tow bar PONTIAC FIERO 1988 Service Repair Manual

3-10 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
Reminder Keeps Operating With Key In Lock
Cylinder, Driver's Door Open Or Closed; Ceases
When Key Is Removed
Inspect
s Door jamb switch on driver's side misadjusted or
inoperative.
e Wire from signal switch to door jamb switch
shorted.
A. This condition indicates the lock cylinder or
the reminder switch is at fault. To verify,
check for continuity at the
"E" and "F"
male column connector contacts, with the
key removed from the lock cylinder. If
continuity exists, the fault is in the column.
B. Insert the key into the lock, then turn the
lock toward the "Start" position. If the
reminder stops when the key is in the
"Run" position or when it is turned past
"Run" toward "Start," the problem is a
sticky lock cylinder actuator.
COLUMN-MOUNTED DIMMER SWITCH
No "Low" or "High" Beam
Inspect
e Loose connector at dimmer switch
e Improper adjustment
e Internally damaged or worn switch. Check the
continuity on the switch at the It. green and at the
tan switch terminals by pushing in the plunger all
the way.
A click should be heard. If there is no
continuity, replace the dimmer switch. If there is
continuity, refer
to'section 8A for electricaldiag-
nosis.
PIVOT AND SWITCH ASSEMBLY
Switch Inoperative: No "Low," "High" and/or
"Wash"
e Loose body-to-switch connector
a Broken or damaged switch
Internally damaged or worn switch. Connect a
new switch without removing the old one. If the
system functions, replace the switch. If the
system doesn't function, refer to Section
8A for
electrical diagnosis.
STEERING GEAR AND PUMP LEAKS
General Procedure
Inspect
s Overfilled reservoir
s Fluid aeration and overflow
e , Hose connections
Verify exact point of leakage Example:
Torsion bar, stub shaft and
adjuster seals are close together; the exact
spot where the system is leaking may not be
clear.
Example: The point from which the fluid is
dripping is not necessarily the point where
the system is leaking; fluid overflowing from
the reservoir, for instance.
e When service is required:
A. Clean leakage area upon disassembly.
B. Replace leaking seal.
C. Check component sealing surfaces for
damage.
D. Reset bolt torque to specifications, where
required.
Some complaints about the power steering system
may be reported as:
A. Fluid leakage on garage floor
B. Fluid leaks visible on steering gear or pump
C. Growling noise, especially when parking or
when engine is cold
D. Loss of power steering when parking
E. Heavy steering effort
When troubleshooting these kinds of complaints,
check for an external leak in the power steering system.
For further diagnosis of leaks, refer to External
Leakage Check in this section.
External Leakage Check
Fig. 12
The purpose of this procedure is to pinpoint the
location of the leak.
In some cases, the leak can easily be located. But,
seepage-type leaks may be more difficult to isolate. To
locate seepage leaks, use the following method.
1. With the engine off, wipe dry the complete power
steering system.
2. Check the fluid level in the pump's reservoir. Add
fluid if necessary.
3. Start the engine, then turn the steering wheel
from stop to stop several times. Do not hold it at
a stop for any length of time, as this can damage
the power steering pump. It is easier if someone
else operates the steering wheel while you search
for the seepage.
4. Find the exact area of the leak and repair leak.
SEAL REPLACEMENT
RECOMMENDATIONS
Lip seals, which seal rotating shafts, require
special treatment. This type of seal is used on the
steering gear and on the drive shaft of the pump. When
there is a leak in one of these areas, always replace the
seal(s), after inspecting and thoroughly cleaning the
sealing surfaces. Replace the shaft only if very severe
pitting is found. If the corrosion in the lip seal contact
zone is slight, clean the surface of the shaft with crocus
cloth. Replace the shaft only if the leakage cannot be
stopped by first smoothing with crocus cloth.

REAR SUSPENSION 30-3
1. Position springs and insulators in spring seats and
raise rear axle until rear axle supports weight of
vehicle at normal curb height position.
