1992 pontiac firebird service repair manual
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About This Presentation
This is the Highly Detailed factory service repair manual for the1992 PONTIAC FIREBIRD, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mecha...
Slide Content
1988
SER
This manual applies to the 1988 Pontiac Firebird Models.
It contains the latest product information available at the
time of publication approval. lnformation pertaining to
the operation of the vehicle is contained in the Owner's
Manual which accompanies each vehicle. The right is
reserved to make changes at any time without notice.
Any references to brand names in this manual is intended
merely as an example of the types of lubricant% tools,
materials, etc, recommended for use in servicing 1988
Pontiac Models. In all cases, an equivalent may be used.
PONTIAC DIVISION
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
48053
1987 General Motors Corp. All Rights Reserved.
No part of this publication may be reproduced, stored in any
retrieval system or transmitted in any form or by any means,
including but not limited to electronic, mechanical,
photocopying, recording or otherwise, without the prior written
permission of General Motors Corp. This includes all text,
illustrations, tables and charts.
S-881 OF 9-87 Printed in Canada
TABLE OF CONTENTS
SECTION NAME
GENERAL INFORMATION
OA. General lnformation
OB. Maintenance
& Lubrication
1 SECT.
HEATING AND AIR CONDITIONING
1A. Heating and Ventilation
1 B. Air Conditioning
1D1. R-4 AIC Com~ressor Overhaul
FRAME AND BUMPERS
2B. Bumpers
2C. Chassis Sheet Metal
STEERING, SUSPENSION, WHEELS
AND TIRES
3. Diagnosis
3A. Wheel Alignment
3B5. Steering Wheels and Columns
3B6. Steering Linkage
3B7. Power Steering Gear and Pump
3C. Front Suspension
3D. Rear Suspension
3E. Tires and Wheels
FINAL DRIVE
4A. Propeller Shaft
4B. Rear Axle
4B1. Bora-Warner Axle
BRAKES
5. Brakes
5A3. Comoosite Master Cvlinder
5B1. Disc r rake Caliper ~ssembly -
300013100 Series
5B6. Disc Brake Caliper Assembly - 3548
Series
5C3. Direct Torque Drum Brake Assembly
5D2. Power Head Assembly - Tandem
Diaohraam
5F. ~~ecifications and Special Tools
ENGINE
6. Engine General lnformation
6A2. 2.8L
6A3. 5.OL & 5.7L
6B. Engine Cooling
6C. En~ine Fuel
6D. ~ngine Electrical
6D1. Battery
6D2. Cranking System
6D3. Charging System
6D4. Ignition System
6D5. Engine Wiring
6E. Driveabilitv and Emissions
6E2. ~missions'
6E3. Emissions - PFI
6F. Engine Exhaust
TRANSMISSION
7A. Automatic Transmission - General
lnformation 7A1. Automatic Transmission - On-Car
Service
700R4. Automatic Transmission
Hydraulic Diagnosis
700R4. Automatic Transmission
Unit Repair
76. 5-Speed Manual Transmission
7C. Clutch
CHASSIS ELECTRICAL
8A. Electrical Diagnosis
8B. Lighting and Horns
8C. Instrument Panel, Gages
& Console
8E. Windshield Wiper &Washer System
ACCESSORIES 9A. Radio Systems and Antennas
9B. Cruise Control
9G. Miscellaneous Accessories
I BODY SERVICE MANUAL
END OF
MANUAL
SER
This manual applies to the 1988 Pontiac Firebird Models.
It contains the latest product information available at the
time of publication approval. lnformation pertaining to
the operation of the vehicle is contained in the Owner's
Manual which accompanies each vehicle. The right is
reserved to make changes at any time without notice.
Any references to brand names in this manual is intended
merely as an example of the types of lubricant% tools,
materials, etc, recommended for use in servicing 1988
Pontiac Models. In all cases, an equivalent may be used.
PONTIAC DIVISION
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
48053
1987 General Motors Corp. All Rights Reserved.
No part of this publication may be reproduced, stored in any
retrieval system or transmitted in any form or by any means,
including but not limited to electronic, mechanical,
photocopying, recording or otherwise, without the prior written
permission of General Motors Corp. This includes all text,
illustrations, tables and charts.
