Pontiac 1969 Firebird Manuals

Manuals and User Guides for Pontiac 1969 Firebird. We have 1 Pontiac 1969 Firebird manual available for free PDF download: Service Manual

Pontiac 1969 Firebird Service Manual

Pontiac 1969 Firebird Service Manual (849 pages)

1969

Brand: Pontiac | Category: Automobile | Size: 42.45 MB

Table of Contents

Table of Contents
2
General Information
3
Vehicle Identification Plate
3
Body Identification Plate
3
Car Model Identification
3
Engine Identification
4
Transmission Serial Number
4
8-Cyl.
4
Turbo Hydra-Matic
4
Lifting and Towing
5
Two-Speed Automatic
5
Towing Precautions
6
Ignition Lock Assembly - Remove
6
Two-Speed Automatic Transmission Serial Number
6
Depressing Lock Cylinder Retainer Pin
6
Coding Side Bar Lock
7
Key Blanks
7
Exploded View of Ignition Lock Assembly
7
Key Coding Diagram
7
Basic Dimensions
8
Rocker Panel Heights
8
Ignition Lock Assembly
10
Lubrication
10
Manifold Heat Control Valve
10
Station Wagon Tailgate Hinge and Linkage
10
Drill Sizes
11
Decimal Equivalents
11
Weights and Measures
12
Hood Latch
12
Hood Hinges
12
Accelerator Linkage
12
Carburetor Fuel Filter
14
Air Cleaner Element
14
Automatic Transmission
14
Cooling System
14
Battery
15
Starting Motor
15
Alternator
15
Speedometer Cable
15
Heating and Ventilation Service
16
Temperature Cable Adjust
16
Air Control Cablgadjust
16
PONTIAC, TEMPEST and Flreblrd
16
Pontiac-Heater Cable and Wire Routing
17
Blower Speed Switch
18
Grand Prix-Heater Cable and Vacuum Hose Routing
18
Tempest and Firebird
19
Blower Motor Resistor
19
Heater Wiring Harness
19
Tempest-Heater Cable Routing
19
Air Control or Defroster Cable
20
Temperature Control Cable
20
Tempest and Firebird-Remove and Replace
20
Defroster Diaphragm and Hose
21
Air Diaphragm and Hose
21
Vacuum Supply Hose
21
Blower Motor; Impeller and or Inlet Duct
21
Grand Prix-Remove and Replace
22
Heater Core And/Or Case
22
Blower Motor and Air Inlet Duct Installation
23
Heater Hose Inlet and Outlet
24
Defroster Duct
24
Heater Wiring Schematic
24
Kick Pad Ventilators
25
Upper Level Ventilation
25
Heater Wiring Schematic-All
25
Pontiac-Upper Ventilation System
26
Tempest and Grand Prix-Upper Ventilation System
26
Firebird Upper Ventilation System
26
Power Flow Ventilation System
27
Vent Motor
27
Typical-Power Flow Vent Motor and Duct
27
Power Flow Ventilation Wire Harness Typical
27
Custom Air Conditioner
28
Component Replacement and Adjustment
28
Precautionary Service Measures
28
Refrigeration Sub-Assemblies
28
Table of Contents
28
Caution--Liquid Indicator
29
Depressurizing the System-All
29
Evacuating the System
29
Preparati~Ns for Evacuating Complete System
29
Evacuating Complete System
30
Charging the System
31
Refrigerant Drum Method
31
Refrigerant-12 Disposable Can Method
32
Schematic - Charging Refrigeration System
32
Service Station Method
33
Filling Charging Cylinder
33
Charging the System Using J 8393
33
Adding Refrigerant 1A-7
34
Checking Compressor Oil Level and Adding Oil
35
Replacing Refrigeration System
35
Components Other than Compressor
35
Removing and Installing Compressor
36
Installing Compressor
36
Compressor Hub and Drive Plate Assembly
37
Compressor Replacement
37
Removing Hub and Drive Plate Lock Nut
38
Removing Hub Retainer Ring and Spacer
38
Removing Hub Retainer and Spacer
38
Compressor Pulley Anwor Bearing Assembly
39
Proper Position of Hub and Drive Key
39
Removing Pulley and Bearing Assembly Retainer Ring
39
Installing Hub and Drive Plate Assembly
39
Compressor Clutch Coil and Housing Assembly
40
Removing Pulley Bearing Retainer Ring
40
Installing Pulley Bearing
40
Remove Compressor Assembly to Service Engine-Pontiac and Tempest
41
Compressor Shaft Seal Assembly
41
Removing Coil Housing Retainer Ring
41
Removing Shaft Seal Seat
42
Removing Shaft Seal Seat Retainer
42
Removing Shaft Seal Assembly
42
Compressor Assembly-Overhaul
43
Preservation and Packing Service Parts
43
Removing O-Ring Seal
43
Major Interior Mechanism
43
Overhaul Compressor
44
Compressor Rear Head Assembly
44
Compressor Major Interior Mechanism
44
Sealing Surface on Head Casting Web
44
Removing Suction Reed
45
Removing Oil Inlet Tube
45
Pistons and Cylinder
45
Separating Cylinder Halves
46
Compressor Parts in Tray
46
Identification of Front End of Piston
46
Removing Rear Thrust Races and Bearings
47
Exploded View Compressor Assembly
48
Mainshaft Thrust Bearing Installed
49
Installing Piston with Balls
49
Zero Shoe and Ball at Front of Piston
49
Installing Rear Cylinder Half on Front Cylinder Half
49
Internal Mechanism in Fixture
50
Measurements and Table of Available Service Shoes and Thrust Races
50
Measuring for Proper Shoe
50
Checking Compressor Mainshaft End Play
50
Assemble with New Parts
51
Measuring for Proper Thrust Race
51
Installing Service Discharge Crossover
51
Installing Service Discharge Crossover Parts
51
Installing Front Head Casing
52
Identification O F Front and Rear Discharge Valve Plate
52
Installing Service Discharge Crossover Tube
52
Installing Oil Intake (Pick-Up) Tube
53
Positioning Oil Pump Outer Gear
53
P.o.a. Valve
54
Seating Seal Seat Retainer
54
Installing Rear Head
54
Refrigeration System Typical Tempest and Grand Prix
55
Expansion Valve and Seals
56
Evaporator Core
57
Evaporator Case Left Half
57
Condenser and Seals
58
Receiver Dehydrator
58
Air Inlet and Valve Assembly 1A-31
58
Blower Motor Impeller Andor Blower Motor Case
59
Air Inlet Assembly Typical Pontiac, Tempest and Grand Prix
59
Heater Core and Case Assembly
60
Air Inlet and Plenum Air Valve
60
Temperature Cable
61
Hi Blower Relay; Resistor Block; and Ambient Switch
61
Heater Core and Case Installation
61
Control Panel .1A-34
61
N C Engine Compartment and Jumper Harnesses
64
Diverter Door Diaphragms
64
Defroster Diaphragm
64
Air Inlet Diaphragms
65
Plenum Air Valve Diaphragm .1A-38
65
Cold Air Distribution: Center Air Outlet; and Side Outlet Ducts
66
Tempest Control Panel Details
66
Pontiac Control Panel Detaik
66
Vacuum Hose Harness
67
In-Car A/C Wiring Harness
67
Air Conditioning Wiring Schematic
69
Compressor Mounting and Belt a D J ~ S T ~ E N T
69
A/C in Car Harness Routing and Connections
72
Adjust
74
Typical Pontiac and Grand Prix Vacu~Irn Schematic
76
Tempest Vacuum Schematic
76
Firebird Vacuum Schematic
77
Automatic Temperature Control
78
In-Car Sensor
78
Ambient Sensor and Switch
79
Vacuum Hose Harness
79
Control Panel Components
80
Temperature Control Switch
80
Variable Resistor
80
Grand Prix Vacuum Hose Installation
81
Pontiac Vacuum Hose Installation
81
Temperature Door Link to Programmer
