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Table Of Contents - Pontiac Grand Prix Service Manual

1969

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Table Of Contents2

General Information3

Vehicle Identification Plate3

Body Identification Plate3

Car Model Identification3

Engine Identification4

Transmission Serial Number4

Turbo Hydra-Matic4

Lifting And Towing5

Two-Speed Automatic5

Towing Precautions6

Ignition Lock Assembly - Remove6

Two-Speed Automatic Transmission Serial Number6

Depressing Lock Cylinder Retainer Pin6

Coding Side Bar Lock7

Exploded View Of Ignition Lock Assembly7

Key Coding Diagram7

Basic Dimensions8

Rocker Panel Heights8

Ignition Lock Assembly10

Manifold Heat Control Valve10

Station Wagon Tailgate Hinge And Linkage10

Decimal Equivalents11

Weights And Measures12

Accelerator Linkage12

Carburetor Fuel Filter14

Air Cleaner Element14

Automatic Transmission14

Cooling System14

Starting Motor15

Speedometer Cable15

Heating And Ventilation Service16

Temperature Cable Adjust16

Air Control Cablgadjust16

Pontiac, Tempest And Flreblrd16

Pontiac-Heater Cable And Wire Routing17

Blower Speed Switch18

Grand Prix-Heater Cable And Vacuum Hose Routing18

Tempest And Firebird19

Blower Motor Resistor19

Heater Wiring Harness19

Tempest-Heater Cable Routing19

Air Control Or Defroster Cable20

Temperature Control Cable20

Tempest And Firebird-Remove And Replace20

Defroster Diaphragm And Hose21

Air Diaphragm And Hose21

Vacuum Supply Hose21

Blower Motor; Impeller And Or Inlet Duct21

Grand Prix-Remove And Replace22

Heater Core And/Or Case22

Blower Motor And Air Inlet Duct Installation23

Heater Hose Inlet And Outlet24

Defroster Duct24

Heater Wiring Schematic24

Kick Pad Ventilators25

Upper Level Ventilation25

Heater Wiring Schematic-All25

Pontiac-Upper Ventilation System26

Tempest And Grand Prix-Upper Ventilation System26

Firebird Upper Ventilation System26

Power Flow Ventilation System27

Typical-Power Flow Vent Motor And Duct27

Power Flow Ventilation Wire Harness Typical27

Custom Air Conditioner28

Component Replacement And Adjustment28

Precautionary Service Measures28

Refrigeration Sub-Assemblies28

Caution--Liquid Indicator29

Depressurizing The System-All29

Evacuating The System29

Preparati~Ns For Evacuating Complete System29

Evacuating Complete System30

Charging The System31

Refrigerant Drum Method31

Refrigerant-12 Disposable Can Method32

Schematic - Charging Refrigeration System32

Service Station Method33

Filling Charging Cylinder33

Charging The System Using J 839333

Adding Refrigerant 1A-734

Checking Compressor Oil Level And Adding Oil35

Replacing Refrigeration System35

Components Other Than Compressor35

Removing And Installing Compressor36

Installing Compressor36

Compressor Hub And Drive Plate Assembly37

Compressor Replacement37

Removing Hub And Drive Plate Lock Nut38

Removing Hub Retainer Ring And Spacer38

Removing Hub Retainer And Spacer38

Compressor Pulley Anwor Bearing Assembly39

Proper Position Of Hub And Drive Key39

Removing Pulley And Bearing Assembly Retainer Ring39

Installing Hub And Drive Plate Assembly39

Compressor Clutch Coil And Housing Assembly40

Removing Pulley Bearing Retainer Ring40

Installing Pulley Bearing40

Remove Compressor Assembly To Service Engine-Pontiac And Tempest41

Compressor Shaft Seal Assembly41

Removing Coil Housing Retainer Ring41

Removing Shaft Seal Seat42

Removing Shaft Seal Seat Retainer42

Removing Shaft Seal Assembly42

Compressor Assembly-Overhaul43

Preservation And Packing Service Parts43

Removing O-Ring Seal43

Major Interior Mechanism43

Overhaul Compressor44

Compressor Rear Head Assembly44

Compressor Major Interior Mechanism44

Sealing Surface On Head Casting Web44

Removing Suction Reed45

Removing Oil Inlet Tube45

Pistons And Cylinder45

Separating Cylinder Halves46

Compressor Parts In Tray46

Identification Of Front End Of Piston46

Removing Rear Thrust Races And Bearings47

Exploded View Compressor Assembly48

Mainshaft Thrust Bearing Installed49

Installing Piston With Balls49

Zero Shoe And Ball At Front Of Piston49

Installing Rear Cylinder Half On Front Cylinder Half49

Internal Mechanism In Fixture50

Measurements And Table Of Available Service Shoes And Thrust Races50

Measuring For Proper Shoe50

Checking Compressor Mainshaft End Play50

Assemble With New Parts51

Measuring For Proper Thrust Race51

Installing Service Discharge Crossover51

Installing Service Discharge Crossover Parts51

Installing Front Head Casing52

Identification O F Front And Rear Discharge Valve Plate52

Installing Service Discharge Crossover Tube52

Installing Oil Intake (Pick-Up) Tube53

Positioning Oil Pump Outer Gear53

Seating Seal Seat Retainer54

Installing Rear Head54

Refrigeration System Typical Tempest And Grand Prix55

Expansion Valve And Seals56

Evaporator Core57

Evaporator Case Left Half57

Condenser And Seals58

Receiver Dehydrator58

Air Inlet And Valve Assembly 1A-3158

Blower Motor Impeller Andor Blower Motor Case59

Air Inlet Assembly Typical Pontiac, Tempest And Grand Prix59

Heater Core And Case Assembly60

Air Inlet And Plenum Air Valve60

Temperature Cable61

Hi Blower Relay; Resistor Block; And Ambient Switch61

Heater Core And Case Installation61

Control Panel .1A-3461

N C Engine Compartment And Jumper Harnesses64

Diverter Door Diaphragms64

Defroster Diaphragm64

Air Inlet Diaphragms65

Plenum Air Valve Diaphragm .1A-3865

Cold Air Distribution: Center Air Outlet; And Side Outlet Ducts66

Tempest Control Panel Details66

Pontiac Control Panel Detaik66

Vacuum Hose Harness67

In-Car A/C Wiring Harness67

Air Conditioning Wiring Schematic69

Compressor Mounting And Belt A D J ~ S T ~ E N T69

A/C In Car Harness Routing And Connections72

Typical Pontiac And Grand Prix Vacu~Irn Schematic76

Tempest Vacuum Schematic76

Firebird Vacuum Schematic77

Automatic Temperature Control78

In-Car Sensor78

Ambient Sensor And Switch79

Control Panel Components80

Temperature Control Switch80

Variable Resistor80

Grand Prix Vacuum Hose Installation81

Pontiac Vacuum Hose Installation81

Temperature Door Link To Programmer83

Grand Prix Control Panel83

Using Tool J 23187 To Adjust Variable Resistor84

Programmer Link Assembly84

Amplifier-Remove And Replace85

Programmer Wheel85

Gear Inspection85

Temperature Door Adjustment85

Programmer Amplifier86

Power Resistor87

Bi Level Boost Switch87

Vacuum Schematic88

Wiring Schematic88

Frame And Body Mountings90

Pontiac And Tempest90

Lifting Pontiac Cars With Hoists90

Frame Alignment91

Body To Frame Mountings92

Underbody Alignment92

Flreblrd Body Vibration Dampers92

Pontiac Body Bolts And Frame Gage Line Dimensions93

Tempest And Grand Prix Body Bolts And Frame Gage Line Dimensions94