2. Shocks to rear axle. Torque nuts. 1-17 N.M (13 FT.LB.1 3. Thoroughly clean track bar-to-axle assembly bolt
2-UNDERBODY and nut as outlined under Recommendation for
Reuse of Prevailing Torque Fasteners in Section
3-95 NeM (70 FT.LB.) 4. Track bar mounting bolt at axle and torque nut.
4-AXLE ASM. Torque track bar to body bracket nut.
5. Brake line clip to underbody.
6. Remove adjustable lifting device from beneath
axle and lower car.
TYPICAL SHOCK INSTALLATION TRACK BAR (RH SHOWN)
Remove or Disconnect
at body bracket.
3. Track bar.
Install or Connect
NOTICE: See NOTICE on Page 3D-1 of this
1. Position track bar in body bracket and loosely
install bolt and nut.
2. Thoroughly clean track bar to axle assembly bolt
and nut as outlined under Recommendations for
Reuse of Prevailing Torque Fasteners in Section
3. Position track bar at axle. Install bolt and nut.
4. Torque track bar nut at body bracket to 78 Nem
5. Remove rear axle support and lower car.
TRACK BAR BRACE
1. Hoist car and support rear axle.
2. Heat shield screws from track bar brace.
3. Three track bar brace to body brace screws.
4. Nut and bolt at body bracket. Remove track bar 1-REAR UNDERBODY SHOCK TOWER
AND SPRING SEAT.
2-SPRING INSULATOR
NOTICE: See NOTICE on Page 3D-1 of this 3-COIL SPRING
1. Position track bar brace and loosely install nut Fig. 603 Coil Springs and Insulator and bolt at body bracket.
2. Position other end of track bar brace at body
bracket. Install three screws and torque screws.
3. Torque track bar nut at body brace.

3E-8 TIRES AND WHEELS
nearest the valve stem, and a 1/2 ounce balance weight
should be added 180" opposite the locking nut on the
wheel's inboard side.
When rotating tires, always re-install the locking
nut nearest the tire valve stem so that it remains
opposite the 1/2 ounce balance weight. This procedure
will improve the on-car wheel balance by compensating
for the heavy locking wheel nut.
Off-Car Balancing
Most electronic off-car balancers are more
accurate than the on-car spin balancers. They are easy
to use and give a dynamic (two plane) balance.
Although they do not correct for drum or rotor
unbalance as does on-car spin balancing, this is
overcome by their accuracy (usually to within 1/8
ounce). When balancing off-car, the wheel should
locate on the balancer with a cone through the back
side of the center pilot hole (not by the wheel stud
holes).
On-Car Balancing
When needed, on-car balancing will help correct
vibrations due to brake drum, rotor, and wheel cover
imbalance.
When balancing on car, do not remove the
balance weights from the off-car dynamic balance. If
more than one ounce of additional weight is required,
it should be split between the inner and outer rim
flange.
NOTICE: The driven tire and wheel assemblies
should be spun using the engine. Limit speed as
stated in the following Caution.
CAUTION: Do not spin the drive
wheels faster than
35 mph (55 km/h)
as indicated by the speedometer. This
limit is necessary because the
speedometer indicates only one-half
of the actual wheel speed when one
drive wheel is spinning and the other
drive wheel is stopped. Personal injury
and damage may result from high
speed spinning.
CAUTION: On cars equipped with
limited slip rear axles, do not attempt
to balance a tire on a
drive wheel with
the other drive wheel on the ground.
The car may drive through this wheel
and cause the car to move
unexpectedly, resulting in personal
injury and property damage.
To distinguish between standard rear axle and
limited slip, raise rear of car so both tires are clear of
ground. With the transmission in park (in gear with
manual transmission), attempt to turn one wheel by
hand. If the wheel can be turned, it is a standard rear
axle; if the wheel cannot be turned, it is a limited slip
rear axle. Also, check for Limited Slip
(G80) on Service
Parts Identification label.
