coolant level PONTIAC FIERO 1988 Service Repair Manual

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.

MAINTENANCE AND LUBRICATION OB-5
Throttle linkage inspection -- Inspect for inter-
ference, binding, damaged or missing parts.
Engine drive belts inspection - Inspect all
belts for cracks, fraying and wear. Adjust or replace as
needed.
Rear axle service (if equipped) - Check gear
lubricant level and add if needed. For cars equipped with a
limited slip rear axle, fluid does not require changing
(except Caprice and Corvette
- change fluid and required
additive at first
7,500 miles (12 500 km). See your
Owner's Manual or "Recommended Fluids
& Lubricants
Chart" in this section.
IF YOU USE YOUR GAR TO PULL A TRAILER,
CHANGE GEAR LUBRICANT EVERY 7,500 MILES
(12 500 KM).
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Power antenna - Clean and then lubricate power
antenna mast. The proper lubricant as shown in Figure
OB-2 should be used.
AT LEAST ONCE A YEAR
Lap and shoulder belts condition and opera-
tion
- Inspect belt system, including webbing, buckles,
latch plates, retractors, guide loops and anchors.
Moveable head restraint operation - On cars
with moveable restraints, make sure restraints stay in the
desired position. (See adjustment instructions in your
Owner's Manual.)
Seatback latch and recliner operation on
cars equipped
with recliner seat --- Be sure seat-
backs latch on those cars with folding seats using mechan-
ical latches. Make sure the recliner is holding by pushing
and pulling on the top of the
seatback while it is reclined.
See your Owner's Manual for seat operating information.
Spare tire and jack storage- Be alert to rattles
in rear of car. Make sure the space tire, all jacking equip-
ment, any tire inflator and any covers or doors are securely
stowed at all times. Oil jack ratchet or screw mechanism
after each use.
Key lock service - Lubricate key lock cylinder at
least annually.
Body lubrication service - Lubricate all body
door hinges including the tailgate or hatchback lid (if
equipped). Also lubricate the body hood, fuel door and
rear compartment hinges and latches including interior
glove box and counsel doors, and any folding seat
hardware.
"Fansmissionltransaxle neutral or clutch
starl switch operation
CAUnON: Before pedorming the follow-
ing safety switch check, be sure to have
enough room around the car. Then, firmly
apply both the parking brake (see your
Owner's Manual for procedure) and the
regular brakes. Do not use the accelerator pedal.
If the engine
starls, be ready to turn
off the ignition promptly. Take these pre-
cautions because the car could move
without warning and possibly cause per-
sonal injury or properly damage. On auto-
matic transmissionltransaxle cars, try to
starl the engine in each gear. The starler
should crank only in "Park" or "Neutral."
On manual transmissionltransaxle cars,
place the
shiR lever in "Neutral," push the
clutch halfway and try to starl. The starler
should crank only when the clutch is fully
depressed.
Steering column lock operation
- While
parked, try to turn key to "Lock" in each gear range. The
key should turn to "Lock" only when gear is in "Park" on
automatic or "Reverse" on manual
transmissionltransax-
le. On cars with key release lever, try to turn key toULock"
without depressing the lever. The key should turn to
"Lock" only with the key lever depressed. On all vehicles,
the key should come out only in "Lock."
Parking brake and transmissionltransaxle
"Park" mechanism operation
CAUT1ON:Before checking the holding
ability of the parking brake and automatic
transmissionltransaxle "Park" mecha-
nism, park on a fairly steep hill with
enough room for movement in the down-
hill direction. To reduce the risk of person-
al injury or property damage, be prepared
to apply the regular brakes promptly if the
car begins to move.
To check the parking brake, with the engine running and
transmission/transaxle in "Neutral." slowly remove foot
pressure from the regular brake pedal (until the car is held
by only the parking brake).
To check the automatic transmissionltransaxle "Park"
mechanism holding ability, release all brakes after shift-
ing the transmissionltransaxle to "Park."
ljnderbody flushing - At least every spring,
tlush from the underbody with plain water any corrosive
materials used for ice and snow removal and dust control.
Take care to thoroughly clean any areas where mud and
other debris can collect.
Sediment packed in closed areas
of the vehicle should be loosened before being flushed.
Engine cooling system service - Inspect
coolant and freeze protection. If dirty or rusty, drain, flush
and refill with new coolant. Keep coolant
at the proper
mixture as specified in your Owner's Manual. This pro-
vides proper freeze protection. corrosion inhibitor level
and engine operating temperature. Inspect hoses and re-
place if cracked. swollen or deteriorated. Tighten hose
clamps. Clean outside of radiator and air conditioning
condensor. Wash radiator filler cap and neck.