83
Grand Prix Control Panel
83
Programmer
84
Using Tool J 23187 to Adjust Variable Resistor
84
Programmer Link Assembly
84
Amplifier-Remove and Replace
85
Programmer Wheel
85
Gear Inspection
85
Temperature Door Adjustment
85
Motor
86
Programmer Amplifier
86
Power Resistor
87
Bi Level Boost Switch
87
Vacuum Schematic
88
Wiring Schematic
88
Frame and Body Mountings
90
Pontiac and Tempest
90
Lifting Pontiac Cars with Hoists
90
Pontiac
91
Tempest
91
Frame Alignment
91
Body to Frame Mountings
92
Flreblrd
92
Underbody Alignment
92
Flreblrd BODY VIBRATION DAMPERS
92
Pontiac Body Bolts and Frame Gage Line Dimensions
93
Tempest and Grand Prix Body Bolts and Frame Gage Line Dimensions
94
Firebird Checking Dimensions, Lift Points and Body Bolt Locations
95
Specifications
96
Horizontal Dimensions
96
Vertical Dimensions
96
Side Rail at Spring Rear Shackle Hole
97
Firebird Convertible Floor Pan Reinforcement
97
Firebird Body Damper Locations
97
Front Suspension
98
Front Wheel Bearings
98
Check Adjustment
98
Suspension Alignment
99
Inspection before Checking Front Wheel Alignment
99
Cross Section of Steering Knuckle, Hub and Disc Assembly
99
Adjust Caster and Camber
100
Wheel Bearing Adjustment
100
Checking and Adjusting Sequence-Front Wheel Alignment
100
Checking Wheel Bearing Adjustment
100
Check and Set Toe-In
101
Measuring by Trammel
101
Removing Pontiac Upper Control Arm Nuts
101
Caster-Camber Shims (Tempest Shown)
101
Minor Services
102
Set Toe-In
102
Check Steering Axis Inclination
102
Check Toe-Out on Turns
102
Shock Absorber
103
Typical Shock Absorber Installation
103
Stabilizer Shaft
104
Major Services
104
Spring
104
Stabilizer Link Installation Except Firebird
104
Steering Knuckle
105
Stabilizer Shaft Installation
105
Upper Control Arm
106
Removing Coil Spring with J 23028
106
Coil Spring Position in Lower Control Arm
106
Upper Control Arm Shaft And/Or Bushings
107
Upper Control Arm Shaft Anwor Bushings
108
Lower Control Arm
109
Lower Control Arm Bushing
109
Upper Ball Joint
111
Lower Control Arm Rear Bushing Firebird
111
Lower Ball Joint
112
Lower Ball Joint Installation Except Pontiac
113
Torque Specifications
115
Front Wheel Alignment Specifications
115
Rear Suspension
116
Shock Absorber--Except Firebird
116
Shock Absorber-Firebird
117
Spring and Shock Absorber Anchor Plate
117
Rear Shock Absorber Installation
117
Rear Spring
118
Leaf Spring and Spring Eye Bushing
118
Removing Spring Front Bushing
119
Installing Spring Front Bushing
119
Main Leaf of Leaf Spring-Firebird
120
Upper Control Arm Bushing
120
Pontiac and Grand Prix Automatic Level Control System
122
Compressor, Reservoir and Regulator Valve Assembly
123
Disassembly of Compressor into Major Components
123
Disassembly of Piston--Diaphragm Assembly
123
Disassembly of First Stage Housing and Valve Mechanism
123
Disassembly of Second Stage Housing
124
Cleaning and Inspection of Parts
124
Piston and Diaphragm Assembly
124
First Stage Housing and Valve Mechanism
124
Second Stage Housing
125
Assembly of Second Stage Housing
125
Assembly of First Stage Housing and Valve Mechanism
125
Assembly of Piston--Diaphragm Assembly
126
Assembly of Major Components
126
Instructions for Fastening Tubing
126
Pontiac Automatic Level Control System
127
Grandprix Automatic Level Control System
128
Exploded View of Compressor
129
Removing Diaphragm Retainer
129
Distributor Valve Assembly
129
Trouble Diagnosis Tests
130
Removing Rocker Arm Pin
130
Installing Valve Tension Spring in Boss
130
Installing Check Valve
130
Parts Required
131
Compressor Output Test-On Car
131
Installing Distributor Arm
131
Installing Diaphragm Retainer
131
Height Control Valve Test-On Car Exhaust (Superlifts Inflated)
132
Time Delay Check
132
Installing Piston Seal
132
Filling System through Service Valve
132
Height Control Valve Test-Off Car
133
Test Gage Installed on Regulator Valve
133
Lines and Fittings
134
Superlift - Leak Test
134
Standard Differential
136
Axle Ratios
136
New Car Pre-Delivery Inspection
137
Periodic Service
137
Shock Absorbers
137
Cross Section O F Typical Rear Axle and Differential
137
Exploded V~Ew of Typical Differential Assembly
138
Minor Service and Repairs
143
Companion Flange
143
Checking Pinion Bearing Preload
143
Removing Drive Pinion Nut
143
Pinion Bearing Oil Seal
144
Remove Axle Shaft Assemblies
144
Axle Shaft Bearing
145
Removing Axle Shaft Bearing (Typical)
145
Installing Axle Shaft Bearing (Typical)
145
Replace Axle Shaft Assemblies
145
Major Repairs
146
Rear Axle Assembly
146
Removing Axle Shaft Seal
146
Pre-Repair Investigation
147
Gear Tooth Nomenclature
147
Red Lead Test
147
Effects of Increasing Load on Tooth Contact Pattern
148
Differential Cranking Tool
148
Desired Tooth Contact under Light Load
148
Adjustments Affecting Tooth Contact
148
Effects of Backlash on Tooth Pattern
149
Effects of Pinion Position on Tooth Pattern
149
Overhaul Differential
149
Differential Case
149
Effect on Pattern
150
Removing Difterential Case
150
Clean and Inspect
151
Removing Differential Side Bearing
151
Alignment Marks
151
Grand Prix Medium Duty
152
Removing Pinion Shaft
152
Installing Pinion Shaft Lucking Bolt
152
Install Differential Case Side Bearings
153
Remove Pinion Assembly
153
Disassemble Pinion Assembly
153
Replace Pinion Bearing Outer Races
154
Torquing Case Half Bolts
154
Installing Right Differential Side Bearing
154
Installing Left Differential Side Bearing
154
Setting Pinion Depth
155
Removing Companion Flange
155
Removing Rear Pinion Bearing
155
Installing Rear Pinion Bearing Outer Race
155
Securing Gauge Plate in Carrier
156
Installing Front Pinion Bearing Outer Race
156
Replace Pinion Assembly and Adjust Pinion Preload
157
Gauge Plate Installed
157
Checking Pinion Depth
157
Replace Differential Case and Adjust Side Bearing Preload
158
Pinion Shim
158
Installing Two Service Shims
159
Installing Service Spacer
159
Inserting Feeler Gauge
159
Adjusting Differential Backlash
160
Tapping Final Shim into Place
160
Checking Ring Gear to Pinion Backlash
160
Oil Leaks
161
Safe-T-Track Differential
163
Grand Prix
164
Cleaning and Inspection of Case
167
Differential Case Assemble
168
Installing Differential Side Bearing
168
Compressing Preload Springs
168
Checking Pinion Gear to Side Gear Clearance
168
Tempest, Firebird and Grand Prix
169
Propeller Shaft
174
Alignment of Engine and Propeller Shaft
174
Remove Propeller Shaft
174
Disassemble Universal Joints
174
Assemble Universal Joints
175
Pressing out Bearing
175
Tapping out Bearing
175
Supporting Splined Yoke
