boot PONTIAC FIERO 1988 Service Repair Manual

F CARLINE
ITEM 10
TransmissionRransaxle Service
The manual transmission or transaxle fluid does not
require changing. (Corvette only.) Change fluid in over-
drive unit every 30,000 miles (50 000 km).
For automatic transmissions or transaxles, change
both the fluid and filter every 15,000 miles (25 000 km) if
the car is mainly driven under one or more of these
conditions:
@ In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
@ In hilly or mountainous terrain.
@ Frequent trailer pulling.
@ Uses such as found in taxi, police car or delivery
service.
If you do not use your car under any of these condi-
tions, change both the fluid and filter every 100,000 miles
(160 000 km). See you Owner's Manual for further
details.
ITEM 11
Spark Plug Service*
Replace spark plugs with type listed in your Owner's
Manual.
ITEM 12
Spark Plug Wire Inspection*
Clean wires and inspect for burns, cracks or other dam-
age. Check the wire boot fit at distributor and at spark plugs.
Replace wires as needed.
ITEM 13
Positive Crankcase Ventilation (PCV) Valve
Inspection*
Inspect valve for proper function. Replace valve if
necessary as well as any worn, plugged or collapsed
hoses.
ITEM 14
EGR System Service*
Conduct EGR System Service as referenced in the
EGR System Chart shown in the appropriate 6E Section.
Also, refer to your GM maintenance schedule booklet for
specific applications.
ITEM 15
Air Cleaner and PCV Filter Replacement*
On 1.6 and 2.0 liter engines, replace every 50,000
miles (80 000 km). On all other engines, replace every
30,000 miles (50 000 km). Replace more often under
dusty conditions. Ask your dealer for the proper replace-
ment interval for your driving conditions.
MAINTENANCE AND LUBRICATION 08-3
ITEM 16
Engine Timing Check*
Adjust timing to underhood label specifications. If
no specifications are shown, no adjustment is needed.
ITEM 17
Fuel Tank, Cap and Lines Inspection*
Inspect fuel tank, cap and lines (including fuel rails
and injection assembly, if so equipped) for damage or
leaks. Inspect fuel cap gasket for an even filler neck
imprint or any damage. Replace parts as needed.
ITEM 18
Thermostatically Controlled Air Cleaner
Inspection*
If your car is equipped, inspect all hoses and ducts
for proper hookup. Make sure valve works properly.
OWNER INSPECTIONS AND SERVICES
Listed below are inspections and services which
should be made by either you or a qualified technician at
the intervals shown to help ensure proper safety, emission
performance and dependability of your car. Take any
problems promptly to your dealer or another qualified
technician for service advice. Whenever repairs are neces-
sary, have them completed at once. For your safety and
that of others, any safety-related parts that could have
been damaged in an accident should be inspected and all
needed repairs should be done before operating your car.
Be sure to use the proper fluids and lubricants as shown in
Figure OB-2.
WHILE OPERATING YOUR VEHICLE
Automatic transmissionltransaxle shift indi-
cator operation - Make sure the indicator points to the
gear chosen.
Horn operation - Blow the horn occasionally to
make sure it works. Check all button locations.
I
Brake system operation -- Be alert to abnormal
sounds, increased brake pedal travel or repeated pulling to
one side when braking. Also, if a brake warning light
comes on or flashes, or the anti-lock warning light (if
equipped) comes on or remains on, something may be
wrong with part of the brake system. Have it inspected and
repaired at once.
Exhaust system operation - Be alert to any
changes in the sound of the system or any smell of fumes.
These are signs the system may be leaking or overheating.
.
Have it inspected and repaired at once. Also see "Engine
Exhaust Gas Caution (Carbon Monoxide)" and "Catalytic
Converter" in your Owner's Manual.
*An Emission Control Service

OB-4 MAINTENANCE AND LUBRICATION
Tire and wheel operation - Be alert to a vibra-
tion of the steering wheel or seat at normal highway
speeds. This may mean a wheel balance is needed. Also, a
pull right or left on a straight, level road may show the
need for
a tire pressure adjustment or wheel alignment.