Wheel Weights
Fig. 15
If more than 27 grams (1.0 oz.) are needed, the
wheel weights should be split as equal as possible
between the inboard and outboard flanges.
Balancing of' assemblies with factory aluminum
wheels requires the use of special nylon coated clip-on
type wheel weights. These weights are designed to fit
over the thicker rim flange of the aluminum wheel and
should be installed with a plastic tipped hammer.
Adhesive wheel weights are also available. Use
the following procedure to install adhesive wheel
weights.
Adhesive Wheel Weight Installation
1. Clean wheel by sanding to bare aluminum where
wheel weight is to be located.
2. Wipe wheel weight attachment area with a
mixture of half Isopropyl alcohol and half water.
A clean cloth or paper towel niust be used for this
operat ion.
3. Dry the attachment area with hot air. Surface of
wheel should be warm to the touch.
4. The adhesive backing on wheel weights must be
warmed to room temperature.
5. Remove tape from back of weights. Do not touch
the adhesive surface.
6. Apply wheel weight and press on with hand
pressure.
7. Secure wheel weight with a 70-1 10
N (16-25 lb)
force applied with a roller.
CENTERLINE
1 INSIDE FLANGE CLIPBN WEIGHT 4. ADHESIVE WEIGHT - DYNAMIC 5. ADHESIVE WEIGHT -STATIC ONLY 6. MOUNTING FACE
Fig. 15 Aluminum Wheel Weight Placement
CORRECTING NON-UNIFORM TIRES
There are two ways to correct tires which cause
a vibration even though they are properly balanced.
One method uses an automatic machine which loads
the tire and buffs small amounts of rubber from high
spots on the outer two tread rows. Correction by this
method is usually permanent and, if done properly,
does not significantly affect the appearance or tire
tread life. Tire truing with a blade-type
machine is not
recommended as this reduces the tread life
substantially and often does not permanently correct
the problem.

DISC BRAKE CALIPER ASSEMBLY 588-3
BO LT
FITTING
MOUNTING
31. BRAKE PIPE
Fig. 4 Caliper Attachment
11. Mounting bolts (23) and sleeves (6), using 3/8
inch
allen head socket (Figures 1 & 5).
12. Caliper (12) from rotor. If only shoe and linings
are replaced, suspend caliper with a wire hook
from strut.
Inspect
e Mounting bolts (23) and sleeves (6) for
corrosion (Figures
1 & 5).
e If corrosion is found, use new parts,
including bushings, when installing caliper.
e Do not attempt to polish away corrosion.
Install or Connect
Important
See NOTICE on page 5- 1.
1. Lubricate sleeves (6) and bushings (7 and 11)
with silicone grease (Figure 5).
2. Sleeves
(6) in caliper mounting holes.
3. Caliper (12) over rotor.
4. Mounting bolts (23) to 50 N-m (37 1b.ft.) (Figure
1).
5.
Tube nut on brake pipe (31), if removed, to 20
N-m (15 1b.ft.) (Figure 4).
@ If brass bolt (8) and fitting (10) were
removed with brake pipe, unplug fitting and
install bolt and fitting using two new copper
washers
(9) to 44 N.m (32 lb. ft.) (Figure 8).
6. Disconnect nut (I), lever (2) lever seal (22), and
anti-friction washer (21) and clean (Figure 8).
Clean
Clean contamination from caliper surface in
area of lever seal (22) and around actuator
screw (16) (Figure 8).
7. Anti-friction washer (21).
8. Lubricated lever seal (22) with sealing bead
against caliper housing (12).
9. Lever (2) on actuator screw hex with lever
pointing down.
10. Nut
(I), while holding rotated lever (2) toward
front of car, to 48
N-m (35 1b.ft.). Rotate lever
back against stop on caliper (12).
11. Damper (37) and return spring (3) (Figure 1).
12. Parking brake cable (29). For cable adjustment
see PARKING BRAKE ADJUSTMENT.