175
Install Propeller Shaft Assembly
176
Installing Journal to Yoke
176
Installing Snap Ring Retainer
176
Propeller Shaft Comparison and Usage Information
177
Standard Brakes
178
Service Operations
178
Brake Pedal
178
Pontiac Manual Brake System
178
Pedal Height
179
Brake Warning Light Checking Procedure
179
Tempest and Grand Prix Manual Brake System
179
Stop Light Switch
180
Brake Assembly Mechanism and Drums
180
Firebird Manual Brake System
180
Adjustment
180
Fluid Levels and Master Cylinder Details
181
Preparing to Back off Adjusting Screw
182
Backing off Adjusting Screw
182
Disassembly
182
Inspection &D Cleaning
182
Gauging Shoe to Drum Clearance
183
Typical Self Adjusting Brake Assembly Exploded View
183
Pontiac Parking Brake System
184
Tempest and Grand Prix Parking Brake System
185
Assembly
185
Prix, and Firebird
186
Firebird Parking Brake System
186
Hydraulic System
187
Master Cylinder
187
Wheel Cylinder
189
Master Cylinder Usage Chart
189
Bleeding Brakes
190
Wheel Cylinder
190
Parking Brake
191
Inspection, Cleaning and Lubrication
191
Flushing Hydraulic System
191
Parking Brake Pedal Removal
192
Parking Brake Pedal Installation
192
Front Cable Installation
192
Center Cable Removal and Installation
192
Pontiac Specifications
193
Pontiac Torque Specifications
193
Tempest, Grand Prix and Firebird Specifications
194
Tempest, Grand Prix and Firebird Torque Specifications
194
Delco-Moraine Power Brake
195
Checks and Adjustments on Car
195
Pontiac Power Brake System
195
Special Tools
195
Stop Lamp Switch
196
Front Housing
196
Power Piston
196
Firebird Power Brake System
197
Power Brake
198
Air Filter
198
Exploded View of Pontiac Power Brake Unit
199
Power Piston - Install
200
Removing Locking Ring from Power Piston
202
Removing Reaction Retainer
202
Removing Support Plate
203
Removing Air Valve
203
Exploded View of Master Cylinder
203
Installing Front Housing
204
Push Rod Adjustment
204
Bendix Power Brake
205
Overhaul Bendix Power Brake
206
Valve Plunger Stop Key
207
Inspect Hydraulic Master Cylinder Assembly
208
Inspect Air Filters
208
Power Unit and Master Cylinder
208
Master Cylinder-Exploded View
208
Installing Rear Vacuum Seal
209
Power Piston Assemble
209
Power Unit Assemble
209
Gauging Push Rod Length
209
Power Brake Assembly
210
Heavy Duty Power Brakes
212
Bendix Tandem Diaphragm Type
212
Master Cylinder and External Parts
212
Valve Rod, Retainers, Filter and Poppet
212
Power Section Disassembly
213
Power Unit - Exploded View
213
Removal of Rear Shell Vacuum Seal
214
Diaphragms, Plates, Retainer and Plunger
214
Valve Rod, Retainers, Filters and Poppet
214
Power Unit Special Tool Combination
214
Disassembly of Master Cylinder
215
Assembly of Master Cylinder
215
Power Unit Mounted in Press
215
Removing Center Plate from Rear Shell
215
Assembly of Vacuum Seal in Rear Shell
216
Assembly of Plates Plunger and Diaphragm
216
Assembly of Diaphragms and Plates in Front and Rear Shells
217
Installing Rear Shell Vacuum Seal
217
Master Cylinder Exploded View
217
Assembly of Reaction Disc, Push Rod and Vacuum Check Valve Grommet
218
Assembly of Valve Rod, Air Filter, Retainer and Poppet Parts
218
Gaging Push Rod Length
218
Push Rod Gage
218
Assembly of Push Rod Boot and Master Cylinder to Power Unit
219
Power Cylinder Exploded View
220
Over-All Brake Unit
221
Separating Front and Rear Shells
221
Power Piston Disassemble
222
Power Piston Exploded View
222
Preparing to Separate Primary and Secondary Pistons
223
Preparing to Remove Primary Support Plate
223
Removing Primary Power Piston
223
Removing Air Valve-Pushrod Assembly
223
Master Cylinder Disassemble
224
Installing Control Valve and Retainer
225
Gaging Reaction Piston
225
Installing Snap Ring on Air Valve
225
Installing Housing Divider
226
Securing Front Housing to Arbor Press
227
Securing Rear Housing to Tools
227
Joining Front and Rear Housings
228
Gaging Master Cylinder Piston
228
Power Cylinder Only
229
Master Cylinder Only
229
Disc Brakes
231
Lining Inspection
231
Shoe and Lining Replacement
231
Caliper
231
Disc Brake Assembly
232
New and Worn Linings
233
Removing Mounting Bolts
233
Exploded View of Caliper
234
Boot Installation
234
Inserting Shoe Support Spring
235
Installing Outboard Shoe
235
Installing Inboard Shoe
235
Clinching Outboard Shoe
235
Bleeding Disc Brakes
236
Brake Rotor
236
Installing Mounting Bolts
236
Removing Piston
236
Surface Tolerance and Finish
237
Rotor Service
237
Lateral Runout Check
237
Parallelism Check
237
Checking Rotor for Lateral Runouf
238
Engine Mechanical
240
Six Cylinder Engine
240
Tempest and Firebird Engines
240
Pontiac and G. P. Engine Chart
240
Tempest Engine Chart
241
Firebird Engine Chart
241
Pontiac and Grand Prix Engines
242
Engine Number and Code Location
242
Vehicle Identification Number Location
242
Six-Cylinder Engine
243
Service Operations on Car
243
Engine Insulators
243
Valve Timing Marks
244
Drive Belts-Adjust (Except Timing Belt)
245
Intake and Exhaust Manifold or Gaskets
245
Cyl. Engine Mounting-Tempest
246
Timing Belt Adjustment Procedure
247
Timing Belt Adjustment
247
Cyl. Engine Mounting-Firebird
247
Accessory Drive Hosuing Mounting Bolts
247
Timing Belt Top Front Cover
247
Camshaft Sprocket or Seal
248
Adjusting Timing Belt Tension
248
Replace
248
Rocker Arm Cover Assembly and Gasket
249
Camshaft, Rocker Arm Cover Anwor Rocker Arm Cover Core Plug
249
Removing Camshaft Seal
249
Installing Camshaft Seal
249
Removing Camshaft from Cover
250
Thrust Washer Installation
250
Installing Camshaft Rear Plug
250
Rocker Arm or Hydraulic Valve Lash Adjuster
251
Lash Adjuster-Disassemble
251
Rocker Arm and Lash Adjuster
251
Hydraulic Lash Adjuster Recondition
251
Lash Adjuster-Clean and Inspect
252
Lash Adjuster-Assemble
252
Lash Adjuster-Exploded View
252
Lash Adjuster Test Leak-Down Rate
253
Valve Springs, Shield or Seal
253
Lash Adjuster-Wash Tank and Tray
253
Testing Leak down Rate
253
Cylinder Head or Gasket
254
Valve Spring Removal Hook-Up
254
Valve Spring Removal
254
Replace
254
Cylinder Head and Valves
255
Intake Valve Guide Seal Installation
255
Cylinder Head Locating Dowel Pins
255
Fitting Valve Stems to Guides
256
Valves and Seats Recondition
256
Cleaning Valve Guide Bore
256
Reaming Valve Guide Bore
256
Harmonic Balancer
257
Valve Seat and Face Angle
257
Lower Front Timing Cover Retaining Bolts
257
Lower Front Timing Belt Cover
258
Front Crankcase Cover and Gasket-Remove and Replace
258
Removing Crankshaft Front Seal
258
Crankshaft Timing Belt Sprocket or
258
Oil Pump
259
Housing Assembly
259