Firebird Checking Dimensions, Lift Points And Body Bolt Locations95

Specifications96

Horizontal Dimensions96

Vertical Dimensions96

Side Rail At Spring Rear Shackle Hole97

Firebird Convertible Floor Pan Reinforcement97

Firebird Body Damper Locations97

Front Suspension98

Front Wheel Bearings98

Check Adjustment98

Suspension Alignment99

Inspection Before Checking Front Wheel Alignment99

Cross Section Of Steering Knuckle, Hub And Disc Assembly99

Adjust Caster And Camber100

Wheel Bearing Adjustment100

Checking And Adjusting Sequence-Front Wheel Alignment100

Checking Wheel Bearing Adjustment100

Check And Set Toe-In101

Measuring By Trammel101

Removing Pontiac Upper Control Arm Nuts101

Caster-Camber Shims (Tempest Shown)101

Minor Services102

Check Steering Axis Inclination102

Check Toe-Out On Turns102

Shock Absorber103

Typical Shock Absorber Installation103

Stabilizer Shaft104

Major Services104

Stabilizer Link Installation Except Firebird104

Steering Knuckle105

Stabilizer Shaft Installation105

Upper Control Arm106

Removing Coil Spring With J 23028106

Coil Spring Position In Lower Control Arm106

Upper Control Arm Shaft And/Or Bushings107

Upper Control Arm Shaft Anwor Bushings108

Lower Control Arm109

Lower Control Arm Bushing109

Upper Ball Joint111

Lower Control Arm Rear Bushing Firebird111

Lower Ball Joint112

Lower Ball Joint Installation Except Pontiac113

Torque Specifications115

Front Wheel Alignment Specifications115

Rear Suspension116

Shock Absorber--Except Firebird116

Shock Absorber-Firebird117

Spring And Shock Absorber Anchor Plate117

Rear Shock Absorber Installation117

Leaf Spring And Spring Eye Bushing118

Removing Spring Front Bushing119

Installing Spring Front Bushing119

Main Leaf Of Leaf Spring-Firebird120

Upper Control Arm Bushing120

Pontiac And Grand Prix Automatic Level Control System122

Compressor, Reservoir And Regulator Valve Assembly123

Disassembly Of Compressor Into Major Components123

Disassembly Of Piston--Diaphragm Assembly123

Disassembly Of First Stage Housing And Valve Mechanism123

Disassembly Of Second Stage Housing124

Cleaning And Inspection Of Parts124

Piston And Diaphragm Assembly124

First Stage Housing And Valve Mechanism124

Second Stage Housing125

Assembly Of Second Stage Housing125

Assembly Of First Stage Housing And Valve Mechanism125

Assembly Of Piston--Diaphragm Assembly126

Assembly Of Major Components126

Instructions For Fastening Tubing126

Pontiac Automatic Level Control System127

Grandprix Automatic Level Control System128

Exploded View Of Compressor129

Removing Diaphragm Retainer129

Distributor Valve Assembly129

Trouble Diagnosis Tests130

Removing Rocker Arm Pin130

Installing Valve Tension Spring In Boss130

Installing Check Valve130

Parts Required131

Compressor Output Test-On Car131

Installing Distributor Arm131

Installing Diaphragm Retainer131

Height Control Valve Test-On Car Exhaust (Superlifts Inflated)132

Time Delay Check132

Installing Piston Seal132

Filling System Through Service Valve132

Height Control Valve Test-Off Car133

Test Gage Installed On Regulator Valve133

Lines And Fittings134

Superlift - Leak Test134

Standard Differential136

New Car Pre-Delivery Inspection137

Periodic Service137

Shock Absorbers137

Cross Section O F Typical Rear Axle And Differential137

Exploded V~Ew Of Typical Differential Assembly138

Minor Service And Repairs143

Companion Flange143

Checking Pinion Bearing Preload143

Removing Drive Pinion Nut143

Pinion Bearing Oil Seal144

Remove Axle Shaft Assemblies144

Axle Shaft Bearing145

Removing Axle Shaft Bearing (Typical)145

Installing Axle Shaft Bearing (Typical)145

Replace Axle Shaft Assemblies145

Major Repairs146

Rear Axle Assembly146

Removing Axle Shaft Seal146

Pre-Repair Investigation147

Gear Tooth Nomenclature147

Red Lead Test147

Effects Of Increasing Load On Tooth Contact Pattern148

Differential Cranking Tool148

Desired Tooth Contact Under Light Load148

Adjustments Affecting Tooth Contact148

Effects Of Backlash On Tooth Pattern149

Effects Of Pinion Position On Tooth Pattern149

Overhaul Differential149

Differential Case149

Effect On Pattern150

Removing Difterential Case150

Clean And Inspect151

Removing Differential Side Bearing151

Alignment Marks151

Grand Prix Medium Duty152

Removing Pinion Shaft152

Installing Pinion Shaft Lucking Bolt152

Install Differential Case Side Bearings153

Remove Pinion Assembly153

Disassemble Pinion Assembly153

Replace Pinion Bearing Outer Races154

Torquing Case Half Bolts154

Installing Right Differential Side Bearing154

Installing Left Differential Side Bearing154

Setting Pinion Depth155

Removing Companion Flange155

Removing Rear Pinion Bearing155

Installing Rear Pinion Bearing Outer Race155

Securing Gauge Plate In Carrier156

Installing Front Pinion Bearing Outer Race156

Replace Pinion Assembly And Adjust Pinion Preload157

Gauge Plate Installed157

Checking Pinion Depth157

Replace Differential Case And Adjust Side Bearing Preload158

Installing Two Service Shims159

Installing Service Spacer159

Inserting Feeler Gauge159

Adjusting Differential Backlash160

Tapping Final Shim Into Place160

Checking Ring Gear To Pinion Backlash160

Safe-T-Track Differential163

Cleaning And Inspection Of Case167

Differential Case Assemble168

Installing Differential Side Bearing168

Compressing Preload Springs168

Checking Pinion Gear To Side Gear Clearance168

Tempest, Firebird And Grand Prix169

Propeller Shaft174

Alignment Of Engine And Propeller Shaft174

Remove Propeller Shaft174

Disassemble Universal Joints174

Assemble Universal Joints175

Pressing Out Bearing175

Tapping Out Bearing175

Supporting Splined Yoke175

Install Propeller Shaft Assembly176

Installing Journal To Yoke176

Installing Snap Ring Retainer176

Propeller Shaft Comparison And Usage Information177

Standard Brakes178

Service Operations178

Pontiac Manual Brake System178

Pedal Height179

Brake Warning Light Checking Procedure179

Tempest And Grand Prix Manual Brake System179

Stop Light Switch180

Brake Assembly Mechanism And Drums180

Firebird Manual Brake System180

Fluid Levels And Master Cylinder Details181

Preparing To Back Off Adjusting Screw182

Backing Off Adjusting Screw182

Inspection &D Cleaning182

Gauging Shoe To Drum Clearance183

Typical Self Adjusting Brake Assembly Exploded View183

Pontiac Parking Brake System184

Tempest And Grand Prix Parking Brake System185

Prix, And Firebird186

Firebird Parking Brake System186

Hydraulic System187

Master Cylinder187

Wheel Cylinder189

Master Cylinder Usage Chart189

Bleeding Brakes190

Parking Brake191

Inspection, Cleaning And Lubrication191

Flushing Hydraulic System191

Parking Brake Pedal Removal192

Parking Brake Pedal Installation192