To help
ensure proper operation. a pressure test of both the cooling
system and cap is also recommended. (See maintenance
schedule charts in Figure
OB-l for the recommended
coolant change interval.)

AIR CONDITIONING 1 B-3
A low-side pressure Schrader valve service fit-
ting is located near the top of the accumulator. A
similar Schrader fitting may be provided for mounting
the pressure cycling switch. It is not necessary to dis-
charge the system to replace the switch. The accumu-
lator is serviced only as a replacement assembly.
Heater Core
The heater core heats the air before it enters the
car. Engine coolant is circulated through the core to
heat the outside air passing over the fins of the core.
The core is functional at all times (no water valve) and
may be used to temper conditioned air in
A/C mode,
as well as heat or vent mode.
SYSTEM COMPONENTS --- CON"FOL
Controller
The operation of the A/C system is controlled by
the switches and the lever on the control head. The
compressor clutch and blower are connected electri-
cally to the control head by a wiring harness. The
blower circuit is open in the off mode and air flow is
provided by the four blower speeds available in the
remaining modes. Cooled and dehumidified air is
available in the max, normal, bi-level and defrost
modes.
Temperature is controlled by the position of the
temperature lever on the control head. A cable con-
nects this lever to the temperature door which controls
air flow through the heater core. As the temperature
lever is moved through its range of travel, a sliding
clip on the cable at the temperature valve connection
should assume a position assuring that the temperature
door will seat in both extreme positions. Temperature
door position is independent of mode selection. The
temperature cable attaches to the right side of the air
conditioning module. The temperature door on some
models is controlled electrically, thereby eliminating
the need for the temperature cable.
The electric engine cooling fan on some cars is
not part of the
A/C system; however, the fan is
operational any time the
A/C control is in Max.,
Norm, or Bi-Level modes. Some models provide for
engine cooling fan operation when the controller is in
the defrost mode. This added feature is part of the
A/C
controller function and is aimed at preventing exces-
sive compressor head temperatures. It also allows the
A/C system to function more efficiently. On some
models during road speed (above
35 mph) conditions
when air flow through the condenser coil is adequate
for efficient cooling, the engine cooling fan will be
turned off. The operation of the cooling fan is con-
trolled by the ECM through the cooling fan relay.
Complete wiring diagrams and diagnosis for the
AIC Electrical System are in Section 8A. Section 8A
also contains additional diagnostic information
regarding air flows and vacuum logic.
Vacuum Lines
Vacuum lines are molded to a connector which
is attached to a vacuum control switch on the control
head assembly.
In case of leakage or hose collapse, it will not be
necessary to replace the entire harness assembly.
Replacement can be made by cutting the hose and
inserting a plastic connector. If an entire hose must be
replaced, cut all hoses off at the connector and then
attach hoses directly to the control head vacuum
switch. (NOTE: The Fiero uses an electric motor to
control mode selection. Therefore, it will not have a
vacuum harness.
)
Vacuum Tank
During heavy acceleration, the vacuum supply
from the carburetor drops. A check valve in the vac-
uum tank maintains vacuum so that, under load condi-
tions, vacuum will be available for continuous use.
REWVS AND SWITCHES
High-Pressure Compresssr Gut-OFF Switch
The high-side, high-pressure cut-off switch in
the rear head of the compressor is a protective device
intended to prevent excessive compressor head pres-
sures and reduce the chance of refrigerant escape
through a safety relief valve. Normally closed, this
switch will open the circuit at a high-side pressure of
approximately 2700
kPa (430 psi 9 20 psi) and
reclose the circuit at approximately 1379 kPa (200 psi
9 50 psi).
Lsw-Pressure Cut-On Switch
Compressor protection is provided on some cars
by a low-pressure cut-off switch which will open in
the event of a low-charge condition. This switch can
be located in the liquid line or in the rear head of the
compressor. This switch will also keep the compres-
sor from running during cold weather.
Pressure eyesing Switch
The refrigeration cycle (on and off operation of
the compressor) is controlled by a switch which
senses the low-side pressure as an indicator of evapo-
rator temperature. The pressure cycling switch is the
freeze protection device in the system and senses
refrigerant pressure on the suction side of the system.
This switch is located on a standard Schrader-type
valve low-side fitting. This switch also provides com-
pressor cut-off during cold weather.
Additional compressor protection results from
the operating characteristics of the low-side pressure
cycling system. If a massive discharge occurs or the
orifice tube becomes plugged, low-side pressures
could be insufficient to close the contacts of the pres-
sure switch. In the event of a low charge, insufficient
cooling accompanied by rapid compressor clutch
cycling will be noticed at high air temperatures.