Pressure Regulator Valve-Oil Pump
259
Remove and Replace
259
Oil Filter By-Pass Valve
260
Accessory Drive Housing-Exploded View
260
Oil Pump Gears
260
Remove and Replace
260
Oil Pan
261
Housing Mounting Bolts
261
Oil Filter Bypass Valve
261
Removing Eccentric and Distributor Drive Gear Pin
262
Installing Bearing
262
Removing Bearing and Seal
262
Installing Seal
262
Replace
262
Main Bearings-Remove and Replace
263
Removing Rear Main Bearing Cap
263
Rear Main Bearing Cap Side
263
Connecting Rod Bearings-Remove and Replace
264
Removing Upper Rear Main Oil Seal
264
Tool for Removing Upper Half of Main Bearing
264
Plastigage (or Equivalent) in Place
265
Measuring Plastigage (or Equivalent)
265
Cylinder Bores-Inspect
266
Checking Connecting Rod Side Clearance
266
Cylinder Ring Ridge
266
Checking Crankshaft End Play
266
Honing or Boring
267
Removing Piston Pin-Step
267
Checking Piston Pin Fit
267
Measuring out O F Round Taper
267
Normal Cylinder Wear Pattern
268
Piston Sizing Points
268
Measuring Cylinder Gauge
268
Piston Fit and Replace
268
Connecting Rod to Piston - Assemble
269
Piston Pin Replacement
269
Piston and Rod Assembly
269
Piston Rings - Install
270
Checking Ring Side Clearance
270
Checking Ring Gap
270
Fitted Block Assembly
271
Connecting Rod Guide Tool
271
Installing Piston in Cylinder
271
Crankshaft
271
Replace
271
6 Cylinder Engine Wrench Torque Specifications
272
6 Cylinder Engine Specifications
273
Horsepower and Torque
273
Cylinder Special Engine Tools
276
V-8 Engine - Service
277
Cylinder Block
277
Cylinder Head
277
Camshaft and Drive
278
Pistons and Connecting Rods
278
Valve Train
278
Combustion Chamber
278
Rear Insulator
280
Engine Insulators Tempest
280
Pontiac Engine Insulators
280
Drive Belts
282
Engine Assembly
282
Tempest Engine Insulators
282
Firebird Engine Insulators
282
Right Side Exhaust Manifold or Gasket
283
Intake Manifold or Gasket
284
Left Side Exhaust Manifold or Gasket
284
Intake Manifold Gasket Retainers
284
Push Rod Cover or Gasket
285
Push Rod or Valve Lifter
286
Checking Valve Stem Seal
286
Lifter Wash Tank and Tray
286
Removing Push Rod Seat Retainer
286
Valve Lifter-Recondition
287
Valve Lifter - Clean and Inspect
287
Valve Lifter
287
Valve Lifter Assemble
288
Test Valve Lifter Leak-Down Rate
288
Hydraulic Valve Lifter
289
Testing Leak-Down Rate
289
Rocker Arm Studs
290
Rocker Arm Stud Removal
290
Slots Filed in Rocker Arm Stud
290
Installing Rocker Arm Stud
291
Cleaning Valve Guide
291
Reaming Valve Guide
292
Valve Seat and Face Angles
292
Valve Seat after Grinding with Flat Stone
292
Timing Chain Cover Seal
294
Front of Engine with Timing Chain Cover Removed
294
Aligning Timing Marks
294
Camshaft And/Or Camshaft Bearing
295
Timing Chain and Sprockets
295
Positioning Index Collar
296
Removing Camshaft Bearing
296
Installing Camshaft Bearing
297
Oil Pan Anvor Oil Pan Gasket Pontiac and Firebird Models
298
Oil Pan Gasket Retainers
298
Front Oil Pan Gasket Overlapping Side Gaskets
298
Rear Oil Pan Gasket Positioned in Bearing Cap
298
Oil Pump and Oil Pump Drive Shaft
299
Oil Pan And/Or Oil Pan Gaskets
300
Rear Main Bearing Oil Seal
300
Rear Main Bearing Seal Tool
301
Forming New Seal in Cap
301
Engine Oil Pan Baffle and Dipstick Tube
301
Measuring Plastigage
302
Connecting Rod Bolt Guide Set Installed
303
Installing Piston Assembly
303
Connecting Rod and Piston Assembly
304
Measuring Cylinder Bore
305
Fit and Replace Piston
306
Assemble Connecting Rod to Piston
307
Replace Piston Pin
307
Fitting Pin in Piston
307
Piston Rings
308
Installing Piston Pin
308
Crankshaft
309
Measuring Crankshaft End Play
309
Drain Holes in Lifter Gallery
310
Cylinder Block - View from Left Front
311
Hydraulic Lifter Equipment
314
Engine Wrench Torque Specifications
316
Engine Specifications
316
V-8 Special Engine Tools
321
Engine Cooling and Lubrication
322
Radiator
322
Radiator Cap
322
Water Plimp-6 Cylinder
323
Flushing Cooling System
323
Preparing Cooling System for Coolant
323
Checking and Filling Cooling System
323
Inhibitors
324
Testing Coolant
324
Thermostat Remove and Replace
324
Water Pump-6 Cylinder
324
Radiator Support and Baffle Assembly
325
Engine Oil
326
6 Cyl and 8 Cyl Remove and Replace
326
Fan Types and Usage
330
Radiator Usage
331
Firebird
331
Engine Fuel
332
Carburetor Air Cleaner and Silencer
332
Heat Riser Valve
332
Intake Systems
332
Air Cleaner Installation
333
Air Cleaner and Seal Installation
333
Baffle and Hood Scoop Installation GTO
334
Air Cleaner & Seal Installation Firebird
334
Baffle & Hood Scoop Installation Firebird
335
Ram Air Intake Schematic
335
Idle Stop Solenoid
336
Accelerator Controls
337
TEMPEST, GRAND Prlx and FIREBIRD
337
Vapor Diverter
337
Air Horn Removal
338
Air Horn Disassembly
338
Rochester MV Carburetor
338
Float Bowl Disassembly
339
Throttle Body Removal and Disassembly
339
Float Bowl Assembly
340
Throttle Body Disassembly
340
Carburetor Assembly and Adjustment Procedures
340
Throltle BODY ASSEMBLY and INSTALLATION
340
Metering Rod Adjustment
341
Float Level Adjustment
341
Air Horn Assembly and Installation
342
Fast Idle Adjustment (on Car)
342
Idle Vent Adjustment
342
Choke Rod Adjustment
343
Vacuum Break Adjustment
343
Unloader Adjustment
343
Choke Coil Rod Adjustment
343
Rochester 2Gv Carburetor
344
Idle Speed and Mixture Adjustment
344
Disassembly of Bowl Cover
344
Bowl Cover Attaching Parts
345
Disassembly of Throttle Body
346
Venturi Cluster Passage Identification
347
Flange - Bowl Passage Identification
347
Body to Bowl Cover Passage Identification
347
Throttle Flange Passage Identification
347
Assembly of Throttle Body
348
Assembly of Bowl
348
Assembly of Bowl Cover
348
Pump Rod Adjustment
349
Float Drop Adjustment
349
Air Horn Tightening Sequence
349
Fast Idle Cam Installed
349
Rochester 4Mv Quadrajet Carburetor
351
Rochester 4Mv Carburetor
351
Cleaning & Inspection Procedure
362
Engine Tune-Up
369
Spark Plug Removal
369
Compression Test
369
Clean, Test and Install Spark Plugs
370
Ignition System Service and Repairs
370
Service Battery and Battery Cables
371
Generator and Regulator
371
Fan Belt
371
Check Intake Manifold Bolts
371
Check Fuel Lines and Service Fuel Filter
372
Inspect and Service Cooling System
372
Test Dwell and Dwell Variation
372
Test Ignition Timing and Advance
372
Positive Crankcase Ventilation
373
Test Performance of Car
373
Emission Control Systems
374
Closed P.C.V. System
374
Controlled Combustion System
374
Vacuum Advance Valve
374
Sensor Replacement
375
Curb Idle Setting Procedure (Ram Air)
375
Curb Idle Setting Procedure 6 Cyl.