Front Cable Installation192

Center Cable Removal And Installation192

Pontiac Specifications193

Pontiac Torque Specifications193

Tempest, Grand Prix And Firebird Specifications194

Tempest, Grand Prix And Firebird Torque Specifications194

Delco-Moraine Power Brake195

Checks And Adjustments On Car195

Pontiac Power Brake System195

Special Tools195

Stop Lamp Switch196

Front Housing196

Power Piston196

Firebird Power Brake System197

Exploded View Of Pontiac Power Brake Unit199

Power Piston - Install200

Removing Locking Ring From Power Piston202

Removing Reaction Retainer202

Removing Support Plate203

Removing Air Valve203

Exploded View Of Master Cylinder203

Installing Front Housing204

Push Rod Adjustment204

Bendix Power Brake205

Overhaul Bendix Power Brake206

Valve Plunger Stop Key207

Inspect Hydraulic Master Cylinder Assembly208

Inspect Air Filters208

Power Unit And Master Cylinder208

Master Cylinder-Exploded View208

Installing Rear Vacuum Seal209

Power Piston Assemble209

Power Unit Assemble209

Gauging Push Rod Length209

Power Brake Assembly210

Heavy Duty Power Brakes212

Bendix Tandem Diaphragm Type212

Master Cylinder And External Parts212

Valve Rod, Retainers, Filter And Poppet212

Power Section Disassembly213

Power Unit - Exploded View213

Removal Of Rear Shell Vacuum Seal214

Diaphragms, Plates, Retainer And Plunger214

Valve Rod, Retainers, Filters And Poppet214

Power Unit Special Tool Combination214

Disassembly Of Master Cylinder215

Assembly Of Master Cylinder215

Power Unit Mounted In Press215

Removing Center Plate From Rear Shell215

Assembly Of Vacuum Seal In Rear Shell216

Assembly Of Plates Plunger And Diaphragm216

Assembly Of Diaphragms And Plates In Front And Rear Shells217

Installing Rear Shell Vacuum Seal217

Master Cylinder Exploded View217

Assembly Of Reaction Disc, Push Rod And Vacuum Check Valve Grommet218

Assembly Of Valve Rod, Air Filter, Retainer And Poppet Parts218

Gaging Push Rod Length218

Push Rod Gage218

Assembly Of Push Rod Boot And Master Cylinder To Power Unit219

Power Cylinder Exploded View220

Over-All Brake Unit221

Separating Front And Rear Shells221

Power Piston Disassemble222

Power Piston Exploded View222

Preparing To Separate Primary And Secondary Pistons223

Preparing To Remove Primary Support Plate223

Removing Primary Power Piston223

Removing Air Valve-Pushrod Assembly223

Master Cylinder Disassemble224

Installing Control Valve And Retainer225

Gaging Reaction Piston225

Installing Snap Ring On Air Valve225

Installing Housing Divider226

Securing Front Housing To Arbor Press227

Securing Rear Housing To Tools227

Joining Front And Rear Housings228

Gaging Master Cylinder Piston228

Power Cylinder Only229

Master Cylinder Only229

Lining Inspection231

Shoe And Lining Replacement231

Disc Brake Assembly232

New And Worn Linings233

Removing Mounting Bolts233

Exploded View Of Caliper234

Boot Installation234

Inserting Shoe Support Spring235

Installing Outboard Shoe235

Installing Inboard Shoe235

Clinching Outboard Shoe235

Bleeding Disc Brakes236

Installing Mounting Bolts236

Removing Piston236

Surface Tolerance And Finish237

Rotor Service237

Lateral Runout Check237

Parallelism Check237

Checking Rotor For Lateral Runouf238

Engine Mechanical240

Six Cylinder Engine240

Tempest And Firebird Engines240

Pontiac And G. P. Engine Chart240

Tempest Engine Chart241

Firebird Engine Chart241

Pontiac And Grand Prix Engines242

Engine Number And Code Location242

Vehicle Identification Number Location242

Six-Cylinder Engine243

Service Operations On Car243

Engine Insulators243

Valve Timing Marks244

Drive Belts-Adjust (Except Timing Belt)245

Intake And Exhaust Manifold Or Gaskets245

Cyl. Engine Mounting-Tempest246

Timing Belt Adjustment Procedure247

Timing Belt Adjustment247

Cyl. Engine Mounting-Firebird247

Accessory Drive Hosuing Mounting Bolts247

Timing Belt Top Front Cover247

Camshaft Sprocket Or Seal248

Adjusting Timing Belt Tension248

Rocker Arm Cover Assembly And Gasket249

Camshaft, Rocker Arm Cover Anwor Rocker Arm Cover Core Plug249

Removing Camshaft Seal249

Installing Camshaft Seal249

Removing Camshaft From Cover250

Thrust Washer Installation250

Installing Camshaft Rear Plug250

Rocker Arm Or Hydraulic Valve Lash Adjuster251

Lash Adjuster-Disassemble251

Rocker Arm And Lash Adjuster251

Hydraulic Lash Adjuster Recondition251

Lash Adjuster-Clean And Inspect252

Lash Adjuster-Assemble252

Lash Adjuster-Exploded View252

Lash Adjuster Test Leak-Down Rate253

Valve Springs, Shield Or Seal253

Lash Adjuster-Wash Tank And Tray253

Testing Leak Down Rate253

Cylinder Head Or Gasket254

Valve Spring Removal Hook-Up254

Valve Spring Removal254

Cylinder Head And Valves255

Intake Valve Guide Seal Installation255

Cylinder Head Locating Dowel Pins255

Fitting Valve Stems To Guides256

Valves And Seats Recondition256

Cleaning Valve Guide Bore256

Reaming Valve Guide Bore256

Harmonic Balancer257

Valve Seat And Face Angle257

Lower Front Timing Cover Retaining Bolts257

Lower Front Timing Belt Cover258

Front Crankcase Cover And Gasket-Remove And Replace258

Removing Crankshaft Front Seal258

Crankshaft Timing Belt Sprocket Or258

Housing Assembly259

Pressure Regulator Valve-Oil Pump259

Remove And Replace259

Oil Filter By-Pass Valve260

Accessory Drive Housing-Exploded View260

Oil Pump Gears260

Housing Mounting Bolts261

Oil Filter Bypass Valve261

Removing Eccentric And Distributor Drive Gear Pin262

Installing Bearing262

Removing Bearing And Seal262

Installing Seal262

Main Bearings-Remove And Replace263

Removing Rear Main Bearing Cap263

Rear Main Bearing Cap Side263

Connecting Rod Bearings-Remove And Replace264

Removing Upper Rear Main Oil Seal264

Tool For Removing Upper Half Of Main Bearing264

Plastigage (Or Equivalent) In Place265

Measuring Plastigage (Or Equivalent)265

Cylinder Bores-Inspect266

Checking Connecting Rod Side Clearance266

Cylinder Ring Ridge266

Checking Crankshaft End Play266

Honing Or Boring267

Removing Piston Pin-Step267

Checking Piston Pin Fit267

Measuring Out O F Round Taper267

Normal Cylinder Wear Pattern268

Piston Sizing Points268

Measuring Cylinder Gauge268

Piston Fit And Replace268

Connecting Rod To Piston - Assemble269

Piston Pin Replacement269

Piston And Rod Assembly269

Piston Rings - Install270

Checking Ring Side Clearance270

Checking Ring Gap270

Fitted Block Assembly271

Connecting Rod Guide Tool271

Installing Piston In Cylinder271

6 Cylinder Engine Wrench Torque Specifications272

6 Cylinder Engine Specifications273

Horsepower And Torque273

Cylinder Special Engine Tools276

V-8 Engine - Service277

Cylinder Block277

Cylinder Head277

Camshaft And Drive278

Pistons And Connecting Rods278

