bulb PONTIAC FIERO 1988 Service Repair Manual

AIR CONDITIONING "18-23
10. CONTROL
14. LOWER MODE
DIAPHRAGM
16. DEFROST DIAPHRAGM
17. UPPER MODE
DIAPHRAGM
18. RECIRCULATION
5. TO WATER VALVE 19. lfVPUT (VIOLET)
6. A/C ELECTRICAL 20. DEFROST (BLUE)
21. LOWER MODE (TAN)
22. UPPER MODE (RED)
8. RECIRCULATION
DIAPHRAGM J~OZ~~-IB-F
Figure 20 AIC Vacuum Diagram
NG LlCbUlB LINE
Remove or Disconnect
1. Discharge A!C system.
2. Disconnect liquid line couplings at evaporator
and condenser connections.
3. Remove clip holding line to right frame rail.
4. Remove liquid line.
lnstall or Conne&
1. Reverse removal procedure to reinstall. Use
new O-rings lubricated with
525 viscosity
refrigerant oil.
2. Recharge and test system for proper operation.
COUPLED NC HOSE ASSEMBLY
Remove or Disconne&
lnstall or Conne&
1. Reverse removal procedure to reinstall. Use
new O-rings lubricated with
525 viscosity
refrigerant oil.
2. Recharge and test system for proper operation.
Remove or Disconnect
1. Discharge A!C system.
2. Disconnect electrical connection at pressure
cycling switch and remove switch.
3. Disconnect hose and evaporator fittings.
4. Loosen accumulator clamp-bracket screw.
5. Remove accumulator.
1. Discharge
NC system.
2. Disconnect hose assembly at accumulator, con- Install or Connect
denser, and at rear of c6mpressor head. 1. Reverse removal procedure to reinstall. Use
3. Disconnect clamps or straps that hold hose new
O-rings lubricated with 525 viscosity
assembly in position if so equipped, remove refrigerant
oil.
coupled hose assembly.
2. Recharge and test system for proper operation.

26-8 CHASSIS SWEET METAL
3. Remove headlight bezel.
4. If necessary, move battery rearward to gain
access to rear screw.
5. Lower headlights.
6. Loosen two body screws and adjust headlight
body.
7. If a satisfactory appearance is still not obtained,
remove lower air deflector to gain access to
number 1 and number 2 screws.
8. Loosen two body screws and adjust headlight
body.
9. Repeat procedure, if necessary, to obtain a satis-
factory appearance.
10. Re-position battery and tighten hold-down
screw to specifications.
11. Install lower air deflector.
12. Install headlight bezel.
TO SET FRONT TO REAR
GAP between
headlight door and hood, proceed as follows:
1. Open hood.
2. Raise headlights.
3. Remove headlight bezel.
4. Lower headlights.
5. Loosen two body assembly screws and adjust
headlight body assembly.
6. If a satisfactory appearance is still not obtained,
remove lower air deflector to gain access to two
lower screws.
7. Loosen two lower screws and adjust headlight
body assembly.
8. Repeat procedure, if necessary.
9. Install lower air deflector.
10. Install headlight bezel.
TO SET SIDE-TO-SIDE GAP between head-
light door and hood and headlight door and fender,
proceed as follows:
Open hood.
Raise headlights. Remove headlight bezel.
If necessary, move battery rearward to gain
access to rear screw.
Lower headlights.
Loosen three body screws and adjust headlight
body.
If a satisfactory appearance is still not obtained,
remove lower air deflector to gain access to two
lower screws.
Loosen two lower screws and adjust headlight
body.
Repeat procedure, if necessary.
Re-position battery and tighten hold-down
screw to specifications.
Install lower air deflector.
Install headlight bezel. TO
SET CONTOUR of headlight door to hood,
proceed as follows:
1. Open hood.
2. Raise headlights.
3. Remove headlight bezel.
4. Lower headlights.
5. Loosen two (2) screws and adjust headlight
body assembly.
6. If a satisfactory appearance is still not obtained,
remove lower air deflector to gain access to two
lower screws.
7. Loosen two lower screws and adjust headlight
body assembly.
8. Repeat procedure, if necessary.
9. Install lower air deflector.
10. Install headlight bezel.
HEADLIGHT BODY ASSEMBLY
Remove or Disconnect
1. Rear headlight door attaching screws.
2. Raise headlight doors.
3. Headlight bezel attaching screws.
4. Front headlight door attaching screws and
remove headlight door.
5. Electrical connection at bulb.
6. Lower air deflector (one side only).
7. Headlight body assembly attaching screws and
disconnect electrical connection at actuator
connector.
8. Link.
9. Actuator crank arm.
10. Actuator retaining screws and remove actuator.
11. Unhook headlight capsule lower retaining
spring and remove headlight capsule assembly.
12. Headlight body assembly attaching brackets and
fasteners.
Install or Connect
1. Headlight body assembly attaching brackets and
fasteners.
2. Headlight capsule lower retaining spring and
install headlight capsule
3. Acuator retaining screws and install actuator.
4. Actuator crank arm.
5. Link.
6. Headlight body assembly attaching screws and
connect electrical connection at actuator
connector.
7. Lower air deflector (one side only).
8. Electrical connection at bulb.
9. Front headlight door attaching screws and install
headlight door.

STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-7
e To determine if turn signal switch is inoperative,
substitute new turn signal switch into circuit and
operate switch by hand.
If the car's lights operate
normally, turn signal switch is inoperative.
Front Or Rear Turn Signal Lights Not Flashing
Inspect
s Burned-out or damaged turn signal bulb
e High resistance conection to ground at bulb
socket
s Loose chassis-to-column connector. Disconnect
column-to-chassis connector and connect new
turn signal switch into system and operate switch
by hand.
A. If turn signal lights are now on and flashing,
turn signal switch is inoperative.
B. If car lights do not operate, refer to Section
8A
for electrical diagnosis.
Turn Indicator Panel Lights
Inspect
Burned out bulbs or opens, grounds in the wiring
harness from the front turn signal bulb socket to the
indicator lights. Refer to Section
8A for electrical
diagnosis.
Stop Light Mot On When Turn Indicated
Inspect
s Loose column-to-chassis connection
e Disconnect the column-to-chassis connector and
connect the new turn signal switch into the
system and operate the switch by hand.
A. If the brake lights work when the switch is
in the turn position, the turn signal switch
is inoperative.
B. If the brake lights do not work, refer to Section
8A for electrical diagnosis.
Turn Signal Lights Flash Very Slowly
e Loose chassis-to-column connection
a Disconnect the column-to-chassis connector and
connect a new turn signal switch into the system
and operate the switch by hand.
A. If the lights flash at a normal rate, the turn
signal switch is inoperative.
B. If the Lights still flash very slowly, refer to
Section
8A for electrical diagnosis.
Hazard Signal Lights Will Not Flash - Turn
Signal Functions Normally
~"SPBC~
a Blown fuse
Inoperative hazard warning flasher
e Loose chassis-to-column connection
s Disconnect the column-to-chassis connector and
connect a new turn signal switch into the system,
then press in the hazard warning button and
watch the hazard warning lights.
A. If the lights now work normally, the turn
signal switch is inoperative.
B. If the lights do not flash, check the wiring
harness. Refer to Section
8A for electrical
diagnosis.
IGNITION SWITCH
Electrical System Will Not Function
Damaged ign~rion switch
e Ignition switch not adjusted properly
e Loose connector at the ignition switch
Switch Will Not Turn
Inspect
Damaged ignition switch
Switch Cannot Be Set Correctly
Inspect
Switch actuator rod deformed
e Sector to rack engaged in wrong tooth
KEY REMINDER
Figs. 1 through 11 ,
Weminder Continues To Operate With Key Out,
But Stops When Driver's Door Is Closed
e Chips, foreign material in lock cylinder bore
Sticky lock cylinder actuator tip
Damaged or broken reminder switch
Reminder Does Not Sound With Key Fully
Inserted In Lock Cylinder And The Driver's Door
Open
Inspect
1. Power not available to reminder. Refer to Sec-
tion
8A for electrical diagnosis.
2. Open in chassis wiring. Check by separating
chassis-to-column connector. Connect terminals
"E" and "F" female contacts on the chassis
connector (a bent paper clip will work). If the
reminder sounds, repair chassis wiring. If the
reminder does not sound, go to Step
A.
A. Connect a continuity meter (light) to the
male
"E" and "F" column connector
contacts. Push the key all the way into the
lock cylinder. If the light is on when the key

