engine PONTIAC FIERO 1988 Service Repair Manual

DOORS - F STYLE 5H-1
SEC"610N 5H
DOORS
NOTICE: The anit-theft label found on some major sheet metal, engines, and transmissions must be masked
prior to painting, rustproofing, undercoating, etc. The mask
must be removed following the above operations.
Failure to keep the label clean and readable may result in liability for violation of Federal Vehicle Theft Prevention
Standard, and subject the vehicle owner to possible suspicion that the part was stolen.
Door Trim
...................................................... 5H- 1
Armrest and Pull Handle .......................... 5H- 1
Mirror Remote Controls/Bezel ................... 5H- 1
Inside Handles and Cover Plates ................ 5H- 1
Lock Knob .................................... .... ........... 5H-2
Trim Panel Assemblies .............................. 5H-2
Doors ............................................................ 5H-3
Door Weatherstrip ....................................... 5H-4
Side Roof Rail Weatherstrip ....................... 5H-4
Window Belt Sealing Strips ......................... 5H-6
Insulator Pads - Optional ............................ 5H-6
Inner Panel Water Deflectors ...................... 5H-6
Door Hinge System .................................. .... 5H-7
Door Side Hinge Strap ............................... 5H-8
Body Side Hinge Strap ................................ 5H- 10
Door Window ..................... .. ................... 5H- 10
Window Sash Channel ................................. 5H- 1 1
Window Regulator and Motor .................... 5H- 1 1
Filler Assembly (at Belt) ......................... ... . 5H- 13
Up Stop ............................ .. ...................... 5H- 14
Rear Guide Channel .................................... 5H- 15
DOOR SECnONS
This section of the manual contains the service
operations necessary for the removal, installation,
adjustment and sealing of door assemblies and
individual hardware and trim components. It is divided
into three subsections:
1. DOOR TRIM
- removal and installation
procedures for all door trim items.
2. DOORS - including hinges, door and side roof
rail weatherstrip and all lock system components.
3. EXTERIOR MOLDINGS - removal and
installation of exterior door moldings. Standard Mirror
......................................... 5H- 15
........................... Remote
Control Mirrors 5H- 15
Power-Operated Outside Mirror ................. 5H-16
Spring Clips .................................................. 5H- 16
Connecting Rods and Locking Rods .......... 5H-16
Inside Remote Handle ................................ 5H- 16
......................................... Outside Handle 5H- 16
............................. Lock Cylinder Assembly 5H- 17
...................................... Door Lock Striker 5H- 17
....................................... Door Wedge Plate 5H- 18
....................................... Door Jamb Switch 5H- 19
........................ Door Hardware Lubrication 5H- 19
Hardware Attachment Thread
.................................................. Locking 5H- 19
................................... Door Lock Assembly 5H- 19
............................ Power Door Lock System 5H-20
........................ Power Door Lock Actuator 5H-20
............. .................................... Bell Crank ... 5H-20
.......................................... Exterior Moldings 5H-20
.......................................... Spoiler on Door 5H-21
.......................................... Spoiler on Body 5H-2 1
DOOR OUTSIDE MIRROR REMOTE CONTROLS
AND BEZEL
On styles with remote control door outside
mirror, the remote control mirror cable must be
disengaged from the bezel on the door trim panel to
permit trim panel removal. To disengage the remote
cable from the door trim panel, refer to Figure
2.
DOOR INSIDE HANDLES AND COVER PLATES
Door inside handles are retained by either rivets
or spring clips (Fig.
4). On styles equipped with rivet
retained handles, the rivets are covered by a screw
retained cover plate that can be removed as shown in
Figure
3.
DOOR TRIM Removal and Installation
DOOR ARMREST AND PULL HANDLE 1.
ASSEMBLIES
The armrest and pull handle is a one-piece
assembly and is secured to the door inner panel with
screws after door trim panel is installed (Fig. 1). Clips hidden
by window regulator handles (Fig,
4) can be disengaged by depressing door trim
assembly enough to permit inserting tool J-9886
or equivalent between handle and trim panel or
plastic bearing plate (Fig.