13. Wheels and tires, aligning previous marks.
s Remove lug nuts securing rotor to hub.
e Lower car.
e Torque lug nuts. See WHEELS AND
TIRES.
14. Fill master cylinder to proper lever with clean
brake fluid.
e Bleed caliper if inlet fitting was removed.
Recheck fluid level.
PARKING BRAKE ADJUSTMENT
Apply service brake pedal three times with a
pedal force of approximately 778 N (175 lbs.).
Apply and release parking brake three times.
Raise car and suitably support.
e Mark relationship of wheel to axle flange.
Check parking brake hand lever for full release.
e Turn ignition on.
e "BRAKE" warning lamp should be off. If
"BRAKE" warning lamp is still on, and the
hand lever is completely released, pull
downward on the front parking brake cable
to remove slack from lever assembly.
Turn ignition off.
Remove rear wheels and tires.
e Reinstall two inverted lug nuts to retain
rotor.
Pull parking brake hand lever exactly four (4)
ratchet clicks.
Parking brake levers (2) on both calipers should
be against the lever stops on the caliper housings.
If levers are not against stops, check for binding
in rear cables and/or loosen cables at adjuster
until both left and right levers are against their
stops.
Tighten parking brake cable at adjuster until
either the left or right lever begins to move off the
stop, then loosen adjustment until lever moves
back barely touching stop.
Operate parking brake several times to check
adjustments. After cable adjustment is
performed, parking brake hand lever should
travel 14 clicks. Rear wheels should not rotate
forward when hand lever is applied
8 to 14
ratchet clicks.
Install wheels and tires, aligning previous marks.

2.8 LITER V-6 8A2-23
4. Make sure the gap in the oil ring rails are in "up"
position toward center of engine and the gaps of
the compression rings are positioned as shown in
Figure
6A2-30.
5. Install each connecting rod and piston assembly
in its respective bore. Install with connecting rod
bearing tang slots on side opposite camshaft. Use
Tool J-8037 or J-8910 to compress the rings.
Guide the connecting rod into place on the
crankshaft journal.
Use a hammer handle and light blows to install
the piston into the bore. Hold the ring
compressor firmly against the cylinder block
until all piston rings have entered the cylinder
bore.
6. Install the bearing caps and torque nuts to
specifications. If bearing replacement is required
refer to "Connecting Rod Bearings".
Be sure to install new pistons in the same
cylinders for which they were fitted, and used
pistons in the same cylinder from which they
were removed. Each connecting rod and bearing
cap should be marked, beginning at the front of
the engine.
On V-6 engines, 1,3 and 5 are in the right bank
and 2,
4 and 6 are in the left bank. The numbers
on the connecting rod and bearing cap must be on
the same side when installed in the cylinder bore.
If a connecting rod is ever transposed from one
block or cylinder to another, new bearings should
be fitted and the connecting rod should be
numbered to correspond with the new cylinder
number.
NOTE. All dlrnenslons are In rn~ll~rnetres.
Figure 6A2-3 1 Service Pistons
HONING OR REBORING CYLINDERS (FIGURE
6A2-32)
If one or more cylinder bores are rough, scored
or worn beyond limits, it will be necessary to smooth
or true up such bores to fit new pistons.
If relatively few bores require correction, it will
not be necessary to
rebore all cylinders to the same
oversize in order to maintain engine balance. All
HONED SURFACE
1.
Cross Hatch Angle 20' - 32'
2.
Uniformly Cut in Both Directions
3. Clean Cut Not Sharp Free of Torn and
Folded Metal
4. Micro Ave. 10-20 Micro In. (0.254.30 micrometers) Range 10-1 5 micro in.
(0.25-0.38 micrometers)
5. Cross Hatch Ave.
.0004"-.0006" Wide
Range ,0002"-.0009"
6. Cross Hatch Ave. ,0001 5"-.00025" Deep Ranw ,0081 "-.0003"
7. Plateau to be 1/2 to 2/3 of Surface
8. Free of Burnish or Glaze
I 9. Free of Imbedded Particles I
I I Figure 6A2-32 Honing Specifications
oversize service pistons (Figure 6A2-3 1) are held to the
same weights as standard size pistons.