Combustion Chamber278

Rear Insulator280

Engine Insulators Tempest280

Pontiac Engine Insulators280

Engine Assembly282

Tempest Engine Insulators282

Firebird Engine Insulators282

Right Side Exhaust Manifold Or Gasket283

Intake Manifold Or Gasket284

Left Side Exhaust Manifold Or Gasket284

Intake Manifold Gasket Retainers284

Push Rod Cover Or Gasket285

Push Rod Or Valve Lifter286

Checking Valve Stem Seal286

Lifter Wash Tank And Tray286

Removing Push Rod Seat Retainer286

Valve Lifter-Recondition287

Valve Lifter - Clean And Inspect287

Valve Lifter287

Valve Lifter Assemble288

Test Valve Lifter Leak-Down Rate288

Hydraulic Valve Lifter289

Testing Leak-Down Rate289

Rocker Arm Studs290

Rocker Arm Stud Removal290

Slots Filed In Rocker Arm Stud290

Installing Rocker Arm Stud291

Cleaning Valve Guide291

Reaming Valve Guide292

Valve Seat And Face Angles292

Valve Seat After Grinding With Flat Stone292

Timing Chain Cover Seal294

Front Of Engine With Timing Chain Cover Removed294

Aligning Timing Marks294

Camshaft And/Or Camshaft Bearing295

Timing Chain And Sprockets295

Positioning Index Collar296

Removing Camshaft Bearing296

Installing Camshaft Bearing297

Oil Pan Anvor Oil Pan Gasket Pontiac And Firebird Models298

Oil Pan Gasket Retainers298

Front Oil Pan Gasket Overlapping Side Gaskets298

Rear Oil Pan Gasket Positioned In Bearing Cap298

Oil Pump And Oil Pump Drive Shaft299

Oil Pan And/Or Oil Pan Gaskets300

Rear Main Bearing Oil Seal300

Rear Main Bearing Seal Tool301

Forming New Seal In Cap301

Engine Oil Pan Baffle And Dipstick Tube301

Measuring Plastigage302

Connecting Rod Bolt Guide Set Installed303

Installing Piston Assembly303

Connecting Rod And Piston Assembly304

Measuring Cylinder Bore305

Fit And Replace Piston306

Assemble Connecting Rod To Piston307

Replace Piston Pin307

Fitting Pin In Piston307

Piston Rings308

Installing Piston Pin308

Measuring Crankshaft End Play309

Drain Holes In Lifter Gallery310

Cylinder Block - View From Left Front311

Hydraulic Lifter Equipment314

Engine Wrench Torque Specifications316

Engine Specifications316

V-8 Special Engine Tools321

Engine Cooling And Lubrication322

Radiator Cap322

Water Plimp-6 Cylinder323

Flushing Cooling System323

Preparing Cooling System For Coolant323

Checking And Filling Cooling System323

Testing Coolant324

Thermostat Remove And Replace324

Water Pump-6 Cylinder324

Radiator Support And Baffle Assembly325

6 Cyl And 8 Cyl Remove And Replace326

Fan Types And Usage330

Radiator Usage331

Carburetor Air Cleaner And Silencer332

Heat Riser Valve332

Intake Systems332

Air Cleaner Installation333

Air Cleaner And Seal Installation333

Baffle And Hood Scoop Installation Gto334

Air Cleaner & Seal Installation Firebird334

Baffle & Hood Scoop Installation Firebird335

Ram Air Intake Schematic335

Idle Stop Solenoid336

Accelerator Controls337

Tempest, Grand Prlx And Firebird337

Vapor Diverter337

Air Horn Removal338

Air Horn Disassembly338

Rochester Mv Carburetor338

Float Bowl Disassembly339

Throttle Body Removal And Disassembly339

Float Bowl Assembly340

Throttle Body Disassembly340

Carburetor Assembly And Adjustment Procedures340

Throltle Body Assembly And Installation340

Metering Rod Adjustment341

Float Level Adjustment341

Air Horn Assembly And Installation342

Fast Idle Adjustment (On Car)342

Idle Vent Adjustment342

Choke Rod Adjustment343

Vacuum Break Adjustment343

Unloader Adjustment343

Choke Coil Rod Adjustment343

Rochester 2Gv Carburetor344

Idle Speed And Mixture Adjustment344

Disassembly Of Bowl Cover344

Bowl Cover Attaching Parts345

Disassembly Of Throttle Body346

Venturi Cluster Passage Identification347

Flange - Bowl Passage Identification347

Body To Bowl Cover Passage Identification347

Throttle Flange Passage Identification347

Assembly Of Throttle Body348

Assembly Of Bowl348

Assembly Of Bowl Cover348

Pump Rod Adjustment349

Float Drop Adjustment349

Air Horn Tightening Sequence349

Fast Idle Cam Installed349

Rochester 4Mv Quadrajet Carburetor351

Rochester 4Mv Carburetor351

Cleaning & Inspection Procedure362

Engine Tune-Up369

Spark Plug Removal369

Compression Test369

Clean, Test And Install Spark Plugs370

Ignition System Service And Repairs370

Service Battery And Battery Cables371

Generator And Regulator371

Check Intake Manifold Bolts371

Check Fuel Lines And Service Fuel Filter372

Inspect And Service Cooling System372

Test Dwell And Dwell Variation372

Test Ignition Timing And Advance372

Positive Crankcase Ventilation373

Test Performance Of Car373

Emission Control Systems374

Closed P.c.v. System374

Controlled Combustion System374

Vacuum Advance Valve374

Sensor Replacement375

Curb Idle Setting Procedure (Ram Air)375

Curb Idle Setting Procedure 6 Cyl.375

Dwell And Ignition Timing Specifications376

Engine Electrical377

Cranking Circuit377

Remove From Car377

Check Current Draw378

Armature And Overrunning Clutch Assembly378

Frame And Field379

Testing Armature For Ground379

Testing Field Coils For Open380

Testing Shunt Coil For Open380

Assemble Starter380

Forcing Snap Ring Onto Armature Shaft381

Forcing Retainer Over381

Pinion Clearance Check381

Charging Circuit382

Circuit For Checking Pinion Clearance382

Measuring Pinion Clearance382

Check In Car383

Drive End Frame Bearing384

Slip Ring End Frame Generator385

Checking Stator385

Check For Grounded Brush Lead Clip C.s. I. Generator385

Rectifier Bridge-C.s.i. Generator386

Voltage Regulator387

Slip Ring End Frame Bearing And Seal387

Diodes - Standard Generator388

Ohmmeter Method388

Heat Sink Diodes388

End Frame Diodes388

Removing Diodes389

Installing Diodes389

Assemble Generator390

Standard And Transistor Voltage Regulators390

Ignition Circuit390

Replacing Contact Set390

Checks And Adjustments Off Vehicle391

Exploded View Of 6-Cylinder Distributor391

Adjusting Dwell Angle392

Replace Contact Set393

Arrangement Of Leads393

Exploded View Of V-8 Distributor394

Ignition Timing395

Rotor In No. 1 Firing Position395

Ignition And Starting Switch396

Timing Marks On V-8 Engine396

Ignition Switch397

Replace Switch, Lock Cylinder Or Free Up Lock Cylinder398

Measuring Spark Plug Gap398

Spark Plug Cleaner And Indicator398

Engine Electrical Specifications400

Distributor Specifications401

Clutch, Manual Transmissions402

Clutch Pedal Adjustment402

Clutch Usage402

Clutch Control Linkage403

Pontiac Clutch Controls403

Tempest And Grand Prix Clutch Controls404

Firebird Clutch Controls405

Flywheel Or Clutch Pilot Bearing406

Exploded View Of Clutch And Flywheel406

Starter Ring Gear407

Clutch Pilot Bearing Staked407

Three-Speed Dearborn Manual Transmission408

Transmission408

Column Shift And Back Drive Linkage408

Floor Shift And Back Drive Linkage408

