warning PONTIAC FIERO 1988 Service Repair Manual

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

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

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 1B-17
If prescribed vacuum cannot be reached, close
vacuum control valve, shut off pump and look
for a leak at connections or pump.
3. When gauge reaches prescribed vacuum, the
system is fully evacuated. Close the high-side
gauge set valve and turn off the vacuum pump.
4. Watch low-side gauge to be sure vacuum holds
for five (5) minutes. If vacuum is held, discon-
nect vacuum hose at gauge set and then proceed
to charging.
5. If vacuum does not hold for five (5) minutes,
charge system with
420ml(1/2 pound) Refriger-
ant-12 and leak check. Discharge system again
and repair leak as necessary. Repeat evacuation
procedure.
To Begin Charging of the NC System
1. Start engine and set A/C mode control button on
"OFF. "
2. With the Refrigerant-12 drum or 420ml (14
ounce)
can(s) inverted, open R-12 source
valve(s) and allow 480ml (1 pound) or one
420m1 (14 02.) can of liquid R-12 to flow into
system through low-side service fitting.
3. As soon as 480ml (1 lb.) or one 420ml (14 oz.)
can of R-12 has been added to system, immedi-
ately engage the compressor by setting the
A/C
control button to NORM and blower speed on
HI, to draw in the remainder of the R-12 charge.
See specifications for total R-12 charge. The
charging operation can be sped up by using
a large volume fan to pass air over the con-
denser. If condenser temperature is maintained
below charging cylinder temperature,
Refriger-
ant-12 will enter the system more rapidly.
4. Turn off
R-12 source valve and run engine for
30 seconds to clear lines and gauges.
5. With the engine running, remove the charging
low-side hose adapter from the accumulator ser-
vice fitting. Unscrew rapidly to avoid excess
R-12 escape from system.
CAUTION: NEVER REMOVE A GAGE
LINE FROM ITS ADAPEER WHEN LINE
IS CONNECTED TO A/G SYSTEM.
ALWAYS REMOVE
THE LINE ADAPTER
FROM THE
SERVICE F1miNG TO DIS-
CONNECT A LINE. DO
NOT REMOVE
CHARGING
HOSE AT GAGE SET WHILE
ATTACHED TO ACGUMULBTOR. "THIS
WILL RESULT IN COMPLETE DIS-
CHARGE OF SYSTEM DUE TO THE
DEPRESSED SCHRADER VALVE IN
SERVICE LOW-SIDE
F17$TING, AND MAY
CAUSE PERSONAL
INJURY DUE TO
ESCAPING REFRIGERANT-72;.
6. Replace protective cap on accumulator fitting.
7. Turn engine off.
8. Leak check system with electronic leak detector
5-29547 or equivalent (see Diagnosis).
9. Start engine.
10. With system fully charged and leak-checked,
continue to operate system performance.
THIS HI-PRESS. VALVE IS
EVACUATION
ACCUMULATOR
ISPENSING UNIT
30 LB. DRUM HAS
OWN OPENER-VALVE
WARNING: MAKE SURE OUTLET VALVE
ON OPENER IS CLOSED (CLOCKWISE)
R-12 CQNTAINER.
OPEN AND INVERTED
DURING CHARGING
EVACUATION
Figure 16 Charging the System With Disposable Can or Drum