2.8 LITER V-6 6A2-9
INTAKE MANIFOLD (FIGURE 6A2-7)
Removal
Disconnect battery.
Remove air cleaner.
Drain coolant.
Refer to Section 6E3 for removal of the following
PFI sub-assemblies.
e Plenum
e Fuel Rail
e Runner
Disconnect spark plug wires at spark plugs.
Disconnect wires at coil.
Remove distributor cap and spark plug wires.
Mark distributor position and remove hold down
bracket.
Remove distributor.
Remove air management hose, manual
transmission only.
Disconnect emission canister hoses. Remove pipe
bracket (front left valve cover).
Remove left valve cover.
Remove air management bracket, manual
transmission only.
Remove right valve cover.
Remove upper radiator hose.
Disconnect heater hose.
Disconnect coolant switches.
Remove manifold bolts.
Remove manifold. Discard manifold gaskets and
remove loose RTV from front and rear ridges of
cylinder case.
Installation
When installing intake gaskets, notice that the
gaskets are marked Right Side and Left Side
(carbureted only). Use them only as indicated to
maintain designed efficiency of this engine.
1. Make
sure that no oil or water is present on
surface when new RTV is applied. Place a 5mm
diameter
(3/16") bead of RTV, # 1052917 or
equivalent, on each ridge.
2. Install
new intake gaskets on cylinder heads.
Hold in place by extending ridge RTV bead up
6mm onto the gasket ends. The new intake
gaskets will have to be cut, where indicated, to
install behind push rods. Cut only those areas
that are necessary.
3. Install intake
manifold on engine. Make sure
areas between case ridges and intake are
completely sealed.
4. Install manifold retaining bolts and nuts and
torque in the sequence shown in Figure 6A2-7.
5. Install heater and radiator hose to manifold.
6. Install rocker covers as previously outlined.
7. Connect coolant switches.
8. Install air management bracket.
9. Install pipe bracket (front left rocker cover).
10. Install distributor, distributor cap and retaining
nut. Do not tighten.
11. Refer to Section 6E3 for installation of PFI
sub-assemblies removed. 12.
Connect
necessary wires and hoses.
13. Fill cooling system with
the proper mixture of
ethylene glycol anti-freeze and water. Do not
install radiator cap.
14. Start
engine, set intitial timing. After set, torque
distibutor hold down clamp bolt to 34
N-m (25
lb. ft.). Recheck timing after torquing bolt.
15. Let engine
run until radiator upper hose becomes
hot (thermostat open).
16. With
engine idling, add coolant to radiator, if
necessary, until level reaches bottom of filler
neck.
17. Install
radiator cap, making sure arrows on cap
line up with overflow tube.
Figure 6A2-8 Exhaust Manifold
EXHAUST MANIFOLD (FIGURE 6A2-8)
Removal (Left)
1. Disconnect battery.
2. Raise vehicle.
3. Disconnect exhaust pipe.
4. Remove
(4) rear manifold bolts and (1) nut.
5. Lower vehicle.
6. Disconnect air management, hoses and wires.
7. Remove power steering and fuel line bracket.
8. Remove manifold.
Installation (Left)
1. Clean mating surfaces on manifold and head,
then install manifold in position and install bolts.
2. Torque
manifold bolts to 34
N.m (25 ft. lbs.).
3. Install power steering bracket.
4. Raise vehicle.
5. Install exhaust pipe.
6. Lower vehicle.
7. Connect battery.
Removal (Right)
1. Disconnect battery.
2. Raise vehicle.
3. Disconnect exhaust pipe.
4. Lower vehicle.

2.8 LITER V.6 6A2-15
18-30 N.m (13-22 FT. LBS.)
I 11 47-48 N.m (20-35 FT. LBS.) I
Figure 6A2-17 Water Pump/Front Cover Orientation
CRANKCASE FRONT COVER
Removal
1. Raise engine.
2. Remove oil pan.
3. Lower vehicle.
4. Remove water pump as outlined in Section 6B.
5. If A/C equipped, remove compressor from
mounting bracket and lay aside. Then remove
compressor mounting bracket.
6. Remove torsional damper as previously outlined.
7. Disconnect lower radiator hose at front cover and
heater hose at water pump.
8. Remove remaining front cover bolts and remove
cover.
Installation
1. Install new gasket. When installing new gasket,
be sure sealing surfaces are clean. Care should be
taken not to damage sealing surfaces.
2. Place front cover on the engine, install stud bolt
and bolts, install water pump as outlined in
Section 6B, install retaining bolts and nut and
torque to specifications.
3. Connect lower radiator hose to front cover.
Torque clamps to
3.5 N-m (30 lb. in.).
4. Install torsional damper as previously outlined.
5. Install water pump as outlined in Section 6B.
6. If A/C equipped, install compressor mounting
bracket and install compressor.