Extension Housing Bushing And Oil Seal409

Input Shaft Seal409

Pontiac Column Shift Controls410

Tempest And Grand Prix Floor Shift Controls410

Firebird Floor Shift Controls411

Tempest And Grand Prix Back Drive Linkage411

Firebird Back Drive Linkage412

Exploded View Of Transmission413

Shift Lever Shaft Or Seal Replacement414

Input Shaft Bearing Replacement414

Remov~Ng Countershaft Retaining Pin414

Rotating Second And Third Shift Rail414

Removing Countershaft415

Removing Reverse Idler Gear Shaft415

Removing Rear Bearing415

Pressing Input Shaft Out Of Bearing415

Installing Input Shaft Bearing416

Exploded View Of Second Ana Third Synchronizer416

Exploded View Of Mainshaft417

Removing Reverse Synchronizer Hub And Sliding Gear417

Exploded View Of First And Reverse Synchronizer418

Synchronizer Insert Spring Installation418

Installing Reverse Synchronizer Hub418

Exploded View Of Reverse Idler419

Input Shaft Roller Bearing Installation419

Exploded View Of Countergear419

Detent Pin Installer419

Installing Rear Bearing420

Transmission Identification421

Three-Speed Saginaw Manual Transmission422

Tempest Column Shift Controls423

Extension Housing Seal424

Extension Housing Seal And Bushing424

Transmission Side Cover425

Tempest Floor Shift Controls425

Tempest Back Drive Linkage427

Installing Extension Housing'seal428

Removing Extension Housing Bushing428

Installing Extension Housing Bushing429

Exploded View Of Transmission Side Cover429

Removing Front Bearing429

Removing Reverse Idler Gear Snap Ring429

Removing Mainshaft430

Removing Or Installing Countergear430

Expanding Extension Housing Snap Ring430

Mainshaft, Countergear And Reverse Idler Gear Details431

Synchronizer Assembly432

Loading Bearings Into Countergear432

Installing Front Bearing Retainer Oil Seal433

Loading Bearings Into Main Drive Gear434

Drive Line Damper434

Firebird Driveline Damper435

Four-Speed Saginaw Manual Transmission437

Side Cover Assembly439

Side View Of Transmission440

Four-Speed Muncie Manual Transmission446

Speedometer Driven Gear447

Firebird Shift Controls448

Removing Extension Oil Seal450

Removing And Installing Side Covir450

Installing Extension Oil Seal450

Removing Countershaft With J 22379453

Pressing Mainshaft From First And Second Speed Gears454

Installing Reverse Shifter Shaft And Detent Ball454

Removing Or Installing Extension Case Bushing454

Reverse Shifter Shaft And Seal455

Extension Case Bushing And Oil Seal455

Clutch Keys And Springs455

Installing Rear Bearing Retainer456

Checking Countergear End Play457

Installing Mainshaft Assembly457

Installing Extension To Case458

Transmission Identifications459

Turbo Hydra-Matic ( M-40 ) Transmission461

Periodic Service Recommendations462

Transmission Fluid462

Adjustments With Transmission In C A462

Shift Control And Back Drive Linkage462

Neutralizer Switch Adjustment464

Vehicle Identification Number On Transmission Case464

Column Shift Controls464

Minor Service And Repair464

Fluid Capacity, Draining And Refilling Capacity466

Draining And Refilling Transmission466

Pressure Regulator Valve467

Control Valve Body467

Console Shift Controls468

Removing Pressure Regulator Valve468

Modulator And Modulator Valve469

Parking Linkage469

Removal Of Transmission469

Transmission Disassembly And Reassembly470

Removal Of Converter And Modulator470

Removal Of Control Valve Assembly471

Band Apply Pin Selection472

Checking Rear Band Pin473

Removing Detent Solenoid And Gasket473

Location Of Check Balls473

Removal Of Rear Oil Seal And Extension473

Front End Play Checking Procedure473

Location Of Case Extension Gasket474

Removing Rear Oil Seal From Case Extension474

Checking Front Unit End Play474

Removal Of Oil Pump475

Removing Front Seal475

Removing Pump Assembly475

Removing Direct Clutch Assembly475

Rear End Play Checking Procedure476

Removing Parking Bracket476

Removing Parking Pawl Return Spring476

Removing Parking Shaft Retaining Spring477

Removing Parking Pawl Shaft Cup Plug477

Removing Front Band477

Removing Sun Gear Shaft478

Removing Center Support Bolt478

Checking Rear Unit End Play478

Removing Center Support To Case Snap Ring478

Disassembly Of Gear Unit479

Removing Selective Washer479

Removing Rear Band479

Removing Center Support Assembly479

Removing Center Support Thrust Washer480

Removing Sun Gear480

Removing Output Shaft To Carrier Snap Ring480

Removing Retaining Clip481

Installing Speedometer Drive Gear481

Installing Retaining Clip481

Removing Speedometer Drive Gear481

Governor Assembly481

Disassembly Of Governor482

Inspection Of Governor482

Removing Rear Internal Gear To Mainshaft Snap Ring482

Exploded View Of Governor482

Governor Driven Gear Replacement483

Checking Exhaust Port Opening483

Checking Feed Port Opening483

Removing Governor Gear Retaining Pin483

Assembly Of Governor484

Inspection Of Rear Servo484

Exploded View Of Front Servo484

Disassembly Of Rear Servo484

Control Valve Assembly485

Assembly Of Rear Servo485

Disassembly Of Control Valve Assembly485

Removing Retaining E-Ring From Rear Servo Pin485

Assembly Of R E A R Servo 7 ~ - 2485

Inspection Of Control Valve486

Assembly Of Control Valve486

Installing Compressor Tool To Front Accumulator Piston486

Removing Front Accumulator Piston And Spring486

Exploded View Of Control Valve487

Removing Governor Feed Line Screen487

Installing Detent Regulator And Valve487

Disassembly Of Oil Pump488

Inspection Of Pump Body And Cover488

Removing Pump Regulator Valve Snap Ring488

Exploded View Of Pump Cover488

Removing And Installing Pump Drive Gear489

Pump Body Oil Passages489

Checking Pump Body Face To Gear Face Clearance489

Assembly Of Oil Pump490

Pump Cover Oil Passages490

Installing Pump Cover To Pump Body490

Removing Forward Clutch Housing To Direct Clutch Hub Snap Ring490

Forward Clutch491

Disassembly Of Forward Clutch491

Removing Forward Clutch Hub And Thrust Washers491

Inspection Of Forward Clutch491

Assembly Of Forward Clutch492

Removing And Installing Forward Clutch Piston Outer Seal492

Removing And Installing Forward Clutch Center Seal492

Exploded View Of Forward Clutch492

Installing Forward Clutch Piston493

Clutch Plate Identification493

Installing Forward Clutch Composition And Steel Plates493

Direct Clutch And Intermediate Sprag494

Disassembly Of Direct Clutch And Intermediate Sprag494

Installing Forward Clutch Housing To Direct Clutch Hub Snap Ring494

Removing Intermediate Clutch Retainer Snap Ring494

Assembly Of Direct Clutch And Intermediate Sprag495

Removing Direct Clutch Piston Snap Ring495

Removing Direct Clutch Piston495

Inspection Of Direct Clutch And . . . . . . . . . . . . . Intermediate Sprag Assembly Of Direct Clutch And495