5). Then, with tool in
same plane as inside handle, push tool as
indicated to disengage clip. Pull handle inboard
The removal of the door trim panel on styles with to
remove from
s$n>le. -
door armrest and pull handle assemblies requires 2. To install window regulator handles, engage
removal of screws inserted through the assembly's base retaining clip on handle. Position handle at same
into the armrest hanger plate and removal of the screw angle as opposite side handle and press handle
at the top of the pull handle section.
outboard until clip engages regulator spindle.

DOORS - F STYLE 5H-99
1. SPACER
2. SPACER
3. WEDGE PLATE
4. SCREW (8HORT)
6. SCREW (LONG) G93893.5H-F
Fig. 40 - Door Wedge Plate
DOOR JAMB SWITCH
Door jamb switch assemblies consist of a plunger,
plunger collar, threaded retainer and terminals. They
are installed in the front and rear door hinge pillars.
When the door of the vehicle is closed, the plunger is
depressed which creates an open in the ground circuit.
When the door is opened, the plunger is released and
completes the circuit to ground (Fig. 41).
When a new jamb switch is installed and the door
is closed the first time, the plunger is forced into the
sleeve and automatically adjusts the jamb switch for
that particular door. If a jamb switch fails, it should not
be readjusted by hand. A new jamb switch should be
installed.
Remove or Disconnect
1. Jamb switch
2. Electrical connector
Install or Connect
1. Electrical connector
2. Jamb switch
DOUBLE TERMINAL
I SINGLE TERMINAL I
Fig. 4 1 - Door Jamb Switches
DOOR HARDWARE LUBRICATION
The mechanical components of the door
assembly are lubricated during assembly. If additional
lubrication is required, use the following lubricants.
Black lock cylinders should be lubricated with a light
oil. All other door lock cylinders should be lubricated
with a general purpose silicone lubricant, part no.
1052277 or equivalent. Door hinge pins and rollers
should be lubricated at normal service intervals with 30
weight engine oil. Do not lubricate hinge roller to
hold-open link contacting surfaces as this may prevent
the roller from rolling properly. The remainder of all
door hardware mechanisms except lock assemblies can
be lubricated with part no. 1052349, Lubriplate
Spray-Lube "A", part no. 1052196, Lubriplate
Auto-Lube "A" or equivalent.
HARDWARE ATTACHMENT THREAD LOCKING
All door hardware production attaching screws
contain an epoxy thread-locking compound to insure
that the minimum original torque setting will be
maintained.
Service attaching screws may not contain a
thread-locking compound. To prevent loosening of
service screws or to renew thread-locking
characteristics of production screws, the threads of the
fastener(s) can be treated with part no. 1052279,
Loctite 75 (or equivalent) which is a two-part material
applied to the hardware attachment as a liquid. Upon
installation and tightening, the adhesive cures to bond
the attachment and prevent loosening or back out. The
adhesive bond does not prevent future attachment
removal if required. Loctite 75 or equivalent can be
used on any threaded fastener.
DOOR LOCK SYSTEM
This portion of the manual contains the service
operations necessary to remove the door lock and lock
cylinder assemblies. Any work performed on lock
system hardware requires the removal of the door trim
panel and inner panel water deflector.
Service procedures for spring clips, connecting
rods, locking rods, inside handles, outside handles and
the door lock striker were described previously in this
section.
DOOR LOCK ASSEMBLIES
A fork bolt lock design is utilized which includes
a safety interlock feature. The door is secured in a
closed position when the door lock fork bolt snaps over
the striker bolt. Doors can be locked from the inside
by sliding the door inside locking knob. Both doors can
be locked from the outside by simply sliding the
interior door locking knob and closing the door or by
using the proper key.
Do not attempt repairs to correct lock
discrepancies. Make corrections through
replacement of lock assembly.

REAR QUARTERS - F STYLE 8H-1
SECTION 6H
REAR QUARTERS
NOTICE: The anti-theft label found on some major sheet metal, engines, and transmissions must be masked
prior to painting, rustproofing, undercoating, etc. The mask
must be removed following the above operations.
Failure to keep the label clean and readable may result in liability for violation of Federal Vehicle Theft Prevention
Standard, and subject the vehicle owner to possible suspicion that the part was stolen.