375
Dwell and Ignition Timing Specifications
376
Engine Electrical
377
Cranking Circuit
377
Remove from Car
377
Check Current Draw
378
Armature and Overrunning Clutch Assembly
378
Armature
379
Frame and Field
379
Testing Armature for Ground
379
Field Coil
380
Testing Field Coils for Open
380
Testing Shunt Coil for Open
380
Assemble Starter
380
Forcing Snap Ring Onto Armature Shaft
381
Forcing Retainer over
381
Pinion Clearance Check
381
Charging Circuit
382
Generator
382
Circuit for Checking Pinion Clearance
382
Measuring Pinion Clearance
382
Check in Car
383
Rotor
383
Drive End Frame Bearing
384
Stator
384
Slip Ring End Frame Generator
385
Checking Stator
385
Check for Grounded Brush Lead Clip C.S. I. Generator
385
Rectifier Bridge-C.s.I. Generator
386
Voltage Regulator
387
Slip Ring End Frame Bearing and Seal
387
Diodes - Standard Generator
388
Ohmmeter Method
388
Heat Sink Diodes
388
End Frame Diodes
388
Removing Diodes
389
Installing Diodes
389
Assemble Generator
390
Standard and Transistor Voltage Regulators
390
Ignition Circuit
390
Replacing Contact Set
390
Checks and Adjustments off Vehicle
391
Exploded View of 6-Cylinder Distributor
391
Adjusting Dwell Angle
392
Replace Contact Set
393
Arrangement of Leads
393
Exploded View of V-8 Distributor
394
Ignition Timing
395
Rotor in No. 1 Firing Position
395
Ignition and Starting Switch
396
Timing Marks on V-8 Engine
396
Ignition Switch
397
Replace Switch, Lock Cylinder or Free up Lock Cylinder
398
Measuring Spark Plug Gap
398
Spark Plugs
398
Spark Plug Cleaner and Indicator
398
Engine Electrical Specifications
400
Distributor Specifications
401
Clutch, Manual Transmissions
402
Clutch Pedal Adjustment
402
Clutch Usage
402
Clutch Control Linkage
403
Clutch
403
Pontiac Clutch Controls
403
Tempest and Grand Prix Clutch Controls
404
Firebird Clutch Controls
405
Flywheel or Clutch Pilot Bearing
406
Exploded View of Clutch and Flywheel
406
Starter Ring Gear
407
Clutch Pilot Bearing Staked
407
Three-Speed Dearborn Manual Transmission
408
Transmission
408
Column Shift and Back Drive Linkage
408
Floor Shift and Back Drive Linkage
408
Extension Housing Bushing and Oil Seal
409
Input Shaft Seal
409
Pontiac Column Shift Controls
410
Tempest and Grand Prix Floor Shift Controls
410
Firebird Floor Shift Controls
411
Tempest and Grand Prix Back Drive Linkage
411
Firebird Back Drive Linkage
412
Exploded View of Transmission
413
Shift Lever Shaft or Seal Replacement
414
Input Shaft Bearing Replacement
414
Remov~Ng Countershaft Retaining Pin
414
Rotating Second and Third Shift Rail
414
Removing Countershaft
415
Removing Reverse Idler Gear Shaft
415
Removing Rear Bearing
415
Pressing Input Shaft out of Bearing
415
Installing Input Shaft Bearing
416
Exploded View of Second Ana Third Synchronizer
416
Exploded View of Mainshaft
417
Removing Reverse Synchronizer Hub and Sliding Gear
417
Exploded View of First and Reverse Synchronizer
418
Synchronizer Insert Spring Installation
418
Installing Reverse Synchronizer Hub
418
Exploded View of Reverse Idler
419
Input Shaft Roller Bearing Installation
419
Exploded View of Countergear
419
Detent Pin Installer
419
Installing Rear Bearing
420
Transmission Identification
421
Three-Speed Saginaw Manual Transmission
422
Tempest Column Shift Controls
423
Extension Housing Seal
424
Extension Housing Seal and Bushing
424
Transmission Side Cover
425
Tempest Floor Shift Controls
425
Tempest Back Drive Linkage
427
Installing Extension Housing'seal
428
Removing Extension Housing Bushing
428
Installing Extension Housing Bushing
429
Exploded View of Transmission Side Cover
429
Removing Front Bearing
429
Removing Reverse Idler Gear Snap Ring
429
Removing Mainshaft
430
Removing or Installing Countergear
430
Expanding Extension Housing Snap Ring
430
Mainshaft, Countergear and Reverse Idler Gear Details
431
Synchronizer Assembly
432
Loading Bearings into Countergear
432
Installing Front Bearing Retainer Oil Seal
433
Loading Bearings into Main Drive Gear
434
Drive Line Damper
434
Firebird Driveline Damper
435
Four-Speed Saginaw Manual Transmission
437
Side Cover Assembly
439
Side View of Transmission
440
Four-Speed Muncie Manual Transmission
446
Speedometer Driven Gear
447
Firebird Shift Controls
448
Removing Extension Oil Seal
450
Removing and Installing Side Covir
450
Installing Extension Oil Seal
450
Removing Countershaft with J 22379
453
Pressing Mainshaft from First and Second Speed Gears
454
Installing Reverse Shifter Shaft and Detent Ball
454
Removing or Installing Extension Case Bushing
454
Reverse Shifter Shaft and Seal
455
Extension Case Bushing and Oil Seal
455
Clutch Keys and Springs
455
Installing Rear Bearing Retainer
456
Checking Countergear End Play
457
Installing Mainshaft Assembly
457
Installing Extension to Case
458
Transmission Identifications
459
Turbo Hydra-Matic ( M-40 ) Transmission
461
Towing
462
Periodic Service Recommendations
462
Transmission Serial Number
462
Transmission Fluid
462
Adjustments with Transmission in C a
462
Shift Control and Back Drive Linkage
462
Neutralizer Switch Adjustment
464
Vehicle Identification Number on Transmission Case
464
Column Shift Controls
464
Minor Service and Repair
464
Fluid Capacity, Draining and Refilling Capacity
466
Draining and Refilling Transmission
466
Pressure Regulator Valve
467
Control Valve Body
467
Console Shift Controls
468
Removing Pressure Regulator Valve
468
Governor
469
Modulator and Modulator Valve
469
Parking Linkage
469
Rear Seal
469
Removal of Transmission
469
Transmission Disassembly and Reassembly
470
Removal of Converter and Modulator
470
Removal of Control Valve Assembly
471
Band Apply Pin Selection
472
Checking Rear Band Pin
473
Removing Detent Solenoid and Gasket
473
Location of Check Balls
473
Removal of Rear Oil Seal and Extension
473
Housing
473
Front End Play Checking Procedure
473
Location of Case Extension Gasket
474
Removing Rear Oil Seal from Case Extension
474
Checking Front Unit End Play
474
Removal of Oil Pump
475
Removing Front Seal
475
Removing Pump Assembly
475
Removing Direct Clutch Assembly
475
Rear End Play Checking Procedure
476
Removing Parking Bracket
476
Removing Parking Pawl Return Spring
476
Removing Parking Shaft Retaining Spring
477
Removing Parking Pawl Shaft Cup Plug
477
Removing Front Band
477
Removing Sun Gear Shaft
478
Removing Center Support Bolt
478
Checking Rear Unit End Play
478
Removing Center Support to Case Snap Ring
478
Disassembly of Gear Unit
479
Removing Selective Washer
479
Removing Rear Band
479
Removing Center Support Assembly
479
Removing Center Support Thrust Washer
480
Removing Sun Gear
480
Removing Output Shaft to Carrier Snap Ring
480
Removing Retaining Clip
481
Installing Speedometer Drive Gear
481
Installing Retaining Clip
481
Removing Speedometer Drive Gear
481
Governor Assembly
481
Disassembly of Governor
482
Inspection of Governor
482
Removing Rear Internal Gear to Mainshaft Snap Ring
482
Exploded View of Governor
482
Governor Driven Gear Replacement
483
Checking Exhaust Port Opening
483
Checking Feed Port Opening
483
Removing Governor Gear Retaining Pin
483
Front Servo
484
Assembly of Governor
484
Inspection of Rear Servo
484
Exploded View of Front Servo
484
Disassembly of Rear Servo
484
Control Valve Assembly
485
Assembly of Rear Servo
485
Disassembly of Control Valve Assembly
485
Removing Retaining E-Ring from Rear Servo Pin
485
Assembly of R E a R Servo 7 ~ - 2
485
Inspection of Control Valve
486
Assembly of Control Valve
486
Installing Compressor Tool to Front Accumulator Piston
486
Removing Front Accumulator Piston and Spring
486
Exploded View of Control Valve
487
Removing Governor Feed Line Screen
487
Installing Detent Regulator and Valve
