials must meet
Motor Vehicle Safety Standard No. 302 for
flammability.
When servicing or replacing interior insulators,
the following instructions must be observed:
1. Insulators must be installed in the original
position and sequence. Pieces should be butted
together in order to avoid gapping or
overlapping.
2. If it is necessary to replace an insulator, the
specified material must be used.
3. Use original
part to determine the amount of
replacement material required and as a template
for cutting and fitting the new piece to the floor
pan.
4. When installing insulator, do not enlarge cutouts
or holes that are used for the attachment of
interior components such as seats or seat belts.
5. Cross body harnesses for interior components
such as power seats, lap belt warning light and
buzzer or rear speakers must be routed over the
floor pan insulators in the original location and
clipped in place.

UNDERBODY-F STYLE 3H-3
Fig. 3-2 - Suspension Strut and Upper Rail Dimensions
Front edge of 24 mm (15/16") " ( hole
Leading edge of upper tie
( bar
C Front edge of 16 mm (5/811) gage hole (front edge center
of slot on right side)
I
Front edge of outboard strut
mounting slot
I
Leading edge of lower tie
bar at corner
F Center of 9 mm (23/6411) hole
in rail depression
G Center of 9 mm (23/6411) hole
in rail depression
H Center of 16 mm (5/811) gage / hole
I Front edge of 18 mm (11/16'~) gage hole
J Center of 16 mm (5/811) hole
Front edge of
18 mm (11/16") I hole Lower
surface of engine
compartment rail
None
Lower
compar
(slot surface
of engine
.tment rail at hole
on right side)
Lower surfaces of strut
tower 'at slot
None
None
None
Lower surface of reinforce-
ment rear of rail at hole
Lower surface of rail at
hole
Lower surface of rail at
hole
I Lower surface of rail at hole Eng
ine compartment rai
1 forward of lower tie bar
Engine compartment bar,
upper rai
1
Engine compartment rail,
forward of suspension
pocket
Shock-strut tower
Engine compartment bar
lower rail
En ine compartment upper
si e rail
I%
Engine compartment upper
side rail
Floor pan reinforcement
behind engine compartment
rai
1
Rear longitudinal rail
Shock mounting hole rear
longitudinal rail
I
Rear longitudinal rail,
forward of 25 mm (1") hole 2617
Fig. 3-3 - Underbody Horizontal and Vertical Locations

Battery .......................................................... 6D1-2
Brakes
.................................................................. 5-3
................................ Bumper. Energy Absorber 2B-2
........................................... Charging System 6D3- 1
........................................ Cooling and Radiator 6B-3
....................... ................ Cranking System .. 6D2- 1
Cruise Control
................................. 9B-4, 8A-34-0
......................................... Drive Axles (Rear) 4B1-2
Engine Performance
......................................... 6-3
.............................................. Ignition System 6D4-3
Instrument Panel, Gages and
.................................................... Console 8C-3
............................. Miscellaneous Accessories 9G-2
............................................... Power Antenna 9A-2
Power Recirculation Ball
.................................. 3-3
Power Steering Pumps
........................................ 3-4
.............................................. Propeller Shaft 4A- 1
................................................................ Radio 9A-1
.............. Seal Replacement Recommendations 3- 10
........................ . Steering Gear and Pump Leaks 3-10
.............. Strut Dampener and Shock Absorber 3- 12
.................................................... Trim
Height 3- 14
.................................................. Steering Linkage 3-3
Steering, Suspension, Tires and
Wheels
.............................. .. ................. Section 3
Steering Wheels and Columns
............................ 3-4 ......................................................... Vibrations 3- 14
................................................. Wheel Bearing 3-14 .............................................. Wheels and Tires 3- 13
........................... Windshield Wiper System 8El-2
............................................. Digital Cloclc 8A- 150-0
Disc Brake Caliper Assembly
.......................................... (3000/3 100 Series) 5B1
............... ................... General Description .. 5B 1-2 ............................................... On-Car Service 5B 1-2
...................................... Caliper Assembly 5B 1-2
.......................... Shoe and Lining Assembly 5B 1-4
...................................................... Unit Repair
5B 1-4
.......................................... Caliper Overhaul 5B 1-4
?isc Brake Caliper Assembly (3548
Series)
............................................................. 5B6
General Description
....................................... 5B6-2
On-Car Service
............................................... 5B6-2
....................................... Caliper Assembly 5B6-2