Steering system operation - Be alert to
changes in steering action. An inspection is needed when
the steering wheel is harder to turn or has too much free
play or if unusual sounds are noted when turning or
parking.
Headlight aim operation - Take note of light
pattern occasionally. If beam aim doesn't look right,
headlights should be adjusted.
AT EACH FUEL FILL
Engine oil level check - Check engine oil level
and add if necessary. See your Owner's
Manual for further
details.
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Engine coolant level and condition - Check
engine coolant level in coolant reservoir tank and add if
necessary. Replace if dirty or rusty. See your Owner's
Manual for further details.
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Windshield washer fluid level check -- Check
washer fluid level in container and add if necessary.
Hood latch operation - When opening hood on
cars equipped with hoods that open from the front, note
the operation of secondary latch. It should keep hood from
opening all the way when primary latch is released. Make
sure that hood closes firmly.
AT LEAST MONTI-ILY
Tire and wheel inspection and pressure
check--
Check tires for abnormal wear or damage. Also,
check for damaged wheels. Keep pressures as shown on
Tire Placard on the driver's door (include spare unless it is
a stowaway). Pressure should b\: checked when tires are
"cold". See "Tires" in Owner's Manual for further
infomation.
Light operation check - Check operation of
license plate light, side-marker lights, headlights includ-
ing high beams, parking lights, taillights, brake lights.
turn signals, backup lights, instrument panel and interior
lights and hazard warning flashers.
Fluid leak check - After the car has been parked
for a while, inspect the surface beneath the car for water,
oil, fuel or other fluids. Water dripping from the air
conditioning system after use is normal. If you notice fuel
leaks or fumes, the cause should be found and corrected at
once.
AT LEAST TWICE A YEAR (FOR EXAMPLE,
EVERY SPRING AND FALL)
Power steering pump fluid level check --
Check power steering pump fluid level in accordance with
Owner's Manual instructions and keep at proper level.
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Brake master cylinder reservoir fluid level
check ---- Check fluid and keep at proper level. Note: It is
normal for the brake fluid level to go down slightly as the
brake pads wear
- so be sure to keep reservoir filled.
NOTICE: A large loss in this system may indicate a
problem. Have
it inspected and repaired at once.
Clutch system service --- manual transmis-
sionltransaxle --- For cars equipped with hydraulic
clutch system, check the reservoir fluid level and add fluid
as required. All others, check clutch pedal free travel and
adjust as necessary. See your Owner's Manual for further
details.
~
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Weatherstrip Lubrication - Clean surface and
then apply a thin film of silicone grease with a clean cloth.
EACH TIME OIL IS CHANGED
Automatic and manual transmissionltrans-
axle fluid level check - Check transmission/transaxle
fluid level and add as required. (Corvette only) if equipped
with manual transmission
- check fluid in the overdrive
unit and add as required.
NOTICE: A large loss in this system may indicate a
problem. Have
it inspected and repaired at once.
Brake systems inspection - For convenience,
the following should be done when wheels are removed
for rotation: Inspect lines and hoses for proper hookup,
binding, leaks, cracks, chafing, etc. Inspect disc brake
pads for wear and rotors for surface condition. Also in-
spect drum brake linings for wear and cracks. Inspect
other brake parts, including drums, wheel cylinders, park-
ing brake, etc. at the same time. Check parking brake
adjustment.
INSPECT BRAKES MORE OFTEN IF DRIVING
HABITS OR CONDITIONS RESULT IN FREQUENT
BRAKING.
Steering, suspension and front drive axle
boot and seal inspection
- Inspect front and rear
suspension and steering system for damaged, loose or
missing parts, signs of wear or lack of lubrication. Inspect
power steering lines and hoses for proper hookup, bind-
ing, leaks, cracks, chafing, etc. (On cars equipped with
manual steering gear, check for seal leakage.) On
front-
wheel-drive cars, clean then inspect drive axle boot seals
for damage, tears or leakage. Replace seals if necessary.