BRAKES 5-17
maintaining proper wheel balance, brake drums should be
checked for balance. Brake drums may be checked for
balance on most off-the-car balancers.
COMBINATION VALVE
Testing Combination Valve Electrical Circuit
When removing the electrical wire connector from the
pressure differential switch, squeeze the
eliptical shaped
plastic locking ring and pull up. This will move the locking
tangs away from the switch. Pliers can be used to help
remove the connector.
1. Disconnect wire from switch terminal and use a
jumper to connect wire to a good ground.
2. Turn ignition key to "ON." The warning lamp should
light. If lamp does not light, bulb is burned out or
electrical circuit is faulty. Replace bulb or repair elec-
trical circuit as necessary.
3. When warning lamp lights, turn off ignition switch.
Disconnect jumper and connect wire to switch termi-
nal.
Testing Combination Valve Warning Lamp Switch
1. Attach a bleeder hose to a rear brake bleed screw and
immerse the other end of the hose in a container
partially filled with clean brake fluid. Be sure master
cylinder reservoirs are full.
2. Turn ignition switch to "ON." Open bleeder screw
while an assistant applies moderate pressure to the
brake pedal. Warning lamp should light. Close
bleeder screw before assistant releases brake pedal.
Apply brake pedal with moderate-to-heavy pressure.
Lamp should go out.
3. Attach the bleeder hose to a front brake bleeder
screw and repeat steps
1 and 2. Warning lamp action
should be the same as in step
2. Turn off ignition
switch.
4. If warning lamp does not light during steps 2 and 3,
but does light when a jumper is connected to ground,
the warning lamp switch portion of the combination
valve is faulty. Do not disassemble the combination
valve.
If any portion of the combination valve is faulty,
it must be replaced with a new combination valve.
Combination Valve Replacement
Remove or Disconnect (Figure
16)
r The combination valve is not repairable and must be
serviced as a complete assembly.
1. Hydraulic pipes at combination valve.
Plug pipes to prevent loss of fluid and entrance
of dirt.
2. Wiring harness from valve switch terminal.
3. Nut attaching valve to power booster.
4. Combination valve.
@ Install or Connect (Figure 16)
NOTICE: See "Notice" on page 5-1.
1. Combination valve.
2. Nut attaching valve to power booster.
Tighten
* Nut to 24 N.m (18 Ibs. ft.).
3. Wiring harness to valve switch terminal.
4. Hydraulic pipes at combination valve. * Bleed brakes. See "Bleeding Brake Hydraulic Sys-
tem" in this section.
CAUTION: Do not move the car until a firm brake
pedal is obtained. Air in the brake system can
cause loss of brakes.
POWER BRAKE VACUUM HOSE FILTER
See Figure 17.
COMBINATION VALVE ASM.
MASTER CYLINDER BRAKE PIPES
Figure 16 Combination Valve
2 FILTER 4. BOOSTER
Figure 17 Power Brake Vacuum Hose Filter (Typical)

CHARGING SYSTEM 6D3-1
SECTION 6D3
CHARG NG SYSTEM
CONTENTS
General Description ................................. 6D3- 1 Charging System ........................................ 6D3- 1
.......................................... Charging System - CS ............................... 6D3- 1 On-Car Service 6D3-2
................................................... Diagnosis .. 6D3- 1 Generator 6D3-3 ...................... ......................... ............................................. 6D3- 1 Specifications 6D3-3 Service Procedures .................................. Unit Repair .. 6D3-4-6 ............................... ............
GENERAL DESCRIPTION
The engine electrical system includes the battery,
ignition (primary and secondary), starter (and related
wiring) and the generator (and related wiring).
Diagnostic charts (see Section 6D) will aid in
trouble-shooting system faults. When a fault is traced
to a particular component, refer to that components'
section of the service manual.
CHARGING SYSTEM-CS
The CS Charging System has several sizes
available, including the CS-130 and CS-144. The
number (130 or 144) denotes the
OD in mm of the
stator laminations.
CS generators use a new type regulator and a
diode trio is not used. A delta stator, rectifier bridge,
and rotor with slip rings and brushes are electrically
similar to earlier generators. A conventional pulley and
fan is used and, on the CS-130, an internal fan cools the
slip ring end frame, rectifier bridge and regulator.
Unlike three-wire generators, the CS-130 and
CS-144 may be used with only two connections
-
battery positive and an "L" terminal to the charge
indicator bulb. Use of "P",
"F", and "S" terminals is
optional. The "P" terminal is connected to the stator,
and may be connected externally to
a tachometer or other
device. The
"F" terminal is connected internally
to field positive, and may be used as a fault indicator.
The "S" terminal may be connected externally to a
voltage, such as battery voltage, to sense voltage to be
controlled.
As on other charging systems, the charge
indicator lights when the switch is closed, and goes out
when the engine is running. If the charge indicator is
on with the engine running, a charging system defect
is indicated. For all kinds of defects, the indicator will
glow at full brilliance, not "half lit". Also, the charge
indicator will be on with the engine running if system
voltage is too high or too low. The regulator voltage
setting varies with temperature, and limits system
voltage by controlling rotor field current.
This regulator switches rotor field current on and
off at a fixed frequency of about 400 cycles per second.
By varying the on-off time, correct average field
current for proper system voltage control is obtained.
At high speeds, the on-time may be 10% and the
off-time 90%. At low speeds, with high electrical loads,
on-off time may be 90% and
lo%, respectively.
No periodic maintenance on the generator is
required.
DIAGNOSIS
SERVICE PROCEDURES
CHARGING SYSTEM
The generator does not require periodic
lubrication. The rotor shaft is mounted on ball bearings
at the drive end and roller bearings at the slip ring end.
Each contains a permanent grease supply. At periodic
intervals, check mounting bolts for tightness and adjust
belt tension (see Section
6B), if applicable.
e When adjusting belt tension, apply pressure at
center of generator, never against either end
frame.
GENERATOR BENCH CHECK-CS
To check generator in a test stand, remove as
specified in On-Car Service and proceed as follows: 1.
Make connections as shown in Figure
lH, except
leave the carbon pile disconnected. The ground
polarity of generator and battery must be the
same. The battery must be fully charged. Use a
30-500
OHM resistor between battery and "L"
terminal.
2. Slowly increase generator speed and observe
voltage.
3. If the voltage is uncontrolled and increases above
16.0 volts, the rotor field is shorted, the regulator
is defective, or both.
A shorted rotor field coil can
cause the regulator to become defective. NOTE:
The battery must be fully charged when making
this test.