.......................... Parking Brake Adjustment 5B6-3
.......................... Shoe and Lining Assembly 5B6-4
Unit Repair
............................... ... .................... 5B6-5
Caliper Overhaul
.......................................... 5B6-5
.......................... Door Lock Relay (Circuit) 8A- 130-0
Driveability and Emissions
........................ Section 6E
Fuel Injection (Port)
..................................... 6E3-1
Index
................................... follows 6E3-(213-2
...................................... Fuel Injection (TB 1) .6E
2- 1
...................................... Index follows 6E2-C 14-4
Drum Brake Assembly
................... ......... Section 5C3
General Description
......................... ... ............ 5C3-1
........................................... On-Car Service 5C3- 1
Backing Plate
........................................ 5C3-7
....................................... Brake Adjustment .5C 3-4
..................................... Brake Components 5C3-1
Parking Brake Adjustment
.......................... 5C3-4
Wheel Cylinder ........................................... 5C3-5 ..................................................... Unit Repair 5C3-7
............................ Wheel Cylinder Overhaul 5C3-7
CHASSIS INDEX m3
E
........................ Electric Rear Window Defogger 9G-2 ............................................ Electrical Diagnosis 88-1
Audible Alarms .............................................. 81%-77
.......................................... Component Data 818-201
.................................................... Headlights 8A- 100
........................ Heating and Air Conditioning 8A-60 .............................................................. Index $A- 1
........................................... Instrument Panel .8 A-82
.................................................. Introduction 8A-2
........................................................... Lights .8 A- 100
............................................ Repair Procedure 88-5 ........................................ Seats and Mirrors 8A- 141
......................................................... Symbols 8A-3
Troubleshooting Procedures ............................ 8A-4
.................................................. ... Windows .. .8 A- 120
............................................... Wiper/Washers .8 A-90
Electronic Glare Control Mirror
........................ 9G-4
.......................... Electronic Instrument Cluster 86-4, 6
Emissions and Driveability
....................................... Fuel Injection (Port) 6E3- 1
....................................... Fuel Injection (TB1) 6E2-1
Engine
.... V-6 2.8L VIN CODE S RPO (LB8) Section 6A2
.... V-8 5.OL VIN E and F, 5.7L VIN 8 Section 6A3
................................................. Cooling Section 6B
Engine Specifications
............................................................ V-6 6A2-26
............................................................. V-8 683-28
General Description
.............................................................. V-6 61 ............................................................. V-8 6A3-1
Lubrication System ........................................................... V-6 ..6A 2- 1
................................................................ V-8 6A3-2
Multi-port Fuel Injection
..................................................... VIN S 8A-20-0
................................................. VIN 8 8A-23-0
............ Throttle Body Injection (VIN E) 8A-22-0
................ Tuned Port Injection (VIN F) 8A-2 1-0
On-Vehicle Service Camshaft
......................................................... V-6 6A2-16
................................ ..................... V-8 .. 6A3-16
Camshaft Bearings
......................................................... V-6 6A2-16
...................................................... V-8 ..6A 3-17
Connecting Rod Bearings
......................................................... V-6 .6A 2- 18
................................................... V-8 6A3-13
...................... Crankcase (Front Cover) .6A
2- 15
............ Crankcase/Camshaft Sensors Section 6E3
Crankshaft
....................................................... V-6 6A2-25
......................................................... V-8 .6A 3-28
......................................... Cylinder Block .6A 3-26
Cylinder Head
.......................................................... V-6 682-12
.......................................................... V-8 6A3-11
Dipstick Tube .............................................. 6A3-7
Engine Assembly
....................................................... V-6 6212
.......................................................... V-8 6A3-27
Exhaust Manifold
........................................................ V-6 .6A 2-9
V-8
....................................................... 6A3-7

6- CHASSIS INDEX
Upper Air Outlet Deflectors ...................... 8C-12
Interior Lights ............................................. 8A- 1 17-0