No attempt should be made to cut down oversize
pistons to fit cylinder bores as this will destroy the
surface treatment and affect the weight. The smallest
possible oversize service pistons should be used and the
cylinder bores should be honed to size for proper
clearances.
Before the honing or
reboring operation is
started, measure all new pistons with micrometer
contacting at points exactly 90 degrees from piston pin
centerline then select the smallest piston for the first
fitting. The slight variation usually found
beween
pistons in a set may provide for correction in case the
first piston is fitted too free.
If wear at top of cylinder does not exceed 0.10
mm on the diameter or exceed
0.lOmm out-of-round,
honing is recommended for truing the bore. If wear or
out-of-round exceeds these limits, the bore should be
trued up with a boring bar of the fly cutter type, then
finish honed.
When
reboring cylinders, all crankshaft bearing
caps must be in place and tightened to proper torque
to avoid distortion of bores in final assembly. Always
be sure the crankshaft is out of the way of the boring
cutter when boring each cylinder. When taking the
final cut with boring bar, leave
,025mm on the
diameter for finish honing to give the required
clearance specified.
When honing cylinders, use clean sharps tones of
proper grade for the amount of metal to be removed,
in accordance with instructions of the hone
manufacturer. Dull or dirty stones cut unevenly and
generate excessive heat. When using coarse or medium
grade stones use care to leave sufficient metal so that
all stone marks may be removed with the fine stones
used for finishing to provide proper clearance.
It is of the greatest importance that refinished
cylinder bores are trued up to have not over
.02mm

6E3-A-I8 2.8b (VIN 5) DRIVEABILITY AND EMISSIONS
PUMP INLET FILTER
IN-TANK PUMP
FUEL
PRESSURE CONNECTOR
CHART A-7
(Page 4 of 2)
FUEL SYSTEM DsAGNOSBS
2.8L (VIN S) ""FYSERBES (PORT)
Circuit Description:
When the ignition switch is turned "ON", the electronic control module (ECM) will turn "ON" the in-tank
fuel pump. It will remain "ON" as long as the engine is cranking or running, and the ECM is receiving
HE1
distributor reference pulses.
If there are no reference pulses, the ECM will shut "OFF" the fuel pump within
2 seconds after key "ON" or
engine stopped.
The pump will deliver fuel to the fuel rail and injectors, then to the pressure regulator, where the system
pressure is controlled to about 234 to 317
kPa (34 to 46 psi). Excess fuel is then returned to the fuel tank.
Test Description: Numbers below refer to circled
numbers on the diagnostic chart.
1. Use pressure gage 5-34730-1. Wrap a shop towel
around the fuel pressure tap to absorb any small
amount of fuel leakage that
may occur when
installing the gage.
Ignition "ON", pump pressure should be 280-325
kPa (40.5-47 psi). This pressure is controlled by
spring pressure within the regulator assembly.
2. When the engine is idling, the manifold pressure
is low (high vacuum) and is applied to the fuel
regulator diaphragm. This will offset the spring
and result in a lower fuel pressure.
'This idle
pressure will vary somewhat depending on
barometric pressure, however, the pressure idling
was less indicating pressure regulator control.
3. Pressure that continues to fall is caused by one of
the following:
In-tank fuel pump check valve not holding.
@ Pump coupling hose or pulsator leaking.
Fuel pressure regulator valve leaking.
@ Injector sticking open. 4.
An injector sticking open can best be determined
by checking for a fouled or saturated spark
plug(s).
If a leaking injector can not be determined by a
fouled or saturated spark plug the following
procedure should be used.
e Remove Plenum, cold start valve and remove
fuel rail bolts. Follow the procedures in the
fuel control section of this manual, but leave
fuel lines connected.
@ Reconnect cold start valve.
@ Connect a hose to valve nozzle and insert into
a gasoline container.