7. Raise vehicle.
8. Inspect oil pan gasket replace if necessary.
9. Install oil pan.
10. Lower vehicle.
11. Install serpentine belt.
12. Fill cooling system. Leave radiator cap off.
13. Connect battery negative cable and start engine.
14. Run engine until upper radiator hose becomes
hot (thermostat open).
15. Check coolant level and add as necessary.
16. Install radiator cap, making sure arrows on cap
line up with overflow tube.
OIL SEAL (FRONT COVER)
Replacement
With Cover Removed
1. With cover removed, pry oil seal out of cover
from the front with a large screw driver.
2. Install new seal so that open end of the seal is
toward the inside of cover and drive it into
position with Tool
5-23042. Support cover at seal
area. Pre-lube seal with engine oil prior to
installation of torsional damper.
With Cover Installed
1. With torsional damper removed, pry seal out of
cover from the front with a large screw driver,
being careful not to damage the surface on the
crankshaft.
2. Install new seal so that open end of seal is toward
the inside of cover and drive it into position with
To01 5-23042.
Figure 6A2-18 Timing Chain and Sprockets
TIMING CHAIN AND SPROCKET
Removal
1. Remove crankcase front cover as previously
outlined.
2. Place #1 piston at top dead center with the
marks on the camshaft and crankshaft sprockets
aligned (#4 firing).
3. Remove camshaft sprocket bolts and remove
camshaft sprocket and chain (Figure
6A2- 18).
Sprocket is a light fit on camshaft.
If sprocket
does not come off easily, a light blow on the lower
edge of the sprocket (with a plastic mallet) should
dislodge the sprocket.
Installation
1. Install timing chain on camshaft sprocket, lube
thrust surface with Molykote or its equivalent.
Hold the sprocket vertically with the chain
hanging down and align the marks on the
camshaft and crankshaft sprockets. (Refer to
Figure
6A2- 19).

ENGINE COOLING 6B-1
SECTION 6B
NE COOL
General Description ................................ 6B- 1 Off-Vehicle Leak Testing ............................... 6B-9
Radiator
...................................................... 6B- 1 Repairable Leaks ........................ ... .......... 6B- 10
Radiator Cap
......................... .. ............... 6B- 1 Repair Methods ................................................ 6B- 10
Recovery Bottle ......................................... 6B-2 Cooling Fin Removal ................................ 6B- 10 - ............................................. Fans ............................................................... 6B-2 Tube Blocking 6B- 1 1 ............ Header Repair ....................... .... 6B- 1 1 Temperature Switch ..................................... 6B-2 General Core Repair 6B- 1 1 ....................................
........................... Coolant Temperature Fan Switch ................ 6B-2 Tank
Gasket ~eik Repair 6B- 12
................... Thermostat .. 6B-3 Oil
Cooler Gasket Replacement
6B- 13 ............... ................................
...........................................................
Coolant Recovery System 6B-3 Recore 6B- 14 ............................. Special Tools ..................................................... 6B- 14 Diagnosis ..................................................... 6B-3
.............................. ..................................... Service Procedures 6B-3 On-Vehicle Service 6B-14
Cooling System Care
............................... 6B-3 Thermostat ....................................... 6B-14
Draining and Refilling the Cooling Electric Cooling Fan ............................. 6B-15
System
................................................... 6B-7 Water Pump .................... .... ......... 6B-15
Drive Belt
...................... .. .......................... 6B-7 Coolant Recovery Bottle ........................ 6B-16
.......................................... Aluminum Radiator Service .................... 6B-8 Radiator 6B-17
Diagnosis .................................................... 6B-8
Leak Testing
.............................................. 6B-8
On-Vehicle Pressure Testing
...................... .... 6B-9
GENERAL DESCRIPnIBN
The cooling system maintains engine temperature
5" below the filler neck which reads, "Important - for
at an efficient level during all engine operating repair see Harrison Service Manual". Service
conditions. When the engine is cold the system cools procedures for the aluminum plastic radiator are
slowly, or not at all, to allow the engine to warm up described in that manual and in this section.
quickly.
The cooling system includes a radiator and
Radiator Cap
recovery sub-system, cooling fan, thermostat and
housing, water pump, and drive belts.
Operation of the cooling system requires proper
functioning of all components. Coolant is drawn from
the radiator by the water pump and circulated through
water jackets in the engine block, intake manifold, and
cylinder
head(s), and then directed back to the radiator
where it's cooled.
This system directs some coolant through hoses
to the heater core, to provide for heating and
defrosting. A recovery bottle is connected to the
radiator to recover coolant displaced by expansion
from high temperatures and maintain correct coolant
level. As the coolant cools and contracts it is drawn
back into the radiator by vacuum.