Intermediate Shaft (Steering Column)
.............. 3B5-3
J
Jump Starting .................................................... 6D 1-4
Junction Block
((2238) ................................. 8A-202-2
L
Lamp Monitoring ......................................... 8A- 1 1 1-0
License Plate Lights .............................................. 8B-2
Light Switch
.................................................... 8A- 12-0
Lighting Systems and Horns
...................... Section 8B
General Description ......................................... .8 B- 1
Exterior Lights
............................................ 8B- 1
Horns ....................... .. ................................. 8B-3
On-Car Service
.................................................. 8B-3
Exterior Lights 8B-3
Horns
.............................................................. 8B-9
Replacement Bulb Specifications .................... 8B-10
Lights (Exterior) Electrical Diagnosis
Back-up
...................................................... 8A- 1 12-0
Fog ............................................... 8A- 100.3,10 3.0
Front
Marker/Park/Hazard .................... 8A-110-0
Hazard with Lamp Monitor .................... 8A-103-0
Headlights .................................................. 8A- 100-0
High Level Stop
..................................... 8A-110-0
License .................................................. .8A.110.3, 4
Rear Marker
........................................... .8 A. 1 10.3, 4
Stop ........................................................... 8A-110-1
Tail ......................................................... .8 A. 1 10.3, 4
Tail with Monitor
................ .... ........... 8A- 1 1 1-2
Turn
......................................................... 8A- 1 10-0
Lights (Interior) Electrical
Diagnosis Cargo Compartment
............................. 8A- 1 14- 1
Courtesy
................................................. 8A- 1 14-0
Dome
.................................. .. ...................... 8A- 1 14-0
Glove Box .................................................. 8A- 1 14-0
Lights Dimming
...................................... 8A- 1 17-0
Reading
...................................................... 8A- 1 14-0
Lower Heater Outlet
........................................ 1A-14
Lubrication Fitting Locations .............................. OB-6
M
Maintenance and Lubrication .................... Section OB
Manual Transmission
. 5 Speed 77 mm .... Section 7B
Diagnosis
........... .. ............................................ 7B-2
On-Vehicle Service
.......................................... 7B-3
Repairs
................................... .... .................... 7B- 12
Special Tools
................................................. 7B-20
. Specifications .............................................. 7B 19
Maintenance Items
................................................ OB-2
Master Cylinder
........................................ Section 5A3
General Description
...................................... ..5A 3.2
On-car Sevice
................................................ 5A3-2
Unit Repair ..................................................... .5A 3.2
Master Cylinder Overhaul
......................... .5A 3.2
Master Cylinder Reservoir
......................... .5A 3.3
Metric Fasteners
................................................ OA- 1
Metric-English Conversion Table ..................... .O A. 10
Miscellaneous Accessories
........................ Section 9G
Diagnosis
.......................................................... 9G-2
Dash/Console Mounted Accessory
Switches
.................................................... 9G-4 Electric
Rear Window Defogger
................ 9G-2
Power Remote Control
Rearview
......................... Mirror ...................... .. 9G-2
Rally Gages
................................................. 9G-2
Tachometer
.................................................. 9G-2
..................................... General Description 9G-4
Electric Glare Control Monitor
.................. 9G-4
Electric Rear Window Defogger
................ 9G-2
Power Remote Control
Rearview
Mirror ..................................................... 9G-2
Rally Gages
................................................. 9G-1
Tachometer
................................................. 9G-1
Trip Odometer
............................................ 9G-1
............................................. On-Car Service 9G-4
Power Remote Control Mirror
.................... 9G-4
Rally Gages. Tach
..................................... 9G-4
Rear Window Defogger
.............................. 9G-4
Mirrors..Power ............................................ 8A- 141-0
Automatic
Day/Night ............................. 8A- 143-0
..................................... Defogger. Mirror 8A-61-0
.......................................... Model Identification OA-'
Muffler ................................................................. 6Fi
N
Neutral Start and Back-Up Lamp
Switch
...................................... ..