@ Lift fuel rail out just enough to leave injector
nozzles in the ports.
CAUTION: BE SURE INJEePOR(S) ARE NOT ALLOWED
PO SPRAY ON ENGINE AND THAT INJECTOR
RETAINING
CLIPS ARE INTACT. PHIS SHOULD BE
CAREFULLY
FOLLOWD PO PREVENT FUEL SPRAY ON'
ElZIGlNE WHICH WOULD CAUSE A FIRE HAZARD.
@ Pressurize the fuel system.
@ I.if't each side of rail up and observe for
injc~ctot-l.) It.ulting

6E3-A-18 5.OL (WIN F) & 5.7L(VIN 8) DRIVEABILITY AND EMISSIONS
PRESSURE REGULATOR
COLD START
TUBE ASSEMBLY
FUEL PRESSURE
LINE
CHART A-7
(Page 1 of 2)
FUEL SYSTEM DIAGNOSIS
5.OL (VIN F) & 5.7L (VIN 8) 'TF'3SERlES (PORT)
Circuit Description:
When the ignition switch is turned "ON", the electronic control module (ECM) will turn "ON" the in-tank
fuel pump. It will remain "ON" as long as the engine is cranking or running, and the
ECM is receiving
reference pulses. If there are no reference pulses, the ECM will shut "OFF" the fuel pump within 2 seconds after
ignition "ON" or engine stops.
The pump will deliver fuel to the fuel rail and injectors, then to the pressure regulator, where the system
pressure is controlled at 234 to 325
kPa (34 to 47 psi). Excess fuel is then returned to the fuel tank.
Test Description: Numbers below refer to circled
numbers on the diagnostic chart.
1. Wrap a shop towel around the fuel pressure
connector to absorb any small amount of fuel
leakage that may occur when installing the gage.
Ignition "ON", pump pressure should be 280-325
KPa (40.5-47 psi). This pressure is controlled by
spring pressure within the regulator
assenlbly
2. When the engine is idling, the manifold pressure
is low (high vacuum) and is applied to the fuel
regulator diaphragm. This will offset
the spring
and result in a lower fuel
pressure.This idle
pressure will vary somewhat depending on
barometric pressure; however, the pressure idling
should be less, indicating pressure regulator
control.
3. Pressure that continues to fall is caused by one of
the following:
In-tank fuel pump check valve not holding.
@ Pump coupling hose or pulsator leaking
@ Fuel pressure regulator valve leaking
Injector(s) sticking open.
4. An
injector sticking open can best be determined
by checking for a fouled or saturated spark
plug(s).
If a leaking injector cannot be determined by a
fouled or saturated spark plug, the following
procedure should be used:
@ Remove Plenum, and remove fuel rail bolts.
Follow the procedures in the Fuel Control
Section of this manual, but leave fuel lines
connected.
s Lift fuel rail out just enough to observe
injector nozzles in the ports.
CAUTION: BE SURE INJECTOR(S) ARE NOT ALLOWED
TO SPRAY ON ENGINE AND THAT INJECTOR
RETAINING CLIPS ARE INTACT.
THIS SHOULD BE
CAREFULLY FOLLOWED TO PREVENT FUEL SPRAY ON
ENGINE WHICH WOULD CAUSE A
FIRE HAZARD.
@ Pressurize the fuel syste~rl and observe injector
nozzles.

GENERAL INFORMATION - F STYLE 1 H-1
SECTION IH
GENERAL NFORMAT
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.
Lock Cylinder Coding
..................................... I H-1 Chip Resistant Plastisol Material .................... 1 H-8
...................................................... Lubrication 1 H-2 Flexible Exterior Plastic Parts ......................... 1H-9
Adhesive Body Side Moldings ......................... 1H-3 Metal Replacement Parts Finishing ................ lH-13
Waterleak Diagnosis and Repair ..................... 1H-3 Interior Plastic Trim Parts Finishing .............. 1H-13
.................................................... Anticorrosion Treatment ................................ IH-4 Special Tools I H- 14
LOCK CYL!NDER CODING o Check key operation in the lock cylinder.