Exploded View Of Direct Clutch And Intermediate Sprag496

Exploded View Of Direct Clutch496

Installing Direct Clutch Piston Inner Seal496

Installing Direct Clutch Piston Outer Seal497

Installing Direct Clutch Piston497

Installing Direct Clutch Center Seal497

Identifications Of Clutch Pistons497

Case Center Support498

Disassembly Of Center Support498

Correct Sprag Clutch Rotation498

Inspection Of Center Support499

Air Checking Direct Clutch499

Exploded View O F Center Support499

Inspection Of Reaction Carrier500

Installing Intermediate Clutch Inner Seal500

Installing Intermediate Clutch Piston500

Assembly Of Center Support 7 ~ 1 4500

Pinion Replacement Procedure501

Checking Output Carrier Pinion End Play501

Checking Reaction Carrier Pinion End Play501

Removing Planet Pinion Pin501

Inspection Of Major Units502

Output Shaft502

Rear Internal Gear502

D. Sun Gear Shaft502

Case Extension503

Modulator And Valve503

Checking Concentricity O F Sleeve503

F. Front And Rear Bands503

Manual And Parking Linkage504

Comparison Gauge504

Modulator Bellows Good504

Bringing Modulators Together504

Case Passage Identification505

J. Case Assembly505

Assembly Of Rear Unit506

Air Checking Converter506

Installing Tool J 21371.3506

Installing Tool J 21371-2506

Exploded View Of Rear Unit507

Installing Rear Internal Gear To Main Shaft Snap Ring507

Installing Rear Internal Gear To Sun Gear Bearing And Races507

Installing Output Shaft508

Installing Front Internal Gear Ring To Output Carrier508

Installing Reaction Carrier509

Installing Roller In Roller Clutch509

Installing Center Support To Sun Gear Thrust Bearing And Races509

Assembly Of R E A R Unit509

Assembly Of Units Into Transmission509

Installing Roller Clutch510

Installing Center Support T O Reaction Carrier Thrust Washer510

Installing Case T O Output Shaft Thrust Washer510

Installing Parking Shaft Retaining Spring511

Installing Parking Pawl Return Spring511

Installing New Cup Plug511

Installing Rear Band511

Installing Center Support And Gear Unit512

Installing Center Support Bolt512

Installing Center Support To Case Snap512

Installing Manual Shaft To Case513

Installing Front Band513

Installing Detent Lever And Jam Nut To Manual Shaft513

Installing Direct Clutch Assembly514

Installing Forward Clutch And Turbine Shaft514

Installing Pump Seal514

Rear Extension Housing Assembly515

Installing Rear Extension Seal515

Installation Of Check Balls, Front Servo515

Installing Detent Solenoid And Gasket516

Installation Of Control Valve Assembly And Governor Pipes516

Installation Of Strainer And Intake Pipe517

Installation Of Modulator Valve And Vacuum Modulator517

Installing Rear Accumulator Spring517

Installing Rear Servo Cover And Gasket517

Installation Of Governor518

Installation Of Speedometer Driven Gear518

Installation Of Converter Assembly518

Installation Of Transmission Assembly519

Manual Linkage519

Shift Pattern Check519

Turbo Hydra-Matic Transmission Oil P R E S S U R E Checks519

Oil Pressure Check520

Possible Points Of Oil Leaks521

Transmission Oil Pan Leak521

Rear Extension Leak521

Two-Speed Automatic Transmission525

Vacuum Modulator532

Speedometer Driven Gear And Sleeve532

Downshift Solenoid Replacement533

Installing Governor Driven Gear533

Right Side Of Transmission533

Removing Vacuum Modulator534

Speedometer Driven Gear Assembly534

Removing Oil Strainer Assembly534

Disengaging Manual Control Valve Link535

Removing Shift Control Valve Sleeve535

Downshift Solenoid And Detent Valve535

Modulator Limit Valve535

Transmission Removal536

Shift Valve And Shift Control Valve536

Transmission Disassembly537

Transmission Mounted In Holding Fixture537

Removing Oil Pump537

Removing Input Shaft538

Removing Low Servo Cover Snap Ring538

Removing Forward Clutch Assembly538

Inspection And Overhaul Of Individual Components539

Removing Planet Carrier Assembly539

Removing Reverse Ring Gear539

Removing Reverse Clutch Pack Snap Ring539

Compressing Reverse Piston Return Springs540

Removing Parking Lock Bracket540

Reverse Piston Apply Port540

Removing Range Selector Shaft Retainer540

Reverse Clutch And Piston541

Removing Range Selector Shaft Nut541

Removing Case Bushing541

Removing Parking Lock Pawl Shaft541

Removing Manual Shaft Oil Seal542

Removing Low Sun Gear And Flange Assembly Snap Ring542

Park Lock Actuator And Range Selector Lever542

Removing Low Sun Gear And Flange Assembly542

Clutch Drum Bushing Replacement543

Removing Clutch Hub Rear Thrust Washer543

Removing Clutch Hub Front Thrust Washer543

Removing Clutch Hub543

Low Sun Gear Bushing Replacement544

Removing Clutch Drum Bushing544

Removing Low Sun Gear Bushing544

Installing Clutch Drum Bushing544

Planet Carrier545

Installing Clutch Piston Inner Oil Seal545

Installing Clutch Hub Front Thrust Washer545

Installing Spring Retainer545

Installing Clutch Hub Rear Thrust Washer546

Removing Lock Plate Screws546

Checking Planet Pinion End Clearance546

Removing Low Sun Gear Needle Thrust Bearing546

Output Shaft Bushing Replacement547

Removing Input Sun Gear547

Removing Output Shaft Bushing547

Input Sun Gear Thrust Washer547

Low Servo Assembly548

Long Pinion Rear Thrust Washer548

Installing Long Pinion Front Thrust Washer548

Installing Low Sun Gear Needle Thrust Bearing549

Compressing Low Servo549

Removing Oil Seal Rings549

Removing Timing Valve550

Converter Blow Off Valve550

Removing Boost Valve Sleeve Snap Ring550

Stator Shaft Bushing Replacement551

Pressure Regulator Assembly551

Removing Pump Body Bushing551

Removing Oil Pump Oil Seal551

Converter Leak Test552

Converter End Play Check552

Transmission Reassembly552

Installing Oil Pump Oil Seal552

Installation Of Range Selector Lever, Shaft And Parking Lock Actuator553

Checking Converter End Clearance553

Installing Parking Lock Pawl Shaft553

Installation Of Reverse Piston And Clutch554

Installing Parking Lock Bracket554

Installing Range Selector Shaft Retainer554

Reverse Clutch Cushion Ring554

Installation Of Planetary Gear Set555

Installation Of Low Servo Assembly, Low Band And Forward Clutch555

Installing Reverse Clutch Pack555

Installing Reverse Clutch Pressure Plate555

Determination Of Selective Thrust Washer Thickness556

Installing Low Servo Cover Snap Ring556

Installing Low Band556

Low Band Struts Installed556

Installing Forward Clutch557

Installing Input Shaft Into Pump557

Selective Thrust Washer Chart557

Installation Of Oil Pump558

Installation Of Speedometer Drive Gear558

Installing Thrust Washer558

Installing Oil Seal Rings558

Installation Of Converter559

Maximum Line Pressure559

Driveline Damper559

External Oil Leaks560

Oil Passages In Pump Body560

Oil Passages In Pump Cover561

Oil Passages In Bottom Of Transmission Case561

Oil Passages In Front Of Transmission Case561

Oil Passages In Valve Body561

Case Porosity Repair562

Column Shift Controls - Tempest567

Fluid Capacity570

Adding Fluid To Fill Dry Transmission And Converter Assembly571

Valve Body Assembly571