2C-4 CHASSIS SHEET METAL
3. Clean area to be repaired.
4. Mix and apply the repair material by using a
putty knife or rubber squeegee.
5. Work the material into the repair and build up
the desired contour. For deep filling, and on
vertical surfaces, several layers may be
required.
6. Feather-sand damaged area with No. 200 sand-
paper and finish-sand with No. 320 sandpaper.
7. Prepare repaired area for refinishing. Refinish
with acrylic lacquer as described below.
1. THOROUGHLY CLEAN the entire surface
area, using Naphtha or equivalent solvent, to
insure a surface free of contamination.
2. To promote paint adhesion, a light scuff-sand-
ing of the surface with
#400-grit sandpaper is
recommended.
3. Repeat cleaning of the surface.
4. Color coat with acrylic lacquer for proper color
match.
5. Allow to dry thoroughly, rub out and polish.
PAINT REFINISHING PROCEDURES FOR
URETHANE, P.V.C. AND T.P.R. SURFACES
Urethane material will withstand minor impact
and the resultant damage, such as occurs in parking
lots, by recovering its original shape. Its Endura paint
film responds to impact in a similar manner without
cracking or splitting. If, however, an area of damage
in the Urethane bumper or panel does not recover its
shape, or the surface is punctured, gouged or torn, a
repair system has been developed to restore the origi-
nal shape and appearance of the urethane-base
material.
CALSVON: There are a number of paint
systems available For service use; how-
ever,
many require additives containing
isocyanates.
It is essential that all rec-
ommendations and warnings listed on
the container label for
materials
seleded be followed.
CAUTION: If the paint system selected
specifies an additive containing
isocya-
nates, it is mandatory that adequate
respiratory protection be worn. An
example of such protection
is an air line
respirator with a
full hood or half mask.
If not
avaiable, use a vaporlpaHiculate
respirator that the respirator supplier
recommends as
efFective for isocyanate
vapors and mists (unless local
regula-
tions prevail).
Such protection should be worn during the
entire painting process. Persons with respiratory
problems, or those
allergic to isocyanates must not
be exposed to isocyanate vapors or spray mist.
REPAIRING & REFINISHING URETHANE
BUMPERS AND FRONT END PANELS
Required Materials:
1. 3M No. 8101 Structural Adhesive, or
equivalent.
2. Color Coat - Dexlar (DuPont) Flexible Finish
Enamel Color Coat, or Ditzler Elastomeric
Enamel Color Coat or equivalent.
3. Additive
- DuPont 792s Centari Hardener,
or
Ditzler
DXR-80 Delthane Additive or
equivalent.
4. Thinner
- DuPont 3608s Acrylic
Lacquer
Thinner, or Ditzler Delstar DTR 601 Acrylic
Enamel Reducer or equivalent.
NOTICE: Use the same brand name materials for
the color coat, additive, and thinner.
5. A wax and adhesive cleaner.
Equipment Needed:
1. Wooden spatula (enclosed in repair package).
2. Heat lamp.
3. 36 grit 180-A, 240-A, and 320-A grit disc
sandpaper.
4. Random orbital-type sander.
5. Body repair tape.
6. Suction spray gun (same nozzle and air cap
combination as used for acrylic).
Repair Procedure
There are three types of repairable damage on
urethane material. They are a puncture, a gouge and a
tear.
Following is the basic repair procedure for
repairing these types of damages.
1. Clean the damaged area with 3M #8984 Gen-
eral Purpose Adhesive Cleaner or equivalent. If
the damage is through the thickness of the part,
clean both sides.
Grind away damaged material with a
36 grit
disc. Feather edge the paint around the damage
using a
1808 grit disc.
2. If the part has a puncture or tear, file or rout out
the area where joint line will be. Bevel the edge
of the part with the open edge towards the side
to be filled (fill from the side with easiest
access). Clean the repair area with a clean dry
rag.
3. Apply 3M #6935 Auto Body Repair Tape, or
equivalent, to the underside of the repair area to
backup the repair material.
NOTICE: Before going to the next step, be sure
all of the paint (both topcoat and primer) has been
removed from the area where the structural adhe-
sive is to be applied.