CONTENTS
Quarter Trim .................................................... 6H- 1
Lower Trim Finishing Panel ....................... 6H- 1
Body Lock Pillar Trim Finishing
Panel
., ....................................................... 6H- 1
Upper Trim Finishing Panel Insert ............. 6H- 1
....................................................... Speakers 6H- 1
Lift Window Upper Finishing
Molding
..................................................... 6H-2
....................... Upper Trim Finishing Panel 6H-2
QUARTER TRlM
QUARTER LOWER TRlM FINISHING PANEL
Removal and Installation (Fig. 1)
Remove body lock pillar finishing panel (Fig. 3).
Remove rear
seatback lock striker.
Remove retaining screw in rearward area of
quarter lower trim panel.
Remove rear screws from sill plate and carpet
retainer (Fig.
2).
Grasp quarter lower trim panel with hand; then
pull forward and down to disengage from
pinchweld flange at weatherstrip and quarter
upper trim finishing panel.
Remove seat belt through slot in trim panel.
Remove quarter lower trim finishing panel from
car by lifting up on rear portion of sill plate and
carpet retainer; then pull quarter trim rearward.
To install, place panel retaining slots under
quarter upper trim panel and apply upward
pressure to secure.
Position panel assembly to body. Thread lap and
shoulder belt through respective slots in panel.
Install attaching screws to secure panel to body.
Replace all previously removed components.
BODY LOCK PILLAR TRlM FINISHING PANEL
Removal and lnstallation (Fig. 3)
1. Remove trim panel attaching screws.
2. Using trim removing tool J-24595B, BT-7323A
or equivalent, carefully disengage nylon fasteners
that retain body lock pillar panel to quarter upper
trim finishing panel.
3. To install, reverse removal procedures. Spare
Tire Cover Trim Finishing
Panel
........................................................ 6H-3
Rear Stowage Compartment Box
Assembly
................................................... 6H-4
Luggage Shade Cover Assembly
................. 6H-4
Exterior Moldings
........................................... 6H-6
Fuel Tank Filler Door and Pocket
Assembly
....................................................... 6H-7
Spoiler Extension
............................ .. ........... 6H-7
QUARTER UPPER TRlM FINISHING PANEL
INSERT
Removal and Installation (Fig. 4)
1. Remove coat hook.
2. Grasp panel insert with hand and pull upward to
disengage retainers from cutout slots in quarter
upper trim finishing panel (Fig. 4).
3. To install, reverse removal procedures.
REAR QUARTER SPEAKERS
The rear quarter speakers are installed to a
speaker retainer. The retainer and speaker are then
attached to the quarter inner panel by screws.
Standard Speakers
Remove or Disconnect
1. Quarter upper trim finishing panel insert
2. Screws securing speaker retainer
3. Disconnect electrical
connector from speaker
4. Speaker
Install or Connect
1. Speaker to body
2. Electrical connector
3. Screws securing speaker to retainer
4. Quarter upper trim finishing panel insert
Subwoofer Speakers (2FS/FW/FX Styles)
Remove or Disconnect (Fig. 5)
1.
Quarter upper trim finishing panel insert (Fig. 4)
2. Body lock pillar trim finishing panel (Fig. 3)
3. Two rear screws from carpet retainer (Fig.
2)
4.
Quarter lower trim finishing panel

REAR END - F STYLE 7H-1
SECTION 7H
REAR END
NOTICE: The anti-theft label found on some major sheet metal, engines, and transmissions must be masked
prior to painting, rustproofing, undercoating, etc. The mask
must be removed following the above operations.
Failure to keep the label clean and readable may result in liability for violation of Federal Vehicle Theft Prevention
Standard, and subject the vehicle owner to possible suspicion that the part was stolen.
CONTENTS
Moldings, Emblems and Name Plates ............ 7H- 1
Compartment Lift Window
.......................... ... 7H-2
Adjustments ........................... .. ................ 7H-2
Removal and Installation ............................. 7H-3
Removal of Lift Window Panel from
Glass
....................................................... 7H-3
Glass Replacement and Adjustment ........... 7H-5
Gas Support Assembly ............................. 7H-7
Lock Cylinder ....................... .. .............. 7H-8
REAR COMPARTMENT
The service operations for the removal,
installation, adjustment and sealing of the
compartment lift window assembly, individual
hardware components, moldings, emblems and name
plates attached to the compartment lift window or rear
end panel are contained in this section.