Intermediate Clutch Accumulator Piston Assembly572

Vacuum Modulator And Modulator Valve Assembly572

Extension Housing Oil Seal572

Removal Of Transmission Assembly573

Transm Isslon Disassembly573

Removal Of Extension Housing, Speed0 Drive Gear And Governor574

Removal Of Valve Body Assembly574

Removing Valve Body Assembly575

Removing Spacer Support Plate575

Removal Of Oil Pump And Internal Components576

Removing Governor Feed Screen576

Removing Inner Lever And Actuating Rod576

Removing Manual Shaft Retainer576

Removing Parking Pawl Shaft577

Removing Oil Pump Attaching Bolts577

Intermediate Servo Piston Assembly577

Removing Intermediate Clutch Plates577

Removing Forward And Direct Clutch Assemblies578

Removing Output Carrier Assembly578

Removing Input Ring Gear578

Removing Sun Gear Drive Shell Assembly578

Removing Low And Reverse Clutch Support Retaining Ring579

Removing Clutch Support Retainer Spring579

Location Of Clutch Support Retainer Spring579

Removing Reaction Carrier Assembly579

Overhaul And/Or Inspection580

Removing Output Ring Gear Needle Bearing580

Compressing Low And Reverse Clutch Piston Assembly580

Output Ring Gear And Output Shaft Assembly580

Compressing Intermediate Clutch Accumulator Piston Cover581

Removing Accumulator Piston Assembly581

Removing Accumulator Cover And Spring581

Checking Governor Feed Port Opening582

Exploded View Of Valve Body Assembly583

Compressing Direct Clutch Accumulator Piston583

Oil Pump Assembly585

Removing Pump Attaching Bolts585

Removing Oil Seal Rings And Selective Thrust Washer585

Removing Drive And Driven Gears585

Removing Cooler By-Pass Valve Seat586

Removing Priming Valve And Spring586

Removing Oil Pump Body Oil Seal586

Exploded View Of Oil Pump Assembly587

Pump Cover(Case Face) Oil Passages587

Stator Shaft Front Bushing588

Stator Shaft Rear Bushings588

Installing Stator Shaft Front Bushing588

Installing Stator Shaft Rear Bushings588

Installing Oil Pump Body Oil Seal589

Installing Seals In Intermediate Clutch Piston589

Installing New Cooler By-Pass Valve Seat589

Removing Intermediate Overrun Clutch Retainer589

Removing Intermediate Overrun Roller Clutch Assembly590

Removing Retaining Ring And Pressure Plate590

Removing Direct Clutch-To-Forward Clutch Thrust Bearing590

Identification Of Direct Clutch Piston590

Direct Clutch Assembly591

Removing Direct Clutch Piston Inner And Outer Seals591

Removing Direct Clutch Piston Center Seal591

Direct Clutch Bushing592

Forward Clutch Assembly593

Exploded View O F Direct Clutch Assembly593

Removing Direct Clutch Drum Bushing593

Installing Direct Clutch Drum Bushing594

Removing Forward Clutch Retaining R'ing And Pressure Plate594

Installing Direct Clutch Piston Assembly594

Removing Forward Clutch Plates594

Removing Spring Seat And Return Springs595

Clutch Piston Inner And Outer Seals595

Exploded View Of Forward Clutch Assembly595

Forward Clutch Drum Ball Check596

Checking Free Back Height596

Installing Forward Clutch Piston Assembly596

Forward Clutch Pressure Plate Identification596

Sun Gear And Sun Gear Drive Shell Assembly597

Removing Retaining Ring From Rear Of Sun Gear Drive Shell597

Removing Sun Gear From Sun Gear Drive Shell597

Removing Rear Flat Thrust Washer597

Low And Reverse Roller Clutch Support Assembly598

Sun Gear Bushings598

Exploded View Of Low And Reverse Roller Clutch And Support Assembly598

Input Ring Gear599

Output Carrier Assembly599

Reaction Carrier Assembly599

Removing Or Installing Input Ring Gear Bushing599

Transmission Case600

Installing Output Shaft Bushing600

Case Passage Identification - Front View600

Extension Housing601

Case Passage Identification - Bottom View601

Installing Case Bushing601

Removing Or Installing Extension Housing Bushing601

Intermediate Overrun Brake Band602

Vacuum Modulator Assembly602

Vacuum Modulator Seams And Seal602

Cross Section Of Vacuum Modulator602

Converter Assembly603

Comparison Gage603

Installing Tool J 21371-3604

Checking Converter End Play604

Installation Of Internal Components And Oil Pump605

Exploded View Of Intermediate Clutch Accumulator605

Low And Reverse Clutch Piston And Springs In Case605

Installing Reaction Carrier Into Case606

Installing Low And Reverse Clutch ~ G C K606

Selecting Proper Band Apply Pin608

Checking For Proper Band Apply Pin608

Installation Of Parking Linkage, Valve Body And Oil Pan609

Exploded View Of Intermediate Servo Assembly609

Installing Parking Pawl Disengaging Spring609

Installation Of Governor, Speed0 Drive Gear And Extension Housing610

Installing Valve Body Assembly610

Installation Of Modulator And Converter611

Installing Converter Assembly611

Shift Point Information612

Transmission Oil Pressure Checks613

Determining Source Of Oil Leak614

Fuel Tank And Exhaust System618

Fuel Tank Drain Hose618

Fuel Tank Drain618

Fuel Tank Gage Unit619

Vent Hose Routing620

Fuel Tank Gage Unit (Station Wagon)621

Tank Gage Unit Tool J 23346621

Installation Of Fuel Tank Pontiac Station Wagon622

Installation Of Fuel Tank Tempest Station Wagon623

Installation Of Fuel Tank624

Pontiac Fuel Gage Wiring624

Tempest Fuel Gage Wiring625

Fuel Gage Wiring625

Tempest 6-Cylinder Engine Exhaust System627

Firebird Muffler And Tail Pipe Installation628

Firebird 6-Cylinder Engine Exhaust System629

Tempest V-8 Engine Single Exhaust System630

Firebird V-8 Engine Single Or Dual Exhaust System632

Tempest And Grand Prix Dual Exhaust System633

Fuel Tank Capacity639

Exploded View Of Steering Wheel And Horn641

Steering Wheel642

Turn Signal Switch642

Locating Steering Wheel Position642

Removing Snap Ring And Lock Plate642

Lock Cylinder643

Connector And Wires With Tape643

Removing Wire Protector From Turn Signal Harness643

Removing Turn Signal Switch643

Removing Buzzer Switch645

Installing Buzzer Switch645

Steering Column645

Installing Steering Shaft To Flexible Coupling646

Exploded View Of Typical Regular Column647

Steering Column (Non-Tilting)648

Disassemble Upper End648

Exploded View Of Typical Tilt Column649

Mounting Bracket Assembly650

Mounting Column In Vise By Welded Tapping Nuts650

Removing Upper Bearing Housing651

Removing Or Installing Rack And Lock Bolt651

Removing Or Installing Thrust Cup651

Removing Or Installing Rack Load Spring651

Assemble Lower End652

Removing Or Installing Shift Gate652

Removing Back-Up Light Or Neutral Start Switch652

Removing Sector652

Removing Bearing Adapter And Shift Tube Spring653

Removing Lower Shift Tdbe Support Screws Manual Transmission653

Removing Or Installing Wave Washer And Lower Shift Bowl Bearing653

Assemble Upper End654

Adjusting Lower Shift Lever Clearance654

Bolt And Rack Assembled654

Installing Sector654

Tilt Steering Column655

Removing Or Installing Tilt Spring Retainer655

Removing.pivot Pin655

Disassemble Bearing Housing656

Upper Shift Lever Spring656

Installation Of Shift Tube Remover J 23072656

Removing Or Installing Lock Bolt Spring657

Removing Tilt Release Lever Pin657

Assemble Column657