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

385-2 STEERING WHEELS AND COLUMNS
Fig. 385-2--The Flat on Worm Shaft
5. With wheels in a straight ahead position and the
steering gear on highpoint, check the steering
wheel alignment (Fig.
1). If the spokes are not
within the
limits specified, the wheel should be
removed
and centered. (See steering wheel
removal in this section).
NOTICE: The outer mast jacket shift tube,
steering shaft and instrument panel mounting
bracket are designed as energy absorbing units.
Because of the design of these components, it is
absolutely necessary to handle the column with
care when performing any service operation.
Avoid hammering, jarring, dropping or leaning on
any portion of the column.
NOTICE: When reassembling the column
components, use only the specified screws, nuts
and bolts and tighten to specified torque. Care
should be exercised in using over-length screws or
bolts as they may prevent a portion of the column
from compressing under impact.
I COLUMN REMOVAL AND INSTALLATION
The front of dash mounting plates must be
loosened whenever the steering column is to be lowered
from the instrument panel.
Refer to Fig. 3B5-3 for view of column attachment
provisions.
1. Remove nut and bolt from upper intermediate
shaft coupling. Separate coupling from lower end
of steering column. See Figure
3B5-4.
] 2. Disconnect shift linkage from lower shift lever.
3. Disconnect all electrical connectors from column
assembly.
4. Remove screws securing toe pan cover to floor
5. Remove nuts securing bracket to instrument
panel.
ON-CAR SERVICE
STEERING COLUMN
To perform service procedures on the steering
column upper end components, it is not necessary to
remove the column from the vehicle.
The steering wheel, horn components, directional
signal switch, ignition lock cylinder and ignition key
warning switch may be removed with the column
remaining in the vehicle as described earlier in this
section.

GENERAL MOTORS CORPORATION
1 - RETAINER
35 - ACTUATOR ASM, IGNITION SWITCH 69 - JACKET ASM, STEERING COLUMN
2 - NUT, HEXAGON JAM
36 - RACK, SWITCH ACTUATOR 70 - ADAF"TER, LOWER BEARING
3 - COVER, SHAn LOCK 37 - SPRING, RACK PRELOAD 71 - BEARING ASM
4
- RING, RETAINING 38 - HOUSING, STEERING COLUMN 72 - RETAINER, BEAR1NG ADAPTER
5 - LOCK, SHAn 39 - SECTOR, SWITCH ACTUATOR
73 - CLIP, LOWER BEARING ADAPTER
6
- CAM ASM, TURN SIGNAL CANCELLING 40 - SCREW, HEX WASHER HEAD 74 - LEVER ASM, T/S MULTlFUNCTBON
7 - SPRING, UPPER
BEARING
41 - GUIDE, SPRING 75 - LEVER ASM, TILT RELEASE
8
- SCREW, BINDING HEAD CROSS RECESS 42 - SPRING, WHEEL TILT 76 - KNOB, HAZARD WARNING SWlTCH
9 - SCREW, ROUND WASHER MEAD
43 - RETAINER, SPRING 77 - SPRING, HAZARD WARNING
10 - ARM ASM, SIGNAL SWITCH 44 - CAP, COLUMN HOUSING COVER END 78 - BUTBON, HAZARD WARNING
11 - SWITCH
ASM, TURN SIGNAL 45 - PIN, SWITCH ACTUATOR PIVOT 79 - SCREW, OVAL HEAD
12
- SEAT, UPPER BEARING INNER RACE 46 - SWITCH ASM, PIVOT &
13 - RACE, INNER 47 - SPRING, PIN PRELOAD
14
- SCREW, PAN HEAD CROSS RECESS 48 - SWITCH ASM, IGNITION
15 - SWITCH
ASM, BUZZER 49 - STUD, DlMMER & IGNITION SWITCH ASSEMBLIES
16 - CLIP, BUZZER SWITCH RETAINING MOUNTlNG
17 - SCREW,
LOCK RETAINING 50 - SCREW, WASHER HEAD 0 - COLUMN
ASM, EiA STEERING
18
- COVER, LOCK HOUSING 51 - PLATE, SHROUD RETAINING 101 - COVER ASM, LOCK HOUSING
19 - LOCK CYLINDER SET, STEERING COLUMN 52 - SCREW,
OVAL HEAD GROSS RECESS 102 - HOUSING
ASM, STEERlNG COLUMN
20
- ACTUATOR, DIMMER SWITCH ROD 53 - PIN, DOWEL 103 - SHAFT
ASM, STEERING
21 -THIS NUMBER NOT USED 54 - PROTECTOR, WIRING
104 - SUPPORT
ASM, STEERING COLUMN
22
- BEARING ASM 55 - SHAFT
ASM, RACE & UPPER HOUSING
23
- BOLT, LOCK 56 - SPHERE,
CENTERING
24
- SPRING, LOCK BOLT 57 - SPRING, JOINT PRELOAD
25
- SHOE, STEERING WHEEL LOCK 58 - SHAFT ASM, LOWER STEERING
26 - SHOE, STEERING WHEEL LOCK 59 - SCREW,
SUPPORT
27
- SHAFT, DRIVE 60 - SUPPORT, STEERlNG COLUMN HOUSING
28
- PIN, DOWEL 61 - PLATE,
LOCK
29
- PIN, PIVOT 62 - FINGER PAD, RELEASE LEVER
30
- SPRING, SHOE 63 - LEVER, KEY RELEASE
31
- SPRING, RELEASE LEVER 64 - SPRING,
KEY RELEASE
32 - PIN, RELEASE LEVER 65 - SHROUD, STEERING COLUMN HOUSING
33
- LEVER, SHOE RELEASE 66 - ROD, DIMMER SWlTCH
34 - BEARING ASM 67 - SWITCH ASM, DlMrVlER
68 - NUT,
HEXAGON