Exhaust system inspection - Inspect complete
system. Inspect body near the exhaust system. Look for
broken, damaged, missing or out-of-position parts as well
as open seams, holes, loose connections or other condi-
tions which could cause a heat buildup in the tloor pan or
could let exhaust fumes seep into the trunk or passenger
compartment.

5814 DISC BRAKE CALIPER ASSEMBLY .
4. Inboard shoe and lining (6) by snapping retainer
spring (8) into piston (1) ID. Wear sensor (7)
should be at the leading edge of shoe during
forward wheel rotation. Shoe must lay flat against
piston.
5. Outboard
shoe and lining (5). Back of shoe must
lay flat against caliper.
6. Caliper as previously described.
7. Apply approximately
778
N (175 lb) force three
times to brake pedal to seat linings.
8. Position 12-inch channel lock pliers (19) over
brake shoe ears and bottom edge of caliper (13).
While holding moderate force (50 Ibs) on brake
pedal, clinch outboard shoe ears to caliper.
19. CHANNEL LOCK
PLIERS
Figure 58 1-1 0 Clinching Procedure
9. BOOT 10. PISTON 11. PISTON SEAL 12. BLEEDER VALVE 13. CALIPER HOUSING 20. SEAL GROOVE HMO01 1-5B1-BF
Figure 581-1 1 Caliper Assembly
UNIT REPAIR
CALIPER OVERHAUL
Tool Required:
J 26267 Boot Seal Installer (64 mm)
J 22904 Boot Seal Installer (74 mm)
J 28735 Boot Seal Installer (80 mm)
I
13. CALlP-ER HOUSING
I
Figure 58 1-1 2 Removing Piston
Disassemble (Figures 581-1 1 through 5B1-13)
1. Caliper completely from vehicle as previously
described.
2. Piston (10) using compressed air into the caliper
inlet hole.
CAUTION: Do not place fingers in
front of the piston in an attempt to
catch or protect it when applying
comrpessed air. This could result in
serious injury.
Important
e Use clean shop towels to pad the interior of
the caliper (13) during removal.
@ Piston (10) for:
e Scoring
Nicks
e Corrosion
e Worn or damaged chrome plating
e Replace piston if any of the above are found.
3. Boot (9), being careful not to scratch housing
bore,
4. Piston seal
(1 1) from groove (20) in caliper (13)
bore with a small wood or plastic tool. Do not use
a metal tool since this may damage caliper bore
or seal groove.
Inspect
@ Caliper bore and seal groove for:
e Scoring
e Nicks
e Corrosion
Wear
e Use crocus cloth to polish out light
corrosion.
@ Replace caliper housing if corrosion in and
around seal groove will not clean up with
crocus cloth.

DISC BRAKE CALIPER ASSEMBLY 581-5
5. Bleeder valve (12) from caliper (13).
Figure 581-13 Removing Boot
Figure
58 1-1 4 Installing Boot Onto Piston
Assemble (Figures 581-1 1,581-14,581.15)
@ See NOTICE on page 5-1.
Figure 58 1-1 5 Seating Boot Into Housing
e All parts in clean, denatured alcohol.
@ Dry with unlubricated compressed air.
e Blow out all passages in housing (1 3) and bleeder
valve (12).
Bleeder valve (12) to 13
N-m 1 10 Ib-in).
Lubricated new piston seal
(1 1) into caliper bore
groove (20).
@ Make sure seal is not twisted.
Lubricated boot
(9) onto piston (10).
Piston (10) and boot
(9) into bore of caliper (13)
and push to bottom of bore.
Seat boot
(9) in caliper housing (13) counterbore
using appropriate boot seating tool.
Caliper as previously described.