6EZ-A-10 5.0L (VIN E) DRIVEABILITY AND EMISSIONS
TO OIL PRESS. SW.
&FUEL PUMP RELAY
BATTERY
12 V
. . . . . . . . FUSIBLE LINK 15 WAY
439 PNWBLK
419
BRNNVHT
SERIAL DATA
451
WHTIBLK
450 BLWHT
ALDL CONNECTOR
NO "SERVICE ENGINE SOON" "LIGHT
5.OL (VIN E) "F'" SERIES (TBI)
Circuit Description:
There should always be a steady "Service Engine Soon" light, when the ignition is "ON" and engine stopped.
Battery is supplied directly to the light bulb.
The electronic control module (ECM) will control the light and
turn it "ON" by providing a ground path through CKT 419 to the ECM.
Test Description: Numbers below refer to circled
numbers on the diagnostic chart.
1. Battery feed CKT 340 is protected by a
20amp in-
line fuse. If this fuse was blown, refer to wiring
diagram on the facing page of Code 54.
2. Using a test light connected to 12 volts, probe each
of the system ground circuits to be sure
a good
ground is present. See ECM terminal end view in
front of this section for ECM pin locations of
ground circuits.
Diagnostic Aids:
Engine runs ok, check:
@ Faulty light bulb
@ CKT419open
@ Gage fuse blown. This will result in no oil, or
generator lights, seat belt reminder, etc.
Engine cranks, but will not run.
@ Continuous battery - fuse or fusible link open.
@ ECM ignition fuse open.
@ Battery CKT 340 to ECM open.
o Ignition CKT 439 to ECM open.
@ Poor connection to ECM.

DRIVEABILITY AND EMISSIONS 5.OL (VIN E) 6EZ-A-11
@ DISCONNECT ECM CONNECTORS.
@ IGNITION "ON".
@ PROBE CKT 419, WlTH TEST LIGHT
TO GROUND.
- GAGE FUSE. IGNITION "ON". SHORT TO GROUND IN
- FAULTY BULB. 0 PROBE CKT 340 81 439 CIRCUIT THAT HAD A
- OPEN CKT 419. WITH TEST LIGHT TO
- CKT419 SHORTED TO