S-881 OF 9-87 Printed in Canada
TABLE OF CONTENTS
SECTION NAME
GENERAL INFORMATION
OA. General lnformation
OB. Maintenance
& Lubrication
1 SECT.
HEATING AND AIR CONDITIONING
1A. Heating and Ventilation
1 B. Air Conditioning
1D1. R-4 AIC Com~ressor Overhaul
FRAME AND BUMPERS
2B. Bumpers
2C. Chassis Sheet Metal
STEERING, SUSPENSION, WHEELS
AND TIRES
3. Diagnosis
3A. Wheel Alignment
3B5. Steering Wheels and Columns
3B6. Steering Linkage
3B7. Power Steering Gear and Pump
3C. Front Suspension
3D. Rear Suspension
3E. Tires and Wheels
FINAL DRIVE
4A. Propeller Shaft
4B. Rear Axle
4B1. Bora-Warner Axle
BRAKES
5. Brakes
5A3. Comoosite Master Cvlinder
5B1. Disc r rake Caliper ~ssembly -
300013100 Series
5B6. Disc Brake Caliper Assembly - 3548
Series
5C3. Direct Torque Drum Brake Assembly
5D2. Power Head Assembly - Tandem
Diaohraam
5F. ~~ecifications and Special Tools
ENGINE
6. Engine General lnformation
6A2. 2.8L
6A3. 5.OL & 5.7L
6B. Engine Cooling
6C. En~ine Fuel
6D. ~ngine Electrical
6D1. Battery
6D2. Cranking System
6D3. Charging System
6D4. Ignition System
6D5. Engine Wiring
6E. Driveabilitv and Emissions
6E2. ~missions'
6E3. Emissions - PFI
6F. Engine Exhaust
TRANSMISSION
7A. Automatic Transmission - General
lnformation 7A1. Automatic Transmission - On-Car
Service
700R4. Automatic Transmission
Hydraulic Diagnosis
700R4. Automatic Transmission
Unit Repair
76. 5-Speed Manual Transmission
7C. Clutch
CHASSIS ELECTRICAL
8A. Electrical Diagnosis
8B. Lighting and Horns
8C. Instrument Panel, Gages
& Console
8E. Windshield Wiper &Washer System
ACCESSORIES 9A. Radio Systems and Antennas
9B. Cruise Control
9G. Miscellaneous Accessories
I BODY SERVICE MANUAL
END OF
MANUAL
CAUTION
To reduce the chance of personal injury and/or property damage,
the following instructions must be carefully observed:
Proper service and repair are important to the safety of the service
technician and the safe, reliable operation of all motor vehicles. If
part replacement is necessary, the part must be replaced with one
of the same part number or with an equivalent part. Do not use a
replacement part of lesser quality.
The service procedures recommended and described in this service
manual are effective methods of performing service and repair.
Some of these procedures require the use of tools specially design-
ed for the purpose.
Accordingly, anyone who intends to use a replacement part, ser-
vice procedure or tool, which
is not recommended by the vehicle
manufacturer, must first determine that neither his safety nor the
safe operation of the vehicle
will be jeopardized by the replace-
ment part, service procedure or tool selected.
It is important to note that this manual contains various 'Cautions'
and
'Notices' that must be carefully observed in order to reduce the
risk of personal injury during service or repair, or the possibility
that improper service or repair may damage the vehicle or render
it
unsafe. It is also important to understand that these 'Cautions' and
'Notices' are not exhaustive, because
it is impossible to warn of all
the possible hazardous consequences that might result from fail-
ure to follow these instructions.
To reduce the chance of personal injury and/or property damage,
the following instructions must be carefully observed:
Proper service and repair are important to the safety of the service
technician and the safe, reliable operation of all motor vehicles. If
part replacement is necessary, the part must be replaced with one
of the same part number or with an equivalent part. Do not use a
replacement part of lesser quality.
The service procedures recommended and described in this service
manual are effective methods of performing service and repair.
Some of these procedures require the use of tools specially design-
ed for the purpose.
Accordingly, anyone who intends to use a replacement part, ser-
vice procedure or tool, which
is not recommended by the vehicle
manufacturer, must first determine that neither his safety nor the
safe operation of the vehicle
will be jeopardized by the replace-
ment part, service procedure or tool selected.
It is important to note that this manual contains various 'Cautions'
and
'Notices' that must be carefully observed in order to reduce the
risk of personal injury during service or repair, or the possibility
that improper service or repair may damage the vehicle or render
it
unsafe. It is also important to understand that these 'Cautions' and
'Notices' are not exhaustive, because
it is impossible to warn of all
the possible hazardous consequences that might result from fail-
ure to follow these instructions.