RADIATOR
A cross-flow radiator is used on all models. Tanks
in this type radiator are located to the right and left of
the core, instead of above and below.
Radiators used with automatic transmissions
have oil coolers with inlet and outlet fittings for
transmission fluid circulation. Cars with manual
transmissions use radiators without oil coolers.
Vehicles equipped with air conditioning use a radiator
with extra cooling capability.
An aluminum-plastic radiator, used on some
models, can be identified by a note on the outlet tank A pressure-vent
cap is used on the cross-flow
radiator to allow a buildup of
103 kPa (15 psi) in the
cooling system. This pressure raises the boiling point
of coolant to approximately 125°C (262°F) at sea level.
Do not remove radiator cap to check engine
coolant level; check coolant visually at the
see-through coolant reservoir. Coolant should
be added only
to the reservoir.
CAUTION: As long as there
is
pressure in the cooling system, the
temperature can be considerably
higher than the boiling temperature
of
the solution in the radiator without
causing the solution to boil. Removal
of the radiator cap while engine is hot
and pressure is high will cause
the
solution to boil instantaneously and
possibly with explosive
force, spewing
the solution over engine, fenders and
person removing cap. If the solution
contains flammable antifreeze, such
as alcohol (not recommended for use
at any time), there is also the
possibility
of causing a serious fire.
The pressure-type radiator filler cap contains a
blow off or pressure valve and a vacuum or
atmospheric valve (Figure
1). The pressure valve is
held against its seat by a spring of pre-determined

BB-2 ENGINE COOLING
strength, which protects the radiator by relieving
pressure if it exceeds design limits. The vacuum valve
is held against its seat by a light spring, which permits
opening of the valve to relieve vacuum created in the
system when it cools off and which otherwise might
cause the radiator to collapse.
VACUUM RELIEF PRESSURE RELIEF
Fig. 1 Pressure-Type Radiator Cap
The radiator cap is designed to discourage
inadvertent removal. The finger grips have been
removed so the cap is round in shape. It also must be
pushed downward before it can be removed. A rubber
asbestos gasket is added to the diaphragm spring at the
top of the cap. Embossed on the cap is a caution against
its being opened and arrows indicating the proper
closed position.
Every vehicle has a radiator cap. Also,
J, N and
P Series vehicles with 2.5L engines have a thermostat
housing cap. For these engines, add coolant through
the thermostat housing (with the thermostat and cap
removed).
Recovery Bottle
A "see-through" plastic reservoir, similar to the
familiar windshield washer jar, is connected to the
radiator by a hose. As the car is driven, the coolant is
heated and expands. The portion of the fluid displaced
by this expansion flows from the radiator into the
recovery bottle. When the engine is stopped and the
coolant cools and contracts, the displaced coolant is
drawn back into the radiator by vacuum. Thus, the
radiator is kept filled with coolant to the desired level
at all times, resulting in increased cooling efficiency.
Coolant level should be between "ADD" and
"FULL"
marks on recovery bottle. These marks are
approximately two quarts apart so that a
50/50
mixture can be added (one quart of ethylene glycol
anti-freeze and one quart of water).
FAN
Electric Fan
Fans range in sizes from 290mm (11.6 in) to
422mm (16.9 in) with 4 to 7 blades to aid air flow
through the
radiator/condenser. The fan is driven by
an electric motor which is attached to the radiator
support.
The fan motor is activated by a coolant
temperature switch. If the vehicle is equipped with
Fig. 2 Coolant Recovery Bottle
A/C, a second switch can activate the circuit,
depending upon
A/C compressor head pressure to the
condenser.
CAUTION: If a fan blade is bent or
damaged in any way, no attempt
should be made to repair and reuse the
damaged part.
A bent or damaged fan
assembly should always be replaced
with a new fan assembly. It is
essential that fan assemblies remain
in proper balance and proper balance
cannot be assured once a fan
assembly has been bent or damaged.
A fan assembly that is not in proper
balance could fail and fly apart during
subsequent use, creating an
extremely dangerous condition.
The majority of non-A/C cars use a fan with four
blades which are unevenly spaced and have curled tips
to provide minimum noise.
A fan shroud is used to
prevent recirculation of air around the fan on most
cars.
Thermostatically Controlled Fluid Clutch Fan
A thermostatically controlled fluid clutch fan is
used on some air conditioned vehicles. It operates only
when additional air flow is required to reduce radiator
coolant temperatures. This clutch is of a simple,
functional design. It is made of lightweight metal filled
with silicone oil and is hermetically sealed. The finned
(rear) housing contains a hub assembly (secured to the
housing bearing) which attaches to the engine water
pump. Four bosses with tapped holes in the rear face
provide for attachment of the engine fan. The front
surface of the housing has six deep circular grooves
which index with six matching bosses on the rear face
of a floating clutch. A separator plate and front cover,
with thermostatic coil control, complete the clutch
assembly.