487
Disassembly of Oil Pump
488
Inspection of Pump Body and Cover
488
Removing Pump Regulator Valve Snap Ring
488
Exploded View of Pump Cover
488
Removing and Installing Pump Drive Gear
489
Pump Body Oil Passages
489
Checking Pump Body Face to Gear Face Clearance
489
Assembly of Oil Pump
490
Pump Cover Oil Passages
490
Installing Pump Cover to Pump Body
490
Removing Forward Clutch Housing to Direct Clutch Hub Snap Ring
490
Forward Clutch
491
Disassembly of Forward Clutch
491
Removing Forward Clutch Hub and Thrust Washers
491
Inspection of Forward Clutch
491
Assembly of Forward Clutch
492
Removing and Installing Forward Clutch Piston Outer Seal
492
Removing and Installing Forward Clutch Center Seal
492
Exploded View of Forward Clutch
492
Installing Forward Clutch Piston
493
Clutch Plate Identification
493
Installing Forward Clutch Composition and Steel Plates
493
Direct Clutch and Intermediate Sprag
494
Disassembly of Direct Clutch and Intermediate Sprag
494
Installing Forward Clutch Housing to Direct Clutch Hub Snap Ring
494
Removing Intermediate Clutch Retainer Snap Ring
494
Assembly of Direct Clutch and Intermediate Sprag
495
Removing Direct Clutch Piston Snap Ring
495
Removing Direct Clutch Piston
495
Inspection of Direct Clutch and . . . . . . . . . . . . . Intermediate Sprag Assembly of Direct Clutch and
495
Exploded View of Direct Clutch and Intermediate Sprag
496
Exploded View of Direct Clutch
496
Installing Direct Clutch Piston Inner Seal
496
Installing Direct Clutch Piston Outer Seal
497
Installing Direct Clutch Piston
497
Installing Direct Clutch Center Seal
497
Identifications of Clutch Pistons
497
Case Center Support
498
Disassembly of Center Support
498
Correct Sprag Clutch Rotation
498
Inspection of Center Support
499
Air Checking Direct Clutch
499
Exploded View O F Center Support
499
Inspection of Reaction Carrier
500
Installing Intermediate Clutch Inner Seal
500
Installing Intermediate Clutch Piston
500
Assembly of Center Support 7 ~ 1 4
500
Pinion Replacement Procedure
501
Checking Output Carrier Pinion End Play
501
Checking Reaction Carrier Pinion End Play
501
Removing Planet Pinion Pin
501
Inspection of Major Units
502
Output Shaft
502
Rear Internal Gear
502
D. Sun Gear Shaft
502
Case Extension
503
Modulator and Valve
503
Checking Concentricity O F Sleeve
503
F. Front and Rear Bands
503
Manual and Parking Linkage
504
Comparison Gauge
504
Modulator Bellows Good
504
Bringing Modulators Together
504
Case Passage Identification
505
J. Case Assembly
505
K Converter
505
Assembly of Rear Unit
506
Air Checking Converter
506
Installing Tool J 21371.3
506
Installing Tool J 21371-2
506
Exploded View of Rear Unit
507
Installing Rear Internal Gear to Main Shaft Snap Ring
507
Installing Rear Internal Gear to Sun Gear Bearing and Races
507
Installing Output Shaft
508
Installing Front Internal Gear Ring to Output Carrier
508
Installing Reaction Carrier
509
Installing Roller in Roller Clutch
509
Installing Center Support to Sun Gear Thrust Bearing and Races
509
Assembly of R E a R Unit
509
Assembly of Units into Transmission
509
Installing Roller Clutch
510
Installing Center Support T O Reaction Carrier Thrust Washer
510
Installing Case T O Output Shaft Thrust Washer
510
Installing Parking Shaft Retaining Spring
511
Installing Parking Pawl Return Spring
511
Installing New Cup Plug
511
Installing Rear Band
511
Installing Center Support and Gear Unit
512
Installing Center Support Bolt
512
Installing Center Support to Case Snap
512
Ring
512
Installing Manual Shaft to Case
513
Installing Front Band
513
Installing Detent Lever and Jam Nut to Manual Shaft
513
Installing Direct Clutch Assembly
514
Installing Forward Clutch and Turbine Shaft
514
Installing Pump Seal
514
Rear Extension Housing Assembly
515
Installing Rear Extension Seal
515
Installation of Check Balls, Front Servo
515
Installing Detent Solenoid and Gasket
516
Installation of Control Valve Assembly and Governor Pipes
516
Installation of Strainer and Intake Pipe
517
Installation of Modulator Valve and Vacuum Modulator
517
Installing Rear Accumulator Spring
517
Installing Rear Servo Cover and Gasket
517
Installation of Governor
518
Installation of Speedometer Driven Gear
518
Installation of Converter Assembly
518
Installation of Transmission Assembly
519
Manual Linkage
519
Shift Pattern Check
519
Turbo Hydra-Matic Transmission Oil P R E S S U R E Checks
519
Oil Pressure Check
520
Possible Points of Oil Leaks
521
Transmission Oil Pan Leak
521
Rear Extension Leak
521
Case Leak
521
Two-Speed Automatic Transmission
525
Vacuum Modulator
532
Speedometer Driven Gear and Sleeve
532
Downshift Solenoid Replacement
533
Installing Governor Driven Gear
533
Right Side of Transmission
533
Valve Body
534
Removing Vacuum Modulator
534
Speedometer Driven Gear Assembly
534
Removing Oil Strainer Assembly
534
Disengaging Manual Control Valve Link
535
Removing Shift Control Valve Sleeve
535
Downshift Solenoid and Detent Valve
535
Modulator Limit Valve
535
Transmission Removal
536
Shift Valve and Shift Control Valve
536
Transmission Disassembly
537
Transmission Mounted in Holding Fixture
537
Removing Oil Pump
537
Removing Input Shaft
538
Removing Low Servo Cover Snap Ring
538
Removing Forward Clutch Assembly
538
Inspection and Overhaul of Individual Components
539
Removing Planet Carrier Assembly
539
Removing Reverse Ring Gear
539
Removing Reverse Clutch Pack Snap Ring
539
Compressing Reverse Piston Return Springs
540
Removing Parking Lock Bracket
540
Reverse Piston Apply Port
540
Removing Range Selector Shaft Retainer
540
Reverse Clutch and Piston
541
Removing Range Selector Shaft Nut
541
Removing Case Bushing
541
Removing Parking Lock Pawl Shaft
541
Removing Manual Shaft Oil Seal
542
Removing Low Sun Gear and Flange Assembly Snap Ring
542
Park Lock Actuator and Range Selector Lever
542
Removing Low Sun Gear and Flange Assembly
542
Clutch Drum Bushing Replacement
543
Removing Clutch Hub Rear Thrust Washer
543
Removing Clutch Hub Front Thrust Washer
543
Removing Clutch Hub
543
Low Sun Gear Bushing Replacement
544
Removing Clutch Drum Bushing
544
Removing Low Sun Gear Bushing
544
Installing Clutch Drum Bushing
544
Planet Carrier
545
Installing Clutch Piston Inner Oil Seal
545
Installing Clutch Hub Front Thrust Washer
545
Installing Spring Retainer
545
Installing Clutch Hub Rear Thrust Washer
546
Removing Lock Plate Screws
546
Checking Planet Pinion End Clearance
546
Removing Low Sun Gear Needle Thrust Bearing
546
Output Shaft Bushing Replacement
547
Removing Input Sun Gear
547
Removing Output Shaft Bushing
547
Input Sun Gear Thrust Washer
547
Low Servo Assembly
548
Long Pinion Rear Thrust Washer
548
Installing Long Pinion Front Thrust Washer
548
Installing Low Sun Gear Needle Thrust Bearing
549
Compressing Low Servo
549
Removing Oil Seal Rings
549
Removing Timing Valve
550
Converter Blow off Valve
550
Removing Boost Valve Sleeve Snap Ring
550
Stator Shaft Bushing Replacement
551
Pressure Regulator Assembly
551
Removing Pump Body Bushing
551
Removing Oil Pump Oil Seal
551
Converter Leak Test
552
Converter End Play Check
552
Transmission Reassembly
552
Installing Oil Pump Oil Seal
552
Installation of Range Selector Lever, Shaft and Parking Lock Actuator
553
Checking Converter End Clearance
553
Installing Parking Lock Pawl Shaft
553
Installation of Reverse Piston and Clutch
554
Installing Parking Lock Bracket
554
Installing Range Selector Shaft Retainer
554
Reverse Clutch Cushion Ring
554
Installation of Planetary Gear Set
555
Installation of Low Servo Assembly, Low Band and Forward Clutch
555
Installing Reverse Clutch Pack
555
Installing Reverse Clutch Pressure Plate
555
Determination of Selective Thrust Washer Thickness