Installing Lock Bolt To Sector658

Installation Of Shift Tube Installer658

Pot Joint (Lower Steering Shaft)659

Universal Joint659

Steering Linkage660

Steering Gear664

Checking Steering Gear Adjustment664

Overcenter Or Pitman Shaft Adjustment664

View Of Manual Steering Gear665

Pitman Shaft Bushing665

Pitman Shaft Seal666

Upper Or Lower Bearing Cups666

Removing Pitman Shaft Bushing666

Ball Nut Properly Installed On Shaft666

Adjusting Worm Bearing Preload667

Position Of Pitman Shaft And Ball Nut667

Pitman Shaft Seals669

Housing Lower End Plug And Rack-Piston Nut End Plug670

Rack-Piston Nut670

Adjuster Plug Assembly, Rotary Valve With Worm Shaft And Pin Assembly670

Pitman Shaft Gear And Side Cover671

Removing Adjuster Plug Assembly671

Adjuster Plug And O.ring Removal671

Tapping To Loosen Valve Spool671

Rotary Valve672

Removing Valve Spool From Rotary Valve672

Exploded View Of Rotary Valve672

Adjuster Plug673

Removing Pitman Shaft Needle Bearing673

Gear Housing674

Rack-Piston Nut And Worm674

Pitman Shaft Seals And'washers677

Check Worm Preload678

Loading Rack Piston Nut678

Ball Return Guide678

Worm Shaft, Rotary Valve Assembly And Adjuster Plug679

Adjust Worm Bearing Preload679

Installing Rack Piston Nut680

Installing End Plug Retainer Ring680

Flexible Coupling681

Power Steering Pump681

Adjusting Pitman Shaft Preload681

Pontiac Installation Of Power Steering Assembly682

Tempest Installation Of Power Steering Gear Assembly683

Grand Prix Installation Of Power Steering Gear Assembly684

Firebird Installation Of Power Steering Gear Assembly685

Flow Control Valve686

Removing Retaining Ring686

Removing End Plate687

Removing Flow Control Valve687

Removing Pressure Plate687

Pressure Plate And Rotor Ring Removed688

Removing Pump Shaft688

Exploded View Of Power Stciering Pump688

Installing Pump Shaft689

Thrust Plate Installed689

Installing Rotor689

Installing Pump Vanes689

Pump Vanes Installed690

Installing End Plate690

Installing Pressure Plate Spring690

Cooler Pipe - Pontiac And Grand Prix691

Installation Of Power Steering Pump For V-8691

Special Tools For Steering Columns And Steering Gears693

Wheels And Tires695

Recommended Tire Inflation Pressures695

Test For Leaks696

Remove Tire From Wheel696

Puncture Repairs696

Preparation Of Tire697

Preparation Of Rim697

Inspection Before Balancing Wheels And Tires697

Radial Runout Inspection697

Balance Procedure698

Piontiac Wheel Codes698

Tempest Wheel Codes698

Grand Prlx Wheel Codes698

Tire Usage Chart699

Firebird Wheel Codes699

Chassis Sheet Metal700

Hood Attachment Typical700

Front Inner Fender705

Pontiac Front Fenders707

Chassis Electrical Service715

Battery Cable715

Fusible Link715

Pontiac Engnie Compartmerrt Wiring716

Pontiac Passenger Compartment Wiring717

Pontiac Passenger Cempartmemt Wiring718

Pontiac Rear End Wiring719

Tempest Engine Compartment Wiring720

Tempest Passenger Compartment Wiring721

Tempest Rear End Wiring723

Firebird Engine Compartment Wiring724

Firebird Passenger Compartment Wirinn725

Firebird Rear End Wiring727

Grand Prix Engine Compartment Wiring728

Grand Prix Passenger Compartment Wiring729

Grand Prix Rear End Wiring731

Rally Gage Wiring732

Pontiac Battery Cable Routing733

Tempest And Grand Prix Battery,Cable Routing734

Fuse Block And Bulkhead Connector734

Engine Wire Harness734

Firebird Battery Cable Routing735

Typical V8 Engine Harness Installation735

Front End Wiring Harness736

Front Park And Signal Lamps736

Typical 6-Cylinder Engine Harness Installation736

G.t.o. And Firebird737

Fuse Block And Bulkhead Connector Identification737

Typical Front End Harness Installation738

Headlight Aiming Chart738

Horn Relay Buzzer Alarm739

Side Marker Lamps739

Pontiac Instrument Panel Installation739

Brake Warning Light Switch739

Tempest And Grand Prix Instrument Panel Installation741

Firebird Instrument Panel Installation741

Printed Circuit742

Speedometer Cable Attachment742

Speedometer Cable Routing742

Windshield Wiper Switch745

Headlight Switch745

Cigar Lighter745

Dimmer Switch746

Back Up Lamp & Neutralizer Switch746

Clutch Start Switch747

Instrument Panel Harness747

Accessory Schematics747

Vacuum Operated Headlamps747

Power Servo Remove And Replace748

Vacuum Operated Headlamp Doors-Gto752

Vacuum Operated Headlamp Door Schematic753

Windshield Wipers And Washers754

Arm Blade Assembly754

Wiper Transmission And Linkage754

Arm And Blade758

Tempest And Grand Pfix Depressed Park System758

Tempest Standard System And Firebird758

Firebird Wiper Motor Arm And Blade Installation758

Wiper Switch759

Brush Plate And Circuit Breaker759

Depressed Park Gear Box760

Relay-Switch Latch And Terminal Board761

Depressed Park System761

Position Of Resistor Lead761

Wiper Motor Armature End-Play763

Wiper Motor Gear End-Plry763

Wiper Motor Gear Box763

Rectangular Wiper Motor Section764

Wiper Motor Lubrication764

Rectangular Motor764

Depressed Park Motor765

Windshield Washer Pump Overhaul765

Four-Lobe Cam765

Ratchet Pawl And Pawl Spring765

Brush Spring Rectangular Motor766

Exploded View Pump Assembly-Recess Park766

Rectangular Motor Washer Pump767

Solenoid Assembly767

Ratchet Pawl767

Ratchet Wheel767

Valve Assembly768

Radiator Support And Mounting Parts769

Pontiac Support And Baffle Assembly770

Lower Cradle Bracket And Insulator Tempest 6 Cylinder Only772

Firebird Support And Baffle Assembly772

Front And Rear Bumpers773

Bumper Adjustment773

Remove Pontiac Bumper773

Remove Grand Prix Bumper (773

Replace Bumpers778

Rear Bumpers778

Remove Pontiac Rear Bumper778

Remove Tempest Rear Bumper778

Remove Fireboard Rear Bumper779

Polyurethane And Lexan Parts779

Refinishing Polyurethane And Lexan Parts787

Pontiac Bonneville Grille788

Pontiac Catalina And Executive Grille788

Grand Prix Grille789

Tempest Grille790

Firebird Grille790

Adjustment Procedures792

Chain Linkage Adjustment792

Brake Release Switch Adjustment792

Cruise Control Installation793

Electrical Wiring And Vacuum Switch795

Checking For Damaged Cables And Gears797

Exploded View Of Regulator797

Minor Service797

Major Service797

Cover And Intake Filter Assembly798

Adjusting Low Speed Switch798

Valve Body And Magnet Assy.799

Electric Clock800

Safeguard Speedometer800

Clock Installation800

Hood Mounted Tachometer803

Vacuum Tire Pump806

Rear Wheel Opening Cover807

Accessory Switch Cutouts807

Rear Window Defogger808

Heated Rear Window809

Heated Rear Window With Custom Air Conditioning810

Heated Rear Window With Automatic Temperature Control A/C810

Cornering Lamps811

Underhood Lamp812

Luggage Lamp814

Radio And Front Speaker819

Radio Receiver And Front Speaker819

Radio Suppression Equipment821

Manual Antenna823

Power Antenna824

Overhaul Antenna827

To Replace Support Tube827

If Replacement Of Drive Or Mast Is Indicated827

Rear Seat Speaker828

Fm Stereo Radio832

Cyl845

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Tempest Firebird 1969 tempest 1969 firebird 2007 grand prix