During periods of operation when radiator
discharge air temperature is low, below approximately
66°C (150°F), the clutch limits the fan speed to
800- 1400 rpm. In this position, the clutch is disengaged

ENGINE COOLING 88.3
since a small oil pump driven by the separator plate
forces the silicone oil into a reservoir between the
separator plate and the front cover assembly. In this
position, the passage from this cavity to the clutch area
is closed by a slide valve. As operating conditions
produce a high radiator air temperature discharge,
above approximately 66°C
(150"F), the temperature
sensitive bi-metal coil tightens to move the slide valve
(attached to the coil) which opens a port in the
separator plate. This allows a flow of silicone oil into
the clutch chamber to engage the clutch, providing a
maximum fan speed of approximately 2200 rpm. The
clutch coil is calibrated so that, with a road load at an
ambient temperature of approximately 32°C
(90T), the
clutch is just at a point of shift between high and low
fan speed. No attempt should be made to disturb the
calibration of the engine clutch fan assembly as each
assembly is individually calibrated at the time of
manufacture. Under certain temperature conditions
there is a lateral movement at the fan tip which should
not be considered as a hub or bearing failure. This
condition is a design feature of the clutch assembly
which allows up to approximately
1/4" lateral
movement measured at the fan tip.
Testing a clutch fan by holding the small hub
with one hand and rotating the aluminum housing in
a
clockwise/counter-clockwise motion will cause the
clutch to freewheel, which is a normal condition when
operated in this manner. This should not be considered
a test by which replacement is determined.
Temperature Switch
This switch activates a warning lamp in the
instrument cluster if the engine overheats. With
optional instrumentation, a temperature gage replaces
the warning lamp and the temperature switch is
replaced with a transducer. See Section
8A for
Temperature Switch location and diagnosis.
Coolant Temperature Fan Switch
This switch regulates voltage to the coolant fan
relay, which operates the fan whenever the engine
coolant temperature exceeds 230"
F (110" C). For
location and diagnosis see Section 8A for Coolant
Temperature Fan Switch.
Thermostat
A pellet-type thermostat is used in the coolant
outlet passage to control the flow of engine coolant, to
provide fast engine warm-up and to regulate coolant
temperatures.
A wax pellet element in the thermostat
expands when heated and contracts when cooled. The
pellet element is connected through a piston to a valve.
When the pellet element is heated, pressure is exerted
against a rubber diaphragm which forces the valve to
open. As the pellet element is cooled, the contraction
allows a spring to close the valve. Thus, the valve
remains closed while the coolant is cold, preventing
circulation of coolant through the radiator. At this
point, coolant is allowed to circulate only throughout
the engine to warm it quickly and evenly.
As the engine warms, the pellet element expands
and the thermostat valve opens, permitting coolant to flow
through the radiator, where heat is dissipated
through the radiator walls. This opening and closing of
the thermostat permits enough coolant to enter the
radiator to keep the engine within operating limits.
Fig. 3 Pellet Type Thermostat
Coolant Recovery System
A recovery-type cooling system is standard on all
cars and is designed to maintain the engine at proper
operating temperatures. The recovery tank collects
coolant that expands with rising temperature and
would otherwise overflow from the system. When the
system temperature drops, the coolant is drawn from
the recovery tank back into the radiator by the suction
created by coolant contraction. The cooling system has
been filled at the factory with a high-quality, inhibited,
year-around coolant that meets the standards of
General Motors Specification 1825-M. This coolant
solution provides freezing protection to at least -37°C
(-34°F). It has been formulated to be used for two full
calendar years or
30,OO miles, whichever first occurs,
of normal operation without replacement, provided the
proper concentration of coolant is maintained.
DIAGNOSIS
The following diagnostic information covers
common problems and possible causes. When the
proper diagnosis is made the problem should be
corrected by part replacement, adjustment, or repair as
required. Refer to the appropriate section of the service
manual for these procedures.
SERVICE PROCEDURES
Cooling System Care
The radiator cap should not be removed to check
coolant level. Check the coolant level visually in the
"see-through" coolant recovery tank every time hood
is up. Level should be near "ADD" mark when the
system is cold. At normal operating temperature the
coolant level should increase to the "FULL" mark on
the recovery tank. Coolant should be added only to the
reservoir to raise level to the "FULL" mark. Use a
50/50 mixture of high-quality ethylene glycol
antifreeze and water for coolant additions.