556
Installing Low Servo Cover Snap Ring
556
Installing Low Band
556
Low Band Struts Installed
556
Installing Forward Clutch
557
Installing Input Shaft into Pump
557
Selective Thrust Washer Chart
557
Installation of Oil Pump
558
Installation of Speedometer Drive Gear
558
Installing Thrust Washer
558
Installing Oil Seal Rings
558
Installation of Converter
559
Maximum Line Pressure
559
Driveline Damper
559
External Oil Leaks
560
Oil Passages in Pump Body
560
Oil Passages in Pump Cover
561
Oil Passages in Bottom of Transmission Case
561
Oil Passages in Front of Transmission Case
561
Oil Passages in Valve Body
561
Case Porosity Repair
562
Special Tools
564
Column Shift Controls - Tempest
567
Fluid Level
570
Fluid Capacity
570
Adding Fluid to Fill Dry Transmission and Converter Assembly
571
Valve Body Assembly
571
Governor Assembly
571
Intermediate Clutch Accumulator Piston Assembly
572
Vacuum Modulator and Modulator Valve Assembly
572
Extension Housing Oil Seal
572
Removal of Transmission Assembly
573
TRANSM Isslon DISASSEMBLY
573
Removal of Extension Housing, Speed0 Drive Gear and Governor
574
Removal of Valve Body Assembly
574
Removing Valve Body Assembly
575
Removing Spacer Support Plate
575
Removal of Oil Pump and Internal Components
576
Removing Governor Feed Screen
576
Removing Inner Lever and Actuating Rod
576
Removing Manual Shaft Retainer
576
Removing Parking Pawl Shaft
577
Removing Oil Pump Attaching Bolts
577
Intermediate Servo Piston Assembly
577
Removing Intermediate Clutch Plates
577
Removing Forward and Direct Clutch Assemblies
578
Removing Output Carrier Assembly
578
Removing Input Ring Gear
578
Removing Sun Gear Drive Shell Assembly
578
Removing Low and Reverse Clutch Support Retaining Ring
579
Removing Clutch Support Retainer Spring
579
Location of Clutch Support Retainer Spring
579
Removing Reaction Carrier Assembly
579
Overhaul And/Or Inspection
580
Removing Output Ring Gear Needle Bearing
580
Compressing Low and Reverse Clutch Piston Assembly
580
Output Ring Gear and Output Shaft Assembly
580
Compressing Intermediate Clutch Accumulator Piston Cover
581
Removing Accumulator Piston Assembly
581
Removing Accumulator Cover and Spring
581
Checking Governor Feed Port Opening
582
Exploded View of Valve Body Assembly
583
Compressing Direct Clutch Accumulator Piston
583
Oil Pump Assembly
585
Removing Pump Attaching Bolts
585
Removing Oil Seal Rings and Selective Thrust Washer
585
Removing Drive and Driven Gears
585
Removing Cooler By-Pass Valve Seat
586
Removing Priming Valve and Spring
586
Removing Oil Pump Body Oil Seal
586
Exploded View of Oil Pump Assembly
587
Pump Cover(Case Face) Oil Passages
587
Stator Shaft Front Bushing
588
Stator Shaft Rear Bushings
588
Installing Stator Shaft Front Bushing
588
Installing Stator Shaft Rear Bushings
588
Installing Oil Pump Body Oil Seal
589
Installing Seals in Intermediate Clutch Piston
589
Installing New Cooler By-Pass Valve Seat
589
Removing Intermediate Overrun Clutch Retainer
589
Removing Intermediate Overrun Roller Clutch Assembly
590
Removing Retaining Ring and Pressure Plate
590
Removing Direct Clutch-To-Forward Clutch Thrust Bearing
590
Identification of Direct Clutch Piston
590
Direct Clutch Assembly
591
Removing Direct Clutch Piston Inner and Outer Seals
591
Removing Direct Clutch Piston Center Seal
591
Direct Clutch Bushing
592
Forward Clutch Assembly
593
Exploded View O F Direct Clutch Assembly
593
Removing Direct Clutch Drum Bushing
593
Installing Direct Clutch Drum Bushing
594
Removing Forward Clutch Retaining R'ing and Pressure Plate
594
Installing Direct Clutch Piston Assembly
594
Removing Forward Clutch Plates
594
Removing Spring Seat and Return Springs
595
Clutch Piston Inner and Outer Seals
595
Exploded View of Forward Clutch Assembly
595
Forward Clutch Drum Ball Check
596
Checking Free Back Height
596
Installing Forward Clutch Piston Assembly
596
Forward Clutch Pressure Plate Identification
596
Sun Gear and Sun Gear Drive Shell Assembly
597
Removing Retaining Ring from Rear of Sun Gear Drive Shell
597
Removing Sun Gear from Sun Gear Drive Shell
597
Removing Rear Flat Thrust Washer
597
Low and Reverse Roller Clutch Support Assembly
598
Sun Gear Bushings
598
Exploded View of Low and Reverse Roller Clutch and Support Assembly
598
Input Ring Gear
599
Output Carrier Assembly
599
Reaction Carrier Assembly
599
Removing or Installing Input Ring Gear Bushing
599
Transmission Case
600
Installing Output Shaft Bushing
600
Case Passage Identification - Front View
600
Extension Housing
601
Case Passage Identification - Bottom View
601
Installing Case Bushing
601
Removing or Installing Extension Housing Bushing
601
Intermediate Overrun Brake Band
602
Vacuum Modulator Assembly
602
Vacuum Modulator Seams and Seal
602
Cross Section of Vacuum Modulator
602
Converter Assembly
603
Comparison Gage
603
Installing Tool J 21371-3
604
Checking Converter End Play
604
Installation of Internal Components and Oil Pump
605
Exploded View of Intermediate Clutch Accumulator
605
Low and Reverse Clutch Piston and Springs in Case
605
Installing Reaction Carrier into Case
606
Installing Low and Reverse Clutch ~ G C K
606
Selecting Proper Band Apply Pin
608
Checking for Proper Band Apply Pin
608
Installation of Parking Linkage, Valve Body and Oil Pan
609
Exploded View of Intermediate Servo Assembly
609
Installing Parking Pawl Disengaging Spring
609
Installation of Governor, Speed0 Drive Gear and Extension Housing
610
Installing Valve Body Assembly
610
Installation of Modulator and Converter
611
Installing Converter Assembly
611
Road Test
612
Shift Point Information
612
Transmission Oil Pressure Checks
613
Determining Source of Oil Leak
614
Fuel Tank and Exhaust System
618
Fuel Tank Drain Hose
618
Fuel Tank Drain
618
Fuel Tank Gage Unit
619
Vent Hose Routing
620
Fuel Tank Gage Unit (Station Wagon)
621
Fuel Lines
621
Tank Gage Unit Tool J 23346
621
Installation of Fuel Tank Pontiac Station Wagon
622
Installation of Fuel Tank Tempest Station Wagon
623
Installation of Fuel Tank
624
Pontiac Fuel Gage Wiring
624
Tempest Fuel Gage Wiring
625
Fuel Gage Wiring
625
Tempest 6-Cylinder Engine Exhaust System
627
Firebird Muffler and Tail Pipe Installation
628
Firebird 6-Cylinder Engine Exhaust System
629
Tempest V-8 Engine Single Exhaust System
630
Firebird V-8 Engine Single or Dual Exhaust System
632
Tempest and Grand Prix Dual Exhaust System
633
Fuel Tank Capacity
639
Steering
640
Exploded View of Steering Wheel and Horn
641
Steering Wheel
642
Turn Signal Switch
642
Locating Steering Wheel Position
642
Removing Snap Ring and Lock Plate
642
Lock Cylinder
643
Connector and Wires with Tape
643
Removing Wire Protector from Turn Signal Harness
643
Removing Turn Signal Switch
643
Removing Buzzer Switch
645
Installing Buzzer Switch
645
Steering Column
645
Installing Steering Shaft to Flexible Coupling
646
Exploded View of Typical Regular Column
647
Steering Column (Non-Tilting)
648
Disassemble Upper End
648
Exploded View of Typical Tilt Column
649
Mounting Bracket Assembly
650
Mounting Column in Vise by Welded Tapping Nuts
650
Removing Upper Bearing Housing
651
Removing or Installing Rack and Lock Bolt
651
Removing or Installing Thrust Cup
651
Removing or Installing Rack Load Spring
651
Assemble Lower End
652
Removing or Installing Shift Gate
652
Removing Back-Up Light or Neutral Start Switch
652
Removing Sector
652
Removing Bearing Adapter and Shift Tube Spring
653
Removing Lower Shift Tdbe Support Screws Manual Transmission
653
Removing or Installing Wave Washer and Lower Shift Bowl Bearing
653
Assemble Upper End
654
Adjusting Lower Shift Lever Clearance
654
Bolt and Rack Assembled
654
Installing Sector