0
On-Vehicle Service
Air Conditioning
.................................... ... . 1B-20
Automatic Transmission
............................... .7A 1.3
Battery
........................................................ 6D1-5
................................ ......................... Brakes ... 5-7
Bumpers
......................................................... 2B-4
Charging System
.............................. ... ........... 6D3-2
Chassis Sheet Metal
.......................................... 2C-7
Clutch
................................................................ 7C-5
Cranking System
............................................ 6D2-4
Cruise Control ............................................... 9B-6
Disc Brake Caliper Assembly,
3000/3 100 Series .......................................... 5BliC
Disc Brake Caliper Assembly,
3548 Series
................................................... 5B6-3
Drum Brake Assembly .................................... 5C3-1
Engine (V-6) .................................................... 6A2-7
Engine (V-8) ................................................ -6A3-5
Engine Cooling ....................................... .. .... 6B- 14
Front Suspension
........................................... 3C-1
Horns and Lighting System .............................. 8B-3
Ignition System
.............................................. 6D4-5
Instrument Panel, Gages and
Console
.......................................................... 8C-4
Lighting System and Horns
.......................... .... 8B-3
Miscellaneous Accessories
.......................... .... 9G-4
Power Head Assembly
. Tandem
Diaphragm
................................................. 5D-2
Power Steering Gear and Pump
.................... 3B7-3
Propeller Shaft
............................................. 4A-1
.......................... Radio Systems and Antennas 9A-9
Rear Axle
.......................................................... 4B-8
Rear Axle (Borg Warner)
........................... ... 4B 1-7
Steering Linkage ............................................. 3B6-2
........................ Steering Wheels and Columns 3B5-2
Wheel Alignment
......................................... 3A-2
Windshield Wiper
- Washer System ................ 8E-3

8- CHASSIS INDEX
Recommended Fluids and Lubricants ................ OB-6
Relay Rod
......................................................... 3B6-2
Remote Mirror Control
...... See Body Service Section
5H.1. 15
Repair Procedures
.......................................... 88-50
S
........................................ Scheduled Maintenance OB- 1
Seats (Power) ....................................... Lumbar Support 8A- 145-0
............................. Sequential Fuel Injection 6E3-C2- 1
Service Engine Soon Light
.................................... 8C-3
Sheet Metal and Grille
................................ Section 2C
......................................... General Description .2 C. 1
........................................... Service Procedures .2 C. 1
................................................................. Hood .2 C. 1
...................................................... Hood Hinge 2C-2
Hood Latch and Cable
...................................... 2C-2
Paint
.............................................. Color Matching 2C-5
................................................ Identification -32-6
Interior Plastic Parts ...................................... 2C-6
................................................ Shock Absorbers 3D-
1
Shoe and Lining Assembly
. Brake
............................................ 3000/3 100 Series 5B1-3
3548 Series ...................................................... 5B6-4
Side Marker Lights
.............................................. 8B-2
........ Speakers See 8A- 150-0 & Body
Manual Section
6H- 1
.................... Spark Plug Gap .. .................. 6E3-13-3
................................ Speaker and Speaker Grille 9A-9
Special Tools
............................................ Air Conditioning 1 B-3 5
Air Conditioning Compressor
................................................. Overhaul 1D1-21
........................ Automatic Transaxle AT-700-R4-64
................................................................ Brakes SF-1
Clutch ................................................................ 7C-8
................................................................ Rear 4B1-20
....................................... Rear (Borg Warner) 4B-20
........................... Driveability and Emissions .6 E. 17
................................................ Engine Cooling 6B- 14
Power Steering Pump
& Gear ...................... 3B7-17
............................................... Propeller Shaft .4 A. 12
Steering Wheels and Columns
.......................... 5-35
Specifications Automatic Transmission Unit
............................................ Repair AT-700-R4-59
..................................................... Battery 6D 1-7
................................................................ Brakes 5F-1