GENERAL INFORMATION OA-1
SECTION (DA
GENERAL NFORMAT
CONTENTS
................................... General Description OA- 1 Prevailing Torque Fasteners ......................... OA-2
...................................... Body Number Plate OA- 1 Recommendations For Fastener Reuse ........ OA-2
..................... Vehicle Identification Number OA- 1 Vehicle Lifting Procedures ............ ., ............. OA-2
......................................... Metric Fasteners OA- 1 Precautions Against Tipping ........................ OA-7
................... Fastener Strength Identification OA-2 Automotive Abbreviations ................... .... 0.4- 1 1
GENERAL DESCRIPTION
Only general information appears in this section. left of the windshield, see Figure 2. Refer to Figure 3
Detailed specifications on major units are given at the for detailed "VIN" code information. For Engine V.I.
end of each respective section of this manual. N. Location, refer to Figure
4.
BODY NUMBER PLATE METRIC FASTENERS
The Body Number Plate (Fig. 1) is attached to
Pontiac models are primarily dimensioned in the
the front tie bar behind either the right or left headlamp
metric system, Most fasteners are metric and are very
in the engine On The close in dimension to well-known customary fasteners
Number Plate identifies numerous items as outlined in
in the inch system. It is most important that
Figure 1.
re~lacement fasteners be of the correct nominal
VEHICLE IDENTIFICATION NUMBER
d&meter, thread pitch and strength.
Original equipment metric fasteners (except
The Vehicle Identification Number (VIN) Plate "beauty" bolts, such as exposed bumper bolts, and
is located on top of the instrument panel at the lower cross recess head screws) are identified by a number
1 -- BODY STYLE
2 ASSEMBLY PUNT
3 -- UNIT NUMBER
4 -- PAINT TYPE
5 - ROOF OPTION
6 -- SEAT OPTION
7 - TRIM COMBINATION
8 - UPPER BODY
9 - UPPER COLOR
10 -- LOWER BODY
11 - REMAINING LINES
- AVAILABLE FOR
--PLANT USE
12 - LOWER COLOR
13 - MODEL YEAR
14 -- TIME BUILD CODE
15 - DIVISION
16 - BODY TvPE
6200224A
Fig. 1 Body Number Plate
SECTION (DA
GENERAL NFORMAT
CONTENTS
................................... General Description OA- 1 Prevailing Torque Fasteners ......................... OA-2
...................................... Body Number Plate OA- 1 Recommendations For Fastener Reuse ........ OA-2
..................... Vehicle Identification Number OA- 1 Vehicle Lifting Procedures ............ ., ............. OA-2
......................................... Metric Fasteners OA- 1 Precautions Against Tipping ........................ OA-7
................... Fastener Strength Identification OA-2 Automotive Abbreviations ................... .... 0.4- 1 1
GENERAL DESCRIPTION
Only general information appears in this section. left of the windshield, see Figure 2. Refer to Figure 3
Detailed specifications on major units are given at the for detailed "VIN" code information. For Engine V.I.
end of each respective section of this manual. N. Location, refer to Figure
4.
BODY NUMBER PLATE METRIC FASTENERS
The Body Number Plate (Fig. 1) is attached to
Pontiac models are primarily dimensioned in the
the front tie bar behind either the right or left headlamp
metric system, Most fasteners are metric and are very
in the engine On The close in dimension to well-known customary fasteners
Number Plate identifies numerous items as outlined in
in the inch system. It is most important that
Figure 1.
re~lacement fasteners be of the correct nominal
VEHICLE IDENTIFICATION NUMBER
d&meter, thread pitch and strength.
Original equipment metric fasteners (except
The Vehicle Identification Number (VIN) Plate "beauty" bolts, such as exposed bumper bolts, and
is located on top of the instrument panel at the lower cross recess head screws) are identified by a number
1 -- BODY STYLE
2 ASSEMBLY PUNT
3 -- UNIT NUMBER
4 -- PAINT TYPE
5 - ROOF OPTION
6 -- SEAT OPTION
7 - TRIM COMBINATION
8 - UPPER BODY
9 - UPPER COLOR
10 -- LOWER BODY
11 - REMAINING LINES
- AVAILABLE FOR
--PLANT USE
12 - LOWER COLOR
13 - MODEL YEAR
14 -- TIME BUILD CODE
15 - DIVISION
16 - BODY TvPE
6200224A
Fig. 1 Body Number Plate
OA-2 GENERAL INFORMATION
VIN NUMBER PLATE
LOCATION
Fig. 2 Vehicle Identification Number Plate Location
marking indicating the strength of the material in the
fastener as outlined below. Metric cross recess screws
are identified by a Posidriv or Type 1A cross recess as
shown in Figure 8. Either a Phillips head or Type 1A
cross recess screwdriver can be used in Posidriv recess
screw heads, but Type 1A cross recess screwdrivers
will perform better.