MOLDINGS, EMBLEMS AND NAME PLAES
The moldings, emblems and name plates used on
the rear compartment and rear end panels are adhesive
attached. Figure 1 illustrates the different types of
attachment.
Fig. 1 - Molding, Name Plate and Emblem Retention
General Precautions
When removing or installing any body exterior
molding, emblem or name plate, care should be
exercised.
1. Adjacent
finishes should be covered to prevent
damage to finish.
...................................... Pull Down Unit 7H-8
.......................................... Release Solenoid 7H-9
......... ..................................... Lock Striker ... 7H-9
................... ....................... Weatherstrip .. 7H- 1 1
.................................................. Trim Panel 7H- 1 1
..................... Lift Window Wiper System 7H- l l
......... Rear Compartment Trim and Electrical 7H- 1 1
............... Compartment Lift Window Spoilers 7H- 13
.......................................... Exterior Lamps 7H- 15
ADHESIVE-BACKED MOLDINGS, EMBLEMS
AND NAME PLATES
Adhesive-backed emblems and name plates can
be removed from the body with the use of a hot air gun.
Removal
1.
Hold hot air gun 300 mm (12") from the surface
of the part to be removed.
2. Apply heat using a circular motion for about 30
seconds; then using care, peel part from body
surface.
Installation
To install, body surface must be warm (21°C or
70"F), clean and wax free.
1. Check for proper alignment with adjacent
moldings, emblems and/or name plates if
applicable.
2. Remove backing from part to be installed and
press firmly in place.
3. If reinstalling previously removed part or
partially loosened emblem, apply a thin, even film
of Loctite 414 Adhesive or equivalent to adhesive
portion of emblem, align and press firmly in
place.
a. If a separation occurs between the
adhesive-backed tape and name plate or
emblem (tape remains on body panel), do
not remove tape from body. Wipe back of
name plate or emblem and adhesive tape
with oil-free naphtha.
b. Apply a thin even film of Loctite 414
Adhesive or equivalent to the adhesive
portion of the emblem or name plate.
c. Immediately align name plate or emblem
and press firmly in place. Hold in place with
tape strips.
2. Proper tools and care should be used to guard d. Allow to set 15 minutes. If cleanup of
against molding damage. cement squeeze-out is required, use a cloth

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

4 . CHASSIS INDEX
Fitting Pistons ......................................... .6A 2.24
Front (Cover) Crankshaft Oil
Seal
V-6
......................................................... 6A2- 15
V-8
................................................... 6A3- 16
Gear or Sprocket
V-6
......................................................... .6A 2.26
V-8
........................................................ 6A2-28
Honing and Reboring Cylinders ................ 6A2-23
Intake Manifold and Gasket
V-6
......................................................... .6A 2.9
V-8
............................................................ 6A3-6
Main Bearings
V-6
......................................................... .6A 2. 19
V-8
.......................................................... 6A3-20
Oil Filter and Bypass Valve
...................... 6A3-27
Oil Pan and Pump Assembly
V-6
................................................. 6A2.17, 18
V-8
......................................................... 6A3- 18
Oil Seal (Front Cover)
V-6
......................................................... 6A2- 15
V-8 .......................................................... 6A3-16
Piston and Connecting Rod
V-6
......................................................... .6A 2.2 1
V-8
....................................................... .6A 3.23
Piston Rings V-6
......................................................... .6A 2.24
V-8
........................................................ .6A 3.23
Power Train Mounts
V-6
........................................................... .6A 2.7
V-8
.......................................................... 6A3-5
Rear Main Oil Seal
V-6
......................................................... .6A 2.2 1
V-8 ......................................................... .6A 3.22
Rocker Arm Assembly
V-6
............................................................ 6A2-8
V-8 ............................................................ 6A3-8
Rocker Arm and Push Rod
V-6
........................................................... .6A 2.8
V-8
........................................................ 6A3-8
Rocker Arm Studs 6A2- 13
V-6
......................................................... .6A 2. 13
V-8
.......................................................... 6A3-28
Sprocket or Gear Replacement
V-6
......................................................... .6A 2.26
V-8 .......................................................... 6A3-28
Timing Chain and Sprockets
6A2- 15
Torsional Damper
V-6
.......................................................... 6A2- 14
V-8
.......................................................... 6A3- 15
Valves V-6
........................................ .. ............... .6A 2. 14
V-8