KEY IDENTIFICATION AND USAGE
REPLACEMENT LOCK CYLINDERS
The lock cylinder keyway is designed so that
other model keys will not enter a current model lock
cylinder. Two noninterchangeable keys are used.
CB Square headed key is used in the ignition lock
cylinder.
o Oval headed key is used in all other lock
cylinders.
Key identification is obtained from the four
character key code stamped on the knockout portion
of the key head and an identification letter stamped on
the key shank. After the code number has been
recorded by the owner, the plugs should be knocked
out of the key head. From these numbers, the lock
combination can be determined by use of a code list
(available to owners of key cutting equipment from
equipment suppliers). If key code numbers are not
available from records or from the knockout plug, the
lock combination (tumbler numbers and position) can
be determined by laying key on diagram in Figure
1.
I POSITION LEVELS I
Fig. 1 - Key Code Diagram
CUTTING KEYS
Lock cylinders are available from service parts
warehouses. The new cylinder has a locking bar staked
in place. Tumblers are also available and must be
assembled into the cylinder.
ASSEMBLING AND CODING LOCK CYLINDERS
All Lock Cylinders Except Rear Stowage
Compartment
Tumblers for all locks are shaped exactly alike
with the exception of the notch position on one side.
As the key is inserted in the lock cylinder, tumblers are
lowered to the correct height so that notches on each
tumbler are at the same level. When the notches on all
six tumblers line up, the side bar is pushed into the
notches by two small springs. This allows the cylinder
to turn in its bore. Five types of tumblers are used to
make the various lock combinations. Each tumbler is
coded according to a number,
1 through 5, stamped on
its side.
Assemble (Figs. 2 and 3)
1. Determine tumbler numbers and arrangement.
a. With numerical
key code, use code list
provided by key cutting equipment supplier.
b. Without numerical
key code or without
code list, refer to Figure
1.
o Lay key on key code diagram. Be sure
key is outlined by diagram.
Determine special code from the code list or the
key code diagram (Fig.
1). 3.
o Cut a blank key to the proper level for each of six
tumbler positions.
4.
Start with position number one. Find
and record lowest level (tumbler
number) that is visible. Repeat for
each of the remaining five positions.
Starting with position one [open end or head of
cylinder), insert tumblers in their proper slots in
the order called for by the code (Fig.
2).
Pull side bar out with fingers so that tumblers will
drop completely into place.
Insert one tumbler spring above each tumbler.

1 H-2 GENERAL INFORMATION - F STYLE
5. Insert spring retainer so that end prongs slide into
upon cylinder type. Therefore only the last 4 or 5
the slots at each end of cylinder. Press retainer
tumbler combinations are required.
down.
TUMBLER \m , LOCK CYLINDER HEAD
SIDE BAR LOCK CYLINDER
Fig.
2 - Installing Tumblers
TUMBLER SPRING RETAINER
LOCK CYLINDER HEAD
Fig.
3 - Installing Spring Retainer
6. Insert key into lock cylinder to check for proper
installation.
Inspect
Side bar will drop down if tumblers are installed
properly, If incorrectly assembled, disassemble
and reassemble correctly.
NOTICE: Use leather or wood at each vise jaw to
prevent damage to cylinder.
7. Remove key and secure cylinder in a vise with
spring retainer exposed.
8. Stake spring retainer securely in place at each
end. Use suitable staking tool and stake cylinder
metal over retainer.
9. Black lock cylinders should be lubricated with a
light oil. All other lock cylinders should be
lubricated with a general purpose silicone
lubricant, part no. 1052277 or equivalent.