Bumpers
......................................................... 2B-5
Charging System
................ .. ................... 6D3-3
.............................................................. Clutch .7 (2.8
....................................... Cranking System 6D2- 1 1
Driveability and Emissions ............................ 6E-23
................................................ Engine (V-6) ..6A 2.26
Engine (V-8) .................................................. 683-28
........................................ Front Suspension 3C- 10
Power Steering Gear and Pump
.................. 3B7-18 ............................................. Propeller Shaft .4 A. 12 ........................................................ Rear Axle 4B-19 ............................ Rear Axle (Borg Warner) 4B 1- 19
Rear Suspension
.............................................. 3D-9
.......................................... Replacement Bulbs 8Br 10 .............................................. Steering Linkage 3B6-6
Steering Wheels and Columns
...................... 3B5-35
........................................ Wheel Alignments 3A-4
....................................................... Speedometer 8C-2
........................................ Speedometer (Removal) 8C-5
...................................................... Speed Sensors 8C-1
Starter ........................................ Section 6D2. 8A-30-0
............................................. Starter (Circuit) 8A-30-0
Steering Linkage ...................................... Section 3B6
....................................... General Description 3B6-1
........................ Maintenance and Adjustments 3B6-1
................................................ On-Car Service 3B6-2
..................................................... Idler Arm 3B6-4
................................................ Pitman Arm 3B6-5
.................................................... Relay Rod 3B6-3
Tie Rods
...................................................... 3B6-2
.................................................. Specifications 3B6-6
Steering, Suspension, Tires and
Wheels Diagnosis
............................................................. 3-1
Steering Wheels and Columns
............................ 3B5-1
..................................... General Information 3B5- 1
Maintenance and Adjustments
...................... 3B5-'
On-Car Service .............................. .. ........... 3B5
Checking for Accident Damage
.................. 3B5-5
Intermediate Shaft ............... .. .................... 3B5-3
Park Lock Cable .......................................... 3B5-4
Standard Column
............................. Automatic Transaxle 3B5-13
Manual Transaxle ................................. 3B5- 19
Tilt Column
.............................. Automatic Transaxle 3B5-27
.................................. Manual Transaxle 3B5-19
Unit Repair Intermediate Shaft
...................................................... Assembly 3B5-6
................................................. Special Tools 3B5-35
Torque Specifications
.................................... 3B5-35
............................................. Starting System 8A-30-0
........................................ Strut Assembly (Front) 3C-4
.................................... ..... Symbols Chart ... 8A-3-0
T
.......................................................... Tachometer 9G-1
Tail/Stop/Turn Signal/Lights .......................... 8B-2
Temperature Cable
.............................................. 112 A-
Temperature Warning Light ................................ 8C-3
Theft Deterrent (Circuit)
.............................. 8A-133-0
Tie Rods
.............................................................. 3B6-2
Tires and Wheels
........................................ Section 3E
Diagnosis
.................................................. Section 3
General Information
......................................... 3E-1
................................................... Metric Tires 3E-2
....................................... Replacement Tires .31 E-
.................................................... Tire Placard 3E-2
........................................................... Wheels 3E-2
Maintenance and Adjustments
.......................... 3E-2
.......................... Aluminum Wheel Cleaning 3E-9
............................. ......... Inflation of Tires .. 3E-3
........................................ Tire Chain Usage 3E-4
.................................................. Tire Rotation 3E-3
.............................................. Wheel Repair 3E-2
...................................... Wheel Studs/Nuts 3E-3
........................................... Service Operations 3E-4
........................ Aluminum Wheel Cleaning 3E-9
.................................... Balance Precautions 3E-7
............................ Balancing Tire and Wheel 3E-7
.............................................. Compact Spare 3E-6
........................ Correcting Nonuniform Tires 3E-8