NOTICE: Most metric fasteners have a blue color
coating. However, this should not be used as a
positive way of identifying as some metric fasteners
are not color coated.
General Motors Engineering Standards, along
with other North American Industries, have adopted
a portion of the standard metric fastener sizes defined
by
IS0 (International Standards Organization). This
was done to reduce the number of fastener sizes used
and yet retain the best strength qualities in each thread
size. For example, the customary 1/4-20 and 1/4-28
screws are replaced by the metric M6.0 X 1 screw
which has nearly the same diameter and
25.4 threads
per inch. The thread pitch is in between the customary
coarse and fine thread pitches.
Metric and customary thread notation differ
slightly. The difference is shown in Figure 9.
FASTENER STRENGTH
ODENTIFIGATION
Most commonly used metric fastener strength
property classes are 9.8 and 10.9 with the class
identification embossed on the head of each bolt.
Customary (inch) strength classes range from grade 2
to 8 with radial line identification embossed on each
bolt head (i.e., grade 7 bolt will exhibit 5 embossed
radial lines on the bolt head). Some metric nuts will be
marked with single digit strength identification
numbers on the nut face. Figure 12 shows the different
strength markings.
When replacing metric fasteners, be careful to use
bolts and nuts of the same strength or greater than the
original fasteners (the same number marking or higher)
.It is also important to select replacement fasteners of
the correct size. Correct replacement bolts and nuts are
available through the parts division. Many metric
fasteners available in the after-market parts channels
were designed to metric standards of countries other
than the United States. These fasteners may be of a
lower strength, different thread pitch and may not have
the numbered head marking system. The metric
fasteners used on GM products are designed to new,
international standards that may not be used by some
nondomestic bolt and nut suppliers. In general, except
for special applications, the common sizes and pitches
are:
M 6.0
X 1 M 8 x 1.25
M 10 X 1.5 M 12 X 1.75
M 14x2 I
PREVAILING TORQUE FASTENERS
A prevailing torque nut is designed to develop an
interference between the nut and bolt threads. This is
most often accomplished by distortion of the top of an
all-metal nut or by using a nylon patch on the threads
in the middle of the hex flat.
A nylon insert may also
be used as a method of interference between nut and
bolt threads (Fig. 11).
A prevailing torque bolt is designed to develop an
interference between bolt and nut threads, or the
threads of a tapped hole. This is accomplished by
distorting some of the threads or by using a nylon patch
or adhesive (Fig. 11).
RECOMMENDATIONS FOR FASTENER REUSE:
I
Clean, unrusted prevailing torque nuts and bolts
may be reused as follows:
a. Clean dirt and other foreign material off nut
or bolt.
b. Inspect nut or bolt to insure there are no
cracks, elongation, or other signs of abuse
or overtightening. (If there is any doubt,
replace with a new prevailing torque
fastener of equal or greater strength.)
c. Lightly coat bolt & nut with engine oil.
Assemble parts and hand start nut or bolt.
d. Observe that before fastener seats, it
develops torque per the chart in Figure
10.
(If there is any doubt, replace with a new
prevailing torque fastener of equal or
greater strength.)
e. Tighten fastener to torque specified in
appropriate section of this manual.
Bolts and nuts which are rusty or damaged
should be replaced with new parts of equal or
greater strength.
VEHICLE LIF"TING PROCEDURES
NOTICE: When jacking or lifting vehicle from
frame side rails, be certain lift pads do not contact
catalytic converter as damage to converter will
result.
Many dealer service facilities and service stations
are equipped with a type of automotive hoist which
must bear upon some part of the frame in order to lift
the vehicle. Figures 14 and 15 indicate the
recommended areas for hoist contact for Pontiac
Sunbird models.
If any other hoist methods are used, special care
must be used not to damage the fuel tank, filler neck, I
exhaust system or underbody.
I
VIN NUMBER PLATE
LOCATION
Fig. 2 Vehicle Identification Number Plate Location
marking indicating the strength of the material in the
fastener as outlined below. Metric cross recess screws
are identified by a Posidriv or Type 1A cross recess as
shown in Figure 8. Either a Phillips head or Type 1A
cross recess screwdriver can be used in Posidriv recess
screw heads, but Type 1A cross recess screwdrivers
will perform better.
NOTICE: Most metric fasteners have a blue color
coating. However, this should not be used as a
positive way of identifying as some metric fasteners
are not color coated.