BB.4 ENGINE COOLING
ENGINE COOLING SYSTEM COMPLAINT
TO AVOID NEEDLESS
TIME AND COST IN DIAGNOSING COOLING SYSTEM COMPLAINTS, THE CUSTOMER
SHOULD BE QUESTIONED ABOUT DRIVING CONDITIONS THAT PLACE ABNORMAL LOADS ON THE COOLING
SYSTEM.
1. DOES OVERHEATING OCCUR WHILE PULLING A TRAILER?
IF ANSWER IS "YES'- HOW HEAVY IS TRAILER? IF TRAILER WEIGHT IS GREATER THAN 1,000 LBS. & CAR IS EQUIPPED
WITH NORMAL DUTY COOLING SYSTEM, A HEAVY DUTY COOLING PACKAGE IS REQUIRED (PER MFR'S TRAILER HAULING
SPECS.). FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REQUIRED.
2. IS CAR EQUIPPED WlTH ADD-ON OR AFTER MARKET AIR CONDITIONING SYSTEM?
IF ANSWER IS "YES"- WAS HEAVY DUTY RADIATOR INSTALLED WITH THE SYSTEM? IF NOT, INSTALL HEAVY DUTY AIR
CONDITIONING RADIATOR FOR THE CAR MODEL INVOLVED (PER MANUFACTURER'S SPECS.). FURTHER DlAGNOSTlC
CHECKS SHOULD NOT BE REQUIRED.
3. IS OVERHEATING OCCURRING AFTER PROLONGED IDLE, IN GEAR, AIC SYSTEM OPERATING?
IF ANSWER IS "YES - INSTRUCT OWNER ON DRIVING TECHNIQUES THAT WOULD AVOID OVERHEATING SUCH AS: a, IDLE IN NEUTRAL AS MUCH AS POSSIBLE - INCREASE ENGINE R.P.M. TO GET HIGHER AIR FLOW & WATER
FLOW THROUGH RADIATOR.
b. TURN A/C SYSTEM OFF DURING EXTENDED IDLES IF OVERHEATING IS INDICATED BY HOT LIGHT OR TEMP. GAGE.
FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REQUIRED.
4. IS OVERHEATING OCCURRING AFTER PROLONGED DRIVING IN SLOW CITY TRAFFIC, TRAFFIC JAMS,
GARAGES, ETC.?
IF ANSWER IS "YES - INSTRUCT OWNER ON DRIVING TECHNIQUES THAT WOULD AVOID OVERHEATING - SAME AS
FOR PROLONGED IDLES - NO. 3 FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REQUIRED.
IF NONE OF THE ABOVE APPLY, GO TO DIAGNOSTIC CHART
TO EFFECTIVELY USE THlS CHART, QUESTION THE OWNER TO DETERMINE WHICH OF THE FOLLOWING
(3) CATEGORIES APPLIES TO THE COMPLAINT:
1. HOT LlGHT OR HOT INDICATION ON TEMPERATURE GAGE 2. BOILING 3. COOLANT LOSS
1. IF COMPLAINT IS HOT LlGHT OR HOT INDICATION ON TEMPERATURE GAGE -
WAS HOT LlGHT ACCOMPANIED BY BOILING? IF ANSWER IS "YES", GO TO BOILING ON CHART
IF ANSWER IS "NO, GO TO HOT LlGHT ON CHART
2. IF COMPLAINT IS BOILING - GO TO BOILING ON CHART
IF PROBLEM REMAINS, GO TO COOLING
FAN DIAGNOSIS SECTION 8 (IF SO EQUIPPED).
I 3. IF COMPLAINT IS COOLANT LOSS -
DETERMINE IF CUSTOMER IS OVERFILLING THE SYSTEM, THlS WOULD NORMALLY RESULT IN SMALL AMOUNTS OF
I COOLANT LOSS THROUGH THE OVERFLOW TUBE. IF THlS IS THE CASE, INSTRUCT THE CUSTOMER ON PROPER FILL LEVEL & NO FURTHER DIAGNOSTIC CHECKS SHOULD BE REQUIRED.
I IF OVERFILLING IS NOT THE PROBLEM, GO TO COOLANT LOSS ON CHART.
NOTICE:
ANYTIME COOLING SYSTEM IS OBVIOUSLY CONTAMINATED, THE SYSTEM SHOULD BE
DRAINED AND FLUSHED.
1 CAUTION - THE COOLING SYSTEM IS DESIGNED TO OPERATE AT 15 P.S.I. PRESSURE & TEMPERATURES
EXCEEDING 200°F. CAUTION SHOULD BE EXERCISED WHEN REMOVING PRESSURE CAP OR
I SERVICING THE SYSTEM.