REAR AXLE 48-13
2. Drive
pinion oil seal from carrier and remove
front pinion bearing. If the bearing is to be
replaced, remove outer race from carrier.
3. If rear pinion bearing is to be replaced remove
outer race from carrier using a punch in slots
provided for this purpose.
1 -REMOVER J-22912-01 7%" OR J-33868
2-OPENING IN TOOL MUST BE SUPPORTED
Fig.
604 Removing Rear Pinion Bearing
Cleaning and Inspecting
1. Clean
all rear axle bearings thoroughly in clean
solvent (do not use a brush). Examine bearings
visually and by feel. All bearings should feel
smooth when oiled and rotated while applying as
much hand pressure as possible. Minute scratches
and pits that appear on rollers and races at low
mileage are due to the initial pre-load, and
bearings having these marks should not be
rejected.
2. Examine sealing surface of pinion flange for nicks
burrs, or rough tool marks which would cause
damage to the seal and result in an oil leak.
Replace if damaged.
'
3. Examine carrier bore and remove any burrs that
might cause leaks around the O.D. of the pinion
seal.
4. Examine the ring gear and drive pinion teeth for
excessive wear and scoring. If any of these
conditions exist replacement of the gear set will
bs required.
5. Inspect the pinion gear shaft for unusual wear;
also check the pinion and side gears and thrust
washers.
6. Check the press fit of the side bearing inner race
on the rear axle case hub by prying against the
shoulder at the puller recess in the case. Side
bearings must be a tight press fit on the hub.
7. Diagnosis of a rear axle failure such as: chipped
bearings, loose (lapped-in) bearings, chipped
gears, etc., is a warning that some foreign
material is present; therefore the axle housing
must be cleaned.
Drive Pinion
Assemble
I. If a new rear pinion bearing is to be installed,
install new outer race.
2. If a new front pinion bearing is to be installed,
install new outer race.
Fig. 605 Installing Rear Pinion Bearing Outer Race
1- J-8092 DRIVE H-,.wb- 6
Fig. 606 Installing Front Pinion Bearing Outer Race
Setting Drive Pinion Depth
Pinion depth is set with pinion setting gage
J 21777-B. The pinion setting gage provides in effect a
"Nominal" or "Zero" pinion as a gaging reference.
Set up pinion setting gage as follows:
1. Make certain all gage parts are clean.
2. Lubricate front and rear pinion bearings which
will be used in final reassembly and position them
in their respective races in the carrier. Bearings
used with gage set must be those to be installed
in vehicle, in order to insure accurate reading.
3. Assemble pinion setting gage assembly into
carrier housing as follows:
Step 1
Figure 607
a.
Install Pinion Bearing Pre-Load Stud J
21777-43 through Pilot J 23597-12 and into
Gage Plate
J 23597- 11.
b. Install stud and plate assembly into housing
and install Front Pinion Bearing Pilot
J
21777-42 and hex nut over end of stud,
tightening nut until snug and rotate gage