DISC BRAKE CALIPER ASSEMBLY 586-1
SEC"619RI 5B6
SC BRAKE CAL PER ASSEMBLY
3548 SERIES
CONTENTS
General Description ................................. 5B6-2 Unit Repair ........................................... 5B6-5
On-Car Service ........................................ 5B6-2 Caliper Overhaul ....................................... 5B6-5
Caliper Assembly ....................................... 5B6-2
Parking Brake Adjustment ......................... 5B6-3
Shoe and Lining Assembly ......................... 5B6-4
22 LEVER SEAL
1. NUT
2. LEVER
3. RETURN SPRING 4. BOLT 5. BRACKET 8.
BOLT 15.
BALANCE SPRING
23. MOUNT~NG BOLT 9. COPPER WASHER 16. ACUTATOR SCREW 24. BOOT
10 FITTING 17.
PISTON SEAL 25. INBOARD SHOE & LINING 11. BUSHING 18. PISTON ASSEMBLY 26. WEAR SENSOR
12. CALIPER HOUSING 19. TWO
WAY CHECK VALVE 27. OUTBOARD SHOE & LINING 6. SLEEVE 13. SHAFT SEAL 20. BLEEDER SCREW 28. SHOE DAMPENING SPRING 7. BUSHING 14. THRUST WASHER 21. ANTI.FRICTION WASHER 37. DAMPER HM0001-566-F
Fig. 1 Rear Disc Brake Caliper Assembly

DISC BRAKE CALIPER ASSEMBLY 586.5 --
UNIT REPAIR
CALIPER OVERHAUL
Tools Required:
J 23072 Piston Installer
J 2938 1 Boot Seal Installer
Figures 8 thru'l0
Remove or Disconnect
1. Caliper completely from vehicle as previously
described.
2. Shoe dampening spring (28) from end of piston
(18) (Figure 8).
2. LEVER 4. BOLT
5. BRACKET
8. BOLT
9. WASHER
20. BLEEDER VALVE
10. FITTING
21. ANTI-FRICTION
12. CALIPER HOUSING
WASHER
13. SHAFT SEAL
22. LEVER SEAL
14. THRUST WASHER
15. BALANCE SPRING 24. BOOT
16. ACTUATOR SCREW 28.
SHOE DAMPENING
17. PISTON SEAL SPRING
Fig. 8 Caliper
Assembly
3. If installed:
a Nut (1) and lever (2).
a Lever seal (22) and anti-friction washer
(21).
4. Piston (18). Use park brake lever (2) to rotate
adjusting screw (16) to work piston out of caliper (12).
Rotate in parking brake apply direction
(Figures 8
& 9).
Fig. 9 Removing Piston
Important
a Use clean shop towels to pad the interior of
the caliper (12) during removal.
Piston (18) for:
-- Scoring
-- Nicks
-- Corrosion -- Worn or damaged chrome plating
e Replace piston if any of the above are found.
5. Balance spring (15) (Figure 8).
6. Actuator screw (16) by pressing on thread end.
7. Shaft seal (13) and thrust washer (14) form
actuator screw (16).
8. Boot
(24), being careful not to scratch the
housing (12) bore (Figure 10).
1
12 CALIPER HOUSING 24 BOOT 34 SCREWDRIVER
I
Fig. 10 Removing Boot
9.
Piston seal (17) using wooden or plastic tool as as
not to damage caliper (12) bore (Figure 8).
10. Bleeder screw
(20), bolt (8), fitting (10) and
copper washers (9). Remove bracket
(5) only if
damaged.
Inspect
Caliper bore and seal groove for:
-- Scoring
-- Nicks
-- Corrosion
-- Wear

5B6-6 DISC BRAKE CALIPER ASSEMBLY
e Use crocus cloth to polish out light
corrosion.
e Replace caliper housing if corrosion in and
around seal groove will not clean up with
crocus cloth.