......................................................... .6A 2. 15
Valve Guides
V-6
......................................................... .6A 2. 13
V-8
.......................................................... 6A3-14
Valve Lifters
V-6
......................................................... .6A 2. 1 1
V-8
.......................................................... 6A3-10
Valve Mechanism .................................... 6A 10
Valve Seats
V-6
....................................................... .6A 2. 14
V-8
.......................................................... 6A3-14
Valve Spring
.......................................................... V-6 A- 16
............................................................ V-8 6A3-9
................................. Valve Stem Oil Seal .6A 2. 10 Engine Cooling
........................................... Section
6B
Aluminum Radiator Service
............................ 6B-8
Diagnosis
........................................................ 6B-3. 8
Coolant System .............................................. 6B-4
Leak Testing
.................................................. 6B-8
On-Vehicle Pressure Testing
.......................... 6B-9
Repair Methods
........................................... 6B- 10
Special Tools
.............................................. 6B-14
General Description ......................................... .6 B- 1
Coolant Recovery System
.............................. 6B-3
Coolant Temperature Fan Switch
................ 6B-2
Fans
.............................................................. 6B-2
Radiator
...................................................... 6B-1
Radiator Cap
.................................................. 6B-1
Recovery Bottle
.............................................. 6B-2
Temperature Switch
...................................... 6B-2
Thermostat
.................................................... 6B-3
On-Vehicle Service
......................................... 6B- 14
Coolznt Recovery Bottle
............................. .6 B- 16
Electric Cooling Fan
................................... .6 B- 15
Radiator
....................................................... 6B1'
Thermostat ................................................ 5B-, .
Water Pump ................................... .... ......... 6B-15
Service Procedures
............................................ 6B-3
Cooling System Cure
................................. ... 6B-3
Draining and Refilling the
Cooling System
......................................... 6B-7
Drive Belt
................................................... 6B-7
Engine Electrical ...................................... Section 6D
Battery
............................................................. 6D1
Diagnosis
................................................... 6D 1-2
General Description
.................................. 6D 1-1
On-Car Service
.......................................... 6D 1-5
Charging System
............................................... 6D3
Diagnosis
.................................................... 6D3- 1
General Description
.............................. 6D3- 1
On-Vehicle Service
.................................... 6D3-2
Service Procedures
................................. 6D3- 1
Cranking System .......................... ........ ............ 6D2-
Diagnosis .................................................... 6D2- 1 I
General Description .................................. 6D2- 1
On-Car Service
......................................... 6D2J
................ . Engine Wiring .............................. ... 6D
General Description .................................. 6D5- 1
Ignition System
................................................. 6D4
Diagnosis
................................................... 6D4- 1
General Description
............................... 6D4- 1
On-Car Service
.......................................... 6D4-5
Service Procedures
.................................... 6D4-3
Engine Exhaust Systems
...................................... 6F
Engine
- General Information .............................. 6-1
Compression Test
................................................ 6-5
Engine Knock Diagnosis
................................. 6-4
Engine Mechanical
.............................................. 6-3
Engine Performance Diagnosis
.......................... 6-3
Engine Oil Pressure Light
.................................... 8C-3
Engine Performance Specifications
Chart
........................................................ 6E3-C13-3
Evaporator Core
.............................................. 1B 1-24
Exhaust Systems
.......................................... Section 6F
Catalytic Converters
........................................ 6F- 1
Clamp
................................................................ 6F- 1
Component Replacement
.................................. 6F-2
Hangers
......................................................... 6F- 1
Muffler ............................................................. 6F- 1
Removing and Installing Parts ........................ 6F-2
Resonator .......................................................... 6F- 1

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