Fig. 4 Cooling System Diagnosis Chart (I of 3)

ENGINE COOLING BB-7
NOTICE: If recommended quality antifreeze is
used, supplemental inhibitors or additives claiming
to provide increased cooling capability are not
necessary. They may be detrimental to the efficient
operation of the system, and represent an
unnecessary operating expense.
Every 12 months or 15,000 miles, the cooling
system should be serviced as follows;
1. Wash radiator cap and filler neck with clean
water.
2. Check coolant for proper level and freeze
protection.
3. Pressure test system and radiator cap for proper
pressure holding capacity, 103
kPa (15 psi). If
replacement of cap is required, use the proper cap
specified for car model.
4. Tighten hose clamps and inspect all hoses. Replace
hoses whenever cracked, swollen or otherwise
deteriorated.
5. Clean frontal area of radiator core and air
conditioning condenser.
DRAINING AND REFILLING THE COOLING
SYSTEM
Replace hoses every 24 months or 30,000 miles or
earlier if cracked, swollen or otherwise deteriorated.
Every two years or 30,000 miles, whichever first
occurs, the cooling system should be flushed and
refilled using the following recommended procedure:
1. Remove radiator cap, or thermostat housing cap
(VIN
0, J, R and U), when engine is cool by:
a. Slowly
rotating cap counterclockwise to
detent. (Do not press down while rotating.)
b. Wait until any
residual pressure (indicated
by a hissing sound) is relieved.
c. After all hissing ceases, press down on cap
while continuing to rotate
counterclockwise.
CAUTION: To avoid the danger of
being burned, do not remove radiator
cap while engine and radiator are still
hot. Scalding fluid and steam may be
blown out under pressure.
2. Remove the thermostat by using the wire handle
to lift it out of the housing (VIN
0, J, R and U).
3. With the thermostat removed, reinstall the
thermostat housing cap (VIN
0, J, R and U).
4. Open radiator drain valve and block drain plugs
to drain coolant. On VIN R and
9 (P series)
engines, open coolant pipe plugs.
5. Close valve. Reinstall drain plugs, and add
sufficient water to fill system.
6. Run engine, drain and refill the system, as
described in steps
4 and 5 a sufficient number of
times, until the drained liquid is nearly colorless.
Important
BLOCK DRIVE WHEELS, place
transmission in PARK (automatic
transmission) or NEUTRAL (manual
transmission) and set the parking brake. 7.
Allow system to drain completely. Then close
radiator drain valve tightly, and reinstall block
drain plugs.
8. Remove recovery cap leaving hoses in place.
Remove coolant recovery tank and empty of
fluid. Flush tank with clean water, drain and
reinstall.
9. Add sufficient ethylene glycol coolant, meeting
GM specification 1825-M, to provide the
required freezing and corrosion protection
- at
least 50 percent solution -37°C (-34°F). Fill
radiator to the base of the radiator fill neck and
add sufficient coolant to the recovery tank to
raise level to the "FULL" mark. Reinstall
recovery tank cap.
10. Run engine, with radiator cap or thermostat
housing cap removed, until normal operating
temperature is reached. (Radiator upper hose
becomes hot.)
11. With engine idling, add coolant until level
reaches bottom of filler neck and reinstall cap,
making certain arrows line up with overflow tube.
CAUTION: Under some conditions, the
ethylene glycol in engine coolant is
flammable. To help avoid being
burned when adding coolant, DO NOT
spill
it on the exhaust system or hat
engine parts.
It is the owner's responsibility to keep the freeze
protection at a level appropriate to the
temperatures which may occur in the area of
vehicle operation.
a. Maintain
cooling system freeze protection
at
-37°C (-34"F), to ensure protection
against corrosion and loss of coolant from
boiling, even though freezing temperatures
are not expected.
b. Add ethylene glycol base coolant that meets
GM Specification 1825-M, when coolant
additions are required because of coolant
loss, or to provide additional protection
against
freezing at temperatures lower than
-37°C (-34°F).
NOTICE: Alcohol or methanol base coolants, or
plain water, are not recommended at any time.
DRlVE BELT
NOTICE: Routine inspection of the belt may
reveal cracks in the belt ribs. These cracks will
not impair belt performance and therefore should
not be considered a problem requiring belt
replacement. However, the belt should be
replaced if belt slip occurs or if sections of the
belt ribs are missing.
A single (serpentine) belt is used to drive all
engine accessories formerly driven by multiple drive
belts. All belt driven accessories are ridgedly mounted
with belt tension maintained by a spring loaded
tensioner.
The drive belt tensioner has the ability to control
belt tension over a fairly broad range of belt lengths.