6E2-A-12 5.OL (VIN E) DRIVEABILITY AND EMISSIONS
TO OIL PRESS. SW. ECM
&FUEL PUMP RELAY
FUSE
& HOLDER BATTERY 12 V . . . . . . . .
FUSIBLE LINK
439
PNWBLK
419 BRNNVHT
- -
451 WHTIBLK
450
BLWHT
ALDL CONNECTOR
8-4-87
55 1235-6E
CHART A-2
NO ALDL DAM OR WON"T FLASH CODE 12
'SERVICE ENGINE SOON" LLlGHT "ON" "STEADY
5.OL (VIN E) "F" "SERIES (TBI)
Circuit Description:
There should always be a steady "Service Engine Soon" light, when the ignition is "ON" and engine stopped.
Battery is supplied directly to the light bulb. The electronic control module
(ECM) will turn the light "ON" by
grounding CKT 419 at the ECM.
With the diagnostic terminal grounded, the light should flash
a Code 12, followed by any trouble code(s)
stored in memory.
A steady light suggests a short to ground in the light control CKT 419, or an open in diagnostic CKT 451.
Test Description: Numbers below refer to circled
numbers on the diagnostic chart.
1. If there is a problem with the ECM that causes
a
"Scan" tool to not read serial data, then the ECM
should not flash a Code
12. If Code 12 does flash,
be sure that the "Scan" tool is working properly on
another vehicle. If the "Scan" is functioning
properly and CKT 461 is OK, the PROM or ECM
may
be at fault for the NO ALDL symptom.
2. If the light goes "OFF" when the ECM connector is
disconnected, then CKT 419 is not shorted to
ground.
3. This step will check for an open diagnostic CKT
45 1.
4. At this point, the "Service Engine Soon" light
wiring is OK. The problem is a faulty ECM or
PROM. If Code 12 does not flash, the ECM should
be replaced using the original PROM. Replace the
PROM only after trying an ECM, as a defective
PROM is an unlikely cause of the problem.

6E3-A-"I 2.8L (VlN S) DRIVEABILITY AND EMlSSlONS
TO OIL PRESS. SW.
&FUEL PUMP RELAY
FUSE
81 HOLDER BATTERY 12 V .. m.. . n.
. . . . . . . . FUSIBLE LINK
439 PNWBLK
419 BRNNVHT
SERIAL
DATA
451
WHTJBLK
450 BLKNVHT
ALDL CONNECTOR
NO "SERVICE ENGlNE SOON" "LIGHT
2.8b (VIM 5) 'T" "SERIES (PORT)
Circuit Description:
There should always be a steady "Service Engine Soon" light when the ignition is "ON" and engine stopped.
Battery is supplied directly to the light bulb. The electronic control module
(ECNI) will control the light and
turn it "ON" by providing a ground path through CKT 419 to the ECM.
Test Description: Numbers below refer to circled
numbers on the diagnostic chart.
1. If the fuse in holder is blown refer to facing page of
Code
54 for complete circuit.
2. Using a test light connected to 12 volts probe each
of the system ground circuits to be sure a good
ground is present. See ECM terminal end view in
front of this section for
ECM pin locations of
ground circuits.
Diagnostic Aids:
Engine runs OK, check:
@ Faulty light bulb.
@ CKT 419 open.
@ Gage fuse blown.
This will result in no oil or
generator lights, seat belt reminder, etc. Engine
cranks but will not run.
@ Continuous battery - fuse or fusible link open.
@ ECM ignition fuse open.
@ Battery CKT 340 to ECM open.
@ Ignition CKT 439 to ECM open.
e Poor connection to ECM.
Solenoids and relays are turned "ON"
and "OFF"
by the ECM, using internal electronic switches called
"drivers". Each driver is part of a group of four called
"Quad-Drivers". Failure of one driver can damage
any other driver in the set. Solenoid and relay coil
resistance must measure more than 20 ohms. Less
resistance will cause early failure of the ECM
"driver".
Before replacing ECM, be sure to check the coil
resistance of all solenoids and relays controlled by the
ECM. See ECM wiring diagram for the
solenoid(s)
and relay(s) and the coil terminal identification.

DRIVEABILITY AND EMISSIONS 2.8L (VIN 5) 6E3-A-l l
CHART A-1
CLEAR CODES AND CONFIRM "CLOSED LOOP " OPERATION AND NO "SERVICE ENGINE SOON" LIGHT.
DISCONNECT
ECM CONNECTORS. BATTERY
FUSE (IN HOLDER)
IGNITION "ON".
PROBE
CUT 419, WITH TEST LIGHT
TO GROUND.
- GAGE FUSE. SHORT TO GROUND IN
- FAULTY BULB. @ PROBE CKT 340 & 439 CIRCUIT THAT HAD A
- OPEN CUT 419. WITH TEST LIGHT TO
- CKT 419 SHORTED TO
REPAIR OPEN IN
GROUNDS OR ECM. CIRCUIT THAT DID NOT
SEE QUAD DRIVER
CHECK (CHART
C-1).