Assemble (Figs. 4 and 5)
Determine tumbler numbers and arrangement as
previously described and install tumblers,
TUMBLER
I CYLINDER I
Fig. 4 - Installing Tumblers
AFTER INS WOODEN
TAP TUMBLERS BLOCK
FLUSH
WITH CYLINDER
Fig. 5 - Locking Tumblers in Place
LUBRICATION
Mechanical parts having contacting surfaces in
relative motion with other body parts are lubricated
during assembly. To maintain ease of operation, it is
recommended that these parts be lubricated at the
basic service intervals shown in the Maintenance
Schedule with the following lubricants:
Rear Stowage Compartment Lock Cylinder Door hinges - oil (30 weight preferred). Apply
A lock cylinder with snap-in tumblers is used for lubricant
to roller and hinge pin bushings.
the rear stowage compartment lock. The lock cylinder
Important has four or five tumbler positions. The number 1 or 2
position (closest to cylinder head) is a brass retainer Do
not apply to hold-open link and roller
tumbler. The
2 through 5 positions or 3 through 5 contacting
surfaces as this could cause improper
positions are standard tumbler positions depending roller operation.

2H-6 STATIONARY GLASS - F STYLE
all traces of factory installed adhesive must be
removed prior to reinstallation.
5. Wipe sanded mirror support with clean paper
towel saturated with alcohol and allow to dry.
6. Follow directions on manufacturer's kit to
prepare
rearview mirror support prior to
installation on glass.
7. Properly position support to its premarked
location, with rounded end pointed upward; press
support against glass for 30 to 60 seconds,
exerting steady pressure against glass. After five
minutes, any excess adhesive may be removed
with an alcohol moistened paper towel or glass
cleaning solution.
8. Reinstall mirror
4. LOCATING CIRCLE AND BASE OF SUPPORT
LINE ON OUTSIDE GLASS SURFACE
2. CIRCLE ON OUTSIDE GLASS SURFACE
INDICATES AREA TO BE CLEANED
G94301-11 B.BG
Fig. 8-Locating Bonded earv view Mirror Support on
Glass
REAR WlMBOW DEFOGGER
The optional rear window defogger system
consists of a tinted glass that has a number of
horizontal ceramic silver compound element lines and
two vertical bus bars baked into the inside surface
during the glass forming operation. The feed wire or
terminal is soldered to the bus bar on the side. The
ground wire or terminal is soldered to the bus bar on
the right side.
The system operates on 12 volts. Under some
conditions, heat from the glass may not be detected by
finger touch. The length of time required to remove
interior fog from the back glass will vary with such
conditions as vehicle speed, outside glass temperature
and atmospheric pressure and number of passengers. This
system uses an instrument panel mounted
switch with an integral indicator lamp; and will operate
for five to ten minutes and automatically turn off
through the use of an automatic timer. The system can
be turned off during this operating period by turning
either the instrument panel mounted switch or ignition
switch to off.
Testing Grid Lines
To locate inoperative grid lines, start engine and
turn on the rear window defogger system. Ground one
test lamp lead and lightly touch the other prod to each
grid line. Figure
9 illustrates the pattern of test lamp
brilliance to be expected with a properly functioning
grid.
If test lamp bulb shows full brilliance at both ends
of grid lines, check for loose ground wire contact to
body metal.
Fig. 9-Test Lamp Bulb Brilliance Zones - Normal
Operating Rear Window Defogger
The range of zones in Figure 9 may vary slightly
from one glass to another; however, the bulb brilliance
will decrease proportionately to the increased
resistance in the grid line as the prod is moved from the
left bus bar to the right.
All grid lines must be tested in at least two places
to eliminate the possibility of bridging a break. For best
results, contact each grid line a few millimeters (inches)
either side of the glass centerline. If an abnormal light
reading is apparent on a specific grid line, place test
lamp prod on that grid at the left bus bar and move
prod toward the right bus bar until light goes out. This
will indicate a break in the continuity of the grid line
(Fig.
10).
Grid Line Repair
Tools Required:
o Part No. 1052858 (or equivalent) - Rear Window
Defogger Repair Kit
e Heat gun - capable of 260°C (500°F)
Remove or Disconnect
Battery 'feed - rear window defogger system