Install or Connect
Figures 8, 1 1 thru 13
Important - @ See NOTICE on page 5-1,
e All parts in clean, denatured alcohol.
e Dry with unlubricated compressed air.
e Blow out all passages in housing (12) and
bleeder screw (20).
Bleeder screw (20) and torque to 13 N
. m (1 16 lb.
in.). (Figure
8)
Bracket (5), if removed, with bolt (4) to 43 N-m
(3 1 1b.ft.).
Fitting (10) and bolt (8) using new copper
washers (9) to 33
N-m (24 1b.ft.).
Lubricated new piston seal (17) into caliper (12)
bore groove.
a Make sure seal is not twisted.
Lubricated boot (24) onto piston (1 8) with inside
lip of boot in piston groove and boot fold toward
end of piston that contact inboard brake shoe.
Thrust washer (14) on actuator screw (16) with
copper side of washer towards the piston
assembly and the grayish surface towards caliper
housing (12).
Lubricated shaft seal (13) on actuator screw (16).
Actuator screw (16) in piston (18).
Balance spring (15) into piston (18) recess.
Lubricated piston (18) with actuator screw
assembly, balance spring and boot into lubricated
bore of caliper (12). Push piston to bottom of
caliper bore using
J 23072 (35). (Figure 11)
Lubricated anti-friction washer (2 1) and lever
seal (22) over end of actuator screw (16).
a Sealing bead on lever seal should be against
housing
( 12).
Lever (2) on actuator screw (16). Rotate lever
away from stop slightly and hold while installing
nut (1) to 48
N-m (35 Ib.ft.), then rotate lever
back to contact stop. (Figure 12)
Seat boot (24) in caliper housing (12) counterbore
using
J 29381.
Dampening spring (28) in groove in end of piston
(1 8). (Figure 13)
Caliper as previously described.
12 CALIPER HOUSING
18 PISTON
35 TOOL J 23072
Fig. 11 Installing Piston lnto Caliper
Fig.
12 Seating Boot lnto Housing
Fig.
13 Shoe Dampening Spring

DIRECT TORQUE DRUM BRAKE ASSEMBLY 5C3-1
SECTION 5C3
RECT TORQUE DRUM BRAKE ASSEMBLY
CONTENTS
GENERAL DESCRIPTION ....................... 5C3-1 Wheel Cylinder ........................................ 5C3-5
ON-CAR SERVICE ................................... 5C3-1 Backing Plate ............................................ 5C3-7
Brake Components ................... .... ......... 5C3- 1 UNIT REPAIR ........................................... 5C3-7
Brake Adjustment ..................................... 5C3-4 Wheel Cylinder Overhaul .......................... 5C3-7
Parking Brake Adjustment ......................... 5C3-4
1. RETURN SPRING 8. LEVER RETURN SPRING 15. SOCKET 22. SEAL 2. RETURN SPRING 9. SHOE GUIDE 16. PIVOT NUT 23. SPRING ASSEMBLY 3. HOLD-DOWN SPRING 10. PARKING BRAKE STRUT . 17. ADJUSTING SCREW 24. BLEEDER VALVE 4. LEVER PIVOT 11. STRUT SPRING 18. PARKING BRAKE LEVER 25. CYLINDER BODY 5. HOLD.DOWN PIN 12. PRIMARY SHOE 19. WHEEL CYLINDER RETAINER 26. BACKING PLATE 6. ACTUATOR LINK 13. SECONDARY SHOE 20. BOOT 27. ANCHOR PIN 7. ACTUATOR LEVER 14. ADJUSTING SCREW SPRING 21. PISTON HM0001.5C3-FG
Figure 1

DIRECT TORQUE DRUM BRAKE ASSEMBLY 5C3-7
Install or Connect
See NOTICE on page 5- 1.
1. Position wheel cylinder assembly (28) and hold in
place with wooden block between cylinder and
axle flange.
2. New retainer (19) over wheel cylinder abutement
using a 1-
1/8 inch 12-point socket (32) and socket
extention (31) as shown in figure
6.