654
Tilt Steering Column
655
Removing or Installing Tilt Spring Retainer
655
Removing.pivot Pin
655
Disassemble Bearing Housing
656
Upper Shift Lever Spring
656
Installation of Shift Tube Remover J 23072
656
Removing or Installing Lock Bolt Spring
657
Removing Tilt Release Lever Pin
657
Assemble Column
657
Installing Lock Bolt to Sector
658
Installation of Shift Tube Installer
658
Pot Joint (Lower Steering Shaft)
659
Universal Joint
659
Steering Linkage
660
Steering Gear
664
Checking Steering Gear Adjustment
664
Overcenter or Pitman Shaft Adjustment
664
View of Manual Steering Gear
665
Pitman Shaft Bushing
665
Pitman Shaft Seal
666
Upper or Lower Bearing Cups
666
Removing Pitman Shaft Bushing
666
Ball Nut Properly Installed on Shaft
666
Adjusting Worm Bearing Preload
667
Position of Pitman Shaft and Ball Nut
667
Pitman Shaft Seals
669
Housing Lower End Plug and Rack-Piston Nut End Plug
670
Rack-Piston Nut
670
Adjuster Plug Assembly, Rotary Valve with Worm Shaft and Pin Assembly
670
Pitman Shaft Gear and Side Cover
671
Removing Adjuster Plug Assembly
671
Adjuster Plug and O.ring Removal
671
Tapping to Loosen Valve Spool
671
Rotary Valve
672
Removing Valve Spool from Rotary Valve
672
Exploded View of Rotary Valve
672
Adjuster Plug
673
Removing Pitman Shaft Needle Bearing
673
Gear Housing
674
Rack-Piston Nut and Worm
674
Pitman Shaft Seals And'washers
677
Check Worm Preload
678
Loading Rack Piston Nut
678
Ball Return Guide
678
Worm Shaft, Rotary Valve Assembly and Adjuster Plug
679
Adjust Worm Bearing Preload
679
Rack-Piston
680
Installing Rack Piston Nut
680
Installing End Plug Retainer Ring
680
Flexible Coupling
681
Power Steering Pump
681
Adjusting Pitman Shaft Preload
681
Pontiac Installation of Power Steering Assembly
682
Tempest Installation of Power Steering Gear Assembly
683
Grand Prix Installation of Power Steering Gear Assembly
684
Firebird Installation of Power Steering Gear Assembly
685
Flow Control Valve
686
Removing Retaining Ring
686
Pump
686
Removing End Plate
687
Removing Flow Control Valve
687
Removing Pressure Plate
687
Pressure Plate and Rotor Ring Removed
688
Removing Pump Shaft
688
Exploded View of Power Stciering Pump
688
Installing Pump Shaft
689
Thrust Plate Installed
689
Installing Rotor
689
Installing Pump Vanes
689
Pump Vanes Installed
690
Installing End Plate
690
Installing Pressure Plate Spring
690
Cooler Pipe - Pontiac and Grand Prix
691
Installation of Power Steering Pump for V-8
691
Special Tools for Steering Columns and Steering Gears
693
Wheels and Tires
695
Recommended Tire Inflation Pressures
695
Test for Leaks
696
Remove Tire from Wheel
696
Wheel Stud
696
Puncture Repairs
696
Preparation of Tire
697
Preparation of Rim
697
Inspection before Balancing Wheels and Tires
697
Radial Runout Inspection
697
Balance Procedure
698
Piontiac Wheel Codes
698
Tempest Wheel Codes
698
GRAND Prlx WHEEL CODES
698
Tire Usage Chart
699
Firebird Wheel Codes
699
Chassis Sheet Metal
700
Hood
700
Hood Attachment Typical
700
Hood Hinge
701
Fenders
705
Front Inner Fender
705
Pontiac Front Fenders
707
Chassis Electrical Service
715
Battery Cable
715
Fusible Link
715
Pontiac Engnie Compartmerrt Wiring
716
Pontiac Passenger Compartment Wiring
717
Pontiac Passenger Cempartmemt Wiring
718
Pontiac Rear End Wiring
719
Tempest Engine Compartment Wiring
720
Tempest Passenger Compartment Wiring
721
Tempest Rear End Wiring
723
Firebird Engine Compartment Wiring
724
Firebird Passenger Compartment Wirinn
725
Firebird Rear End Wiring
727
Grand Prix Engine Compartment Wiring
728
Grand Prix Passenger Compartment Wiring
729
Grand Prix Rear End Wiring
731
Rally Gage Wiring
732
Pontiac Battery Cable Routing
733
Tempest and Grand Prix Battery,Cable Routing
734
Fuse Block and Bulkhead Connector
734
Engine Wire Harness
734
Firebird Battery Cable Routing
735
Typical V8 Engine Harness Installation
735
Front End Wiring Harness
736
Front Park and Signal Lamps
736
Seal Beam
736
Typical 6-Cylinder Engine Harness Installation
736
G.t.o. and Firebird
737
Horns
737
Fuse Block and Bulkhead Connector Identification
737
Typical Front End Harness Installation
738
Headlight Aiming Chart
738
Horn Relay Buzzer Alarm
739
Side Marker Lamps
739
Pontiac Instrument Panel Installation
739
Brake Warning Light Switch
739
Tempest and Grand Prix Instrument Panel Installation
741
Firebird Instrument Panel Installation
741
Printed Circuit
742
Speedometer Cable Attachment
742
Speedometer Cable Routing
742
Windshield Wiper Switch
745
Headlight Switch
745
Cigar Lighter
745
Dimmer Switch
746
Back up Lamp & Neutralizer Switch
746
Clutch Start Switch
747
Instrument Panel Harness
747
Accessory Schematics
747
Vacuum Operated Headlamps
747
Power Servo Remove and Replace
748
Vacuum Operated Headlamp Doors-GTO
752
Vacuum Operated Headlamp Door Schematic
753
Windshield Wipers and Washers
754
Arm Blade Assembly
754
Wiper Blade
754
Wiper Transmission and Linkage
754
Arm and Blade
758
Tempest and Grand Pfix Depressed Park System
758
Tempest Standard System and Firebird
758
Firebird Wiper Motor Arm and Blade Installation
758
Wiper Motor
759
Wiper Switch
759
Brush Plate and Circuit Breaker
759
Depressed Park Gear Box
760
Relay-Switch Latch and Terminal Board
761
Drive Gear
761
Depressed Park System
761
Position of Resistor Lead
761
Wiper Motor Armature End-Play
763
Wiper Motor Gear End-Plry
763
Wiper Motor Gear Box
763
Rectangular Wiper Motor Section
764
Wiper Motor Lubrication
764
Rectangular Motor
764
Gear Box
764
Depressed Park Motor
765
Windshield Washer Pump Overhaul
765
Four-Lobe Cam
765
Ratchet Pawl and Pawl Spring
765
Brush Spring Rectangular Motor
766
Exploded View Pump Assembly-Recess Park
766
Rectangular Motor Washer Pump
767
Solenoid Assembly
767
Ratchet Pawl
767
Ratchet Wheel
767
Valve Assembly
768
Radiator Support and Mounting Parts
769
Pontiac Support and Baffle Assembly
770
Lower Cradle Bracket and Insulator Tempest 6 Cylinder Only
772
Firebird Support and Baffle Assembly
772
Front and Rear Bumpers
773
Bumper Adjustment
773
Remove Pontiac Bumper
773
Remove Grand Prix Bumper (
773
Replace Bumpers
778
Rear Bumpers
778
Remove Pontiac Rear Bumper
778
Remove Tempest Rear Bumper
778
Remove Fireboard Rear Bumper
779
Polyurethane and Lexan Parts
779
Refinishing Polyurethane and Lexan Parts
787
Pontiac Bonneville Grille
788
Pontiac Catalina and Executive Grille
788
Grand Prix Grille
789
Tempest Grille
790
Firebird Grille
790
Accessories
792
Adjustment Procedures
792
Chain Linkage Adjustment
792
Brake Release Switch Adjustment
792
Cruise Control Installation
793
Electrical Wiring and Vacuum Switch
795
Checking for Damaged Cables and Gears
797
Exploded View of Regulator
797
Minor Service
797
Major Service
797
Cover and Intake Filter Assembly
798
Adjusting Low Speed Switch
798
Valve Body and Magnet Assy.
799
Electric Clock
800
Safeguard Speedometer
800
Clock Installation
800
Rally Gages
801
Hood Mounted Tachometer
803
Vacuum Tire Pump
806
Rear Wheel Opening Cover
807
Accessory Switch Cutouts
807
Rear Window Defogger
808
Heated Rear Window
809
Heated Rear Window with Custom Air Conditioning
810
Heated Rear Window with Automatic Temperature Control A/C
810
Cornering Lamps
811
Underhood Lamp
812
Luggage Lamp
814
Console
815
Radio and Front Speaker
819
Radio Receiver and Front Speaker
819
Radio Suppression Equipment
821
Manual Antenna
823
Power Antenna
824
Overhaul Antenna
827
To Replace Support Tube
827
If Replacement of Drive or Mast Is Indicated
827
Rear Seat Speaker
828
FM Stereo Radio
832
Index
842
Specifications
843
Cyl Engine
843
Lubrication
845
Clutch
845
Cyl.engine
845
Engine
845
Decimal Equivalents
845
Cyl
845
Generator
845

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