BRAKES
NOTICE: All brake attaching fasteners are important attaching parts in that they could affect the performance of vital parts
and systems.
andlor could result in major repair expense . They must be replaced with one of the same part number or with an
equivalent part if replacement becomes necessary
. Do not use a replacement part of lesser quality or substitute design .
Torque values must be used as specified during reassembly to assure proper retention of parts .
CAUTION: When servicing brake parts. do not create dust by grinding. sanding brake linings. or by cleaning brake
parts with a dry brush or with compressed air
. Many brake parts contain asbestos fibers which can become airborne if
dust is created during servicing
. Breathing dust containing asbestos fibers may cause serious bodily harm . A water
dampened cloth or water based solution should be used to remove any dust on brake parts
. Equipment is commer-
cially available to perform this washing function
. These wet methods will prevent asbestos fibers from becoming
airborne
.
CONTENTS
......................... General Description 5.2
Composite Master Cylinder
.................. 5.2
Brake Fluid Level
lndicatgr ................... 5.2
Operation of Disc Brake
..................... 5.2
Operation of Drum Brake
.................... 5.2
Operation of Combination Valve
............... 5.2
Brake Pressure Differential
.......................... Warning Switch 5.2
Diagnosis and Inspection ..................... 5.3
Brake System Testing
....................... 5.3
External Conditions That Affect Brake Performance
.................... -5-3
Warning Lamp Operation .................... 5.3
Brake Fluid Leaks
.......................... 5.3
Master Cylinder Check
...................... 5.3
Substandard or Contaminated
BrakeFluid ............................. 5-3
............................. On-Car Service 5.7
Brake Pedal Replacement
................... 5.7
Stoplamp Switch Adjustment ................. 5-7
Filling Master Cylinder Reservoirs
............. 5-7
Bleeding Brake Hydraulic System
............. 5.7
Manual Bleeding
......................... 5.8
Pressure Bleeding
........................ 5.8
Flushing Brake Hydraulic System
............. 5.9
Brake Pipe Replacement
.................... 5.9
............................. I.S.O. Flare 5.9
Brake Hose Inspection
...................... 5.9
Brake Hose Replacement
.................... 5.11
Front Brake Hose
........................ 5.11
....................... Center Brake Hose 5.12
..................... Rear Disc Brake Hose 5.12
ParkingBrake ............................. 5-13
Parking Brake Control Assembly
.............. 5.13 Parking Brake Cables
....................... 5.14
Parking Brake Front Cable
................. 5.14
Parking Brake Rear Cable (Drum Brakes)
..... 5.14
Parking Brake Rear Cable (Disc Brakes)
...... 5.15
Brake Lining Inspection
..................... 5.15
............. Inspecting and Refinishing Rotors 5-15
Thickness
Variat~on Check ................. 5.15
Lateral
Runout Check ..................... 5.15
Rotor Tolerance and Surface Finish
.......... 5.16
Refinishing Brake Rotors
.................. 5-16
lnspecting and Refinishing Brake
Drums
................................. 5-16
Cracked Scored, or Grooved Drum
.......... 5.16
Out-of-Round or Tapered Drum
............. 5.16
Refinishing Brake Drums
.................. 5.16
Brake Drum Balance
..................... -5-16
Combination Valve ......................... 5.17
Testing Combination Valve Electrical
............................... Circuit 5.17
Testing Combination Valve Warning
.......................... Lamp Switch 5.17
.......... Combination Valve Replacement 5.17
............ Power Brake Vacuum Hose Filter 5.17
Unit Repair
................ Composite Master Cylinder .5A 3.1
Disc Brake Caliper Assembly
....................... 300013100 Series 581 -1
Disc Brake Caliper Assembly
3548 Series
........................... .5B 6.1
........ Direct Torque Drum Brake Assembly .5C 3.1
Power Head Assembly
-
.................... Tandem Diaphragm .5D 2.1
.............. Specifications and Special Tools 5F-1