3. Inlet tube nut to 17 N-m (13 1b-ft).
4. Bleed wheel cylinder.
BACKING PLATE
Remove or Disconnect
1. Raise
car and suitably support, see Section OA.
2. Brake
components as previously described.
3. Axle shaft, see Section 4B.
4. Parking brake
cable from backing plate
5. Brake pipe from wheel cylinder
6. Backing plate bolts and nuts
7. Anchor
pin nut and anchor pin
Install or Connect
1. Backing plate to axle flange
2. Backing plate to axle flange nuts and bolts to 58
N.m (45 lbs. ft.)
3. Anchor
in and nut to 140 N.m ( 103 Ibs. ft.)
4. Brake
pipe to
wheel cylinder to 15 N.nl (I l Ibs.
ft.)
5. Parking brake cable to backing plate
6. Axle shaft, see section 48
7. Brake
components as previously described
8. Lower car.
9. Bleed brake hydraulic syatcm
10. Adjust brake asscnlbly and parking brakc
UNIT REPAIR
WHEEL
CYLINDER OVERHAUL
See Figure 10
+++ Disassemble [I]
1. Wheel cylinder completely from vehicle as
previously described.
2. Boots (20).
3. Pistons (21) and seals (22).
4. Spring assembly (23).
5. Bleeder valve (24).
e Cylinder bore for:
e Scoring
e Nicks
e Corrosion
e Wear
e Use crocus cloth to polish out light corrosion.
e Replace wheel cylinder assembly if bore will not
clean up with crocus cloth.
e Pistons for:
e Scoring
e Nicks
e Corrosion
e Wear
22 SEAL 23 SPRING ASSEMBLY 24 BLEEDER VALVE 25 CYLINDER BODY
Figure 10 Wheel Cylinder Components
Clean
e All parts in clean denatured alcohol.
e Dry with unlubricated compressed air.
e Lubricate new seals with clean brake fluid.
Assemble
e See NOTICE on page 5-1.
1. Bleeder valve (24) to 6 N.m (50 lb-in).
2. Spring assembly (23).
3. Seal
(22), pistons (21) and boots (20).
4. Wheel
cylinder as previously described,

POWER HEAD ASSEMBLY 582-1
SECTION 582
POWER HEAD ASSEMBLY - TANDEM
APHRAGM
CONTENTS
...................... GENERAL DESCRIPTION 5D2-2 Unlocking and Locking Booster ................ 5D2-3
................................. ON-CAR SERVICE 5D2-2 Power Piston Group ................................. 5D2-3
..................................... Booster Assembly 5D2-2 Power Piston Disassembly ......................... 5D2-4
................................. Exterior Components 5D2-2 Gaging Procedure ...................................... 5D2-7
......................................... UNIT REPAIR 5D2-2
I 1. BOOT I 2. SILENCER 3. VACUUM CHECK
VALVE
4. GROMMET 5. VACUUM SWITCH
(SOME MODELS)
6. GROMMET 7. FRONT HOUSING SEAL 8. PRIMARY PISTON
BEARING
9. REAR HOUSING 10. FRONT HOUSING 11. RETURN SPRING 12. PISTON ROD (GAGED)
13. REACTION
RETAINER
14. POWER HEAD
SILENCER
15. DIAPHRAGM
RETAINER
16. PRIMARY
DIAPHRAGM
17. PRIMARY SUPPORT
PLATE
18. SECONDARY PISTON
BEARING
19. HOUSING DIVIDER 20. SECONDARY
DIAPHRAGM
21. SECONDARY
SUPPORT PLATE
22. REACTION DISC 23. REACTION PISTON 24. REACTION BODY
RETAINER
25. REACTION BODY 26. AIR VALVE SPRING 27. REACTION BUMPER 28. RETAINING RING 29. FILTER 30. RETAINER 31. O-RING 32. AIR VALVE PUSH
ROD ASSEMBLY
33. POWER PISTON
Figure 1 Booster Assembly