General Motors Engineering Standards, along
with other North American Industries, have adopted
a portion of the standard metric fastener sizes defined
by
IS0 (International Standards Organization). This
was done to reduce the number of fastener sizes used
and yet retain the best strength qualities in each thread
size. For example, the customary 1/4-20 and 1/4-28
screws are replaced by the metric M6.0 X 1 screw
which has nearly the same diameter and
25.4 threads
per inch. The thread pitch is in between the customary
coarse and fine thread pitches.
Metric and customary thread notation differ
slightly. The difference is shown in Figure 9.
FASTENER STRENGTH
ODENTIFIGATION
Most commonly used metric fastener strength
property classes are 9.8 and 10.9 with the class
identification embossed on the head of each bolt.
Customary (inch) strength classes range from grade 2
to 8 with radial line identification embossed on each
bolt head (i.e., grade 7 bolt will exhibit 5 embossed
radial lines on the bolt head). Some metric nuts will be
marked with single digit strength identification
numbers on the nut face. Figure 12 shows the different
strength markings.
When replacing metric fasteners, be careful to use
bolts and nuts of the same strength or greater than the
original fasteners (the same number marking or higher)
.It is also important to select replacement fasteners of
the correct size. Correct replacement bolts and nuts are
available through the parts division. Many metric
fasteners available in the after-market parts channels
were designed to metric standards of countries other
than the United States. These fasteners may be of a
lower strength, different thread pitch and may not have
the numbered head marking system. The metric
fasteners used on GM products are designed to new,
international standards that may not be used by some
nondomestic bolt and nut suppliers. In general, except
for special applications, the common sizes and pitches
are:
M 6.0
X 1 M 8 x 1.25
M 10 X 1.5 M 12 X 1.75
M 14x2 I
PREVAILING TORQUE FASTENERS
A prevailing torque nut is designed to develop an
interference between the nut and bolt threads. This is
most often accomplished by distortion of the top of an
all-metal nut or by using a nylon patch on the threads
in the middle of the hex flat.
A nylon insert may also
be used as a method of interference between nut and
bolt threads (Fig. 11).
A prevailing torque bolt is designed to develop an
interference between bolt and nut threads, or the
threads of a tapped hole. This is accomplished by
distorting some of the threads or by using a nylon patch
or adhesive (Fig. 11).
RECOMMENDATIONS FOR FASTENER REUSE:
I
Clean, unrusted prevailing torque nuts and bolts
may be reused as follows:
a. Clean dirt and other foreign material off nut
or bolt.
b. Inspect nut or bolt to insure there are no
cracks, elongation, or other signs of abuse
or overtightening. (If there is any doubt,
replace with a new prevailing torque
fastener of equal or greater strength.)
c. Lightly coat bolt & nut with engine oil.
Assemble parts and hand start nut or bolt.
d. Observe that before fastener seats, it
develops torque per the chart in Figure
10.
(If there is any doubt, replace with a new
prevailing torque fastener of equal or
greater strength.)
e. Tighten fastener to torque specified in
appropriate section of this manual.
Bolts and nuts which are rusty or damaged
should be replaced with new parts of equal or
greater strength.
VEHICLE LIF"TING PROCEDURES
NOTICE: When jacking or lifting vehicle from
frame side rails, be certain lift pads do not contact
catalytic converter as damage to converter will
result.
Many dealer service facilities and service stations
are equipped with a type of automotive hoist which
must bear upon some part of the frame in order to lift
the vehicle. Figures 14 and 15 indicate the
recommended areas for hoist contact for Pontiac
Sunbird models.
If any other hoist methods are used, special care
must be used not to damage the fuel tank, filler neck, I
exhaust system or underbody.
I
GENERAL INFORMATION OA-3
PLANT CODE
GM PLANT CODES
LV.1.N. POSITION $11)
Lakrwood
Lanslnq B
Norwood
Pontlac
Tarrytown
W1:low Run
St. Therese
Lordstown
6000 SIE
6000 STE
Trans
Am
Grand
Prlx
Grand Prlx LE
G.P. Brougham
Bonnevlile
Bonnevll le LE
(V.I.N. POSITION $8)
Sunblrd GT
Grand
Am
Grand Am LE Gr~nd Am SE
CARBURETION
I
MPFI Turbo
Sed,in 7 D~,i,r Plaln Lia~.k lIl.~t~'l~li.~ck~
Seci.in 4 Utnir 6 \$lndi,w Nott'I~L,.~ck
c'<jupc 2 1101)r Nuti.Ill,.ick
Statlon W~qun 4 Uc,or
Coupe 1 l>ti~>r Notchbdck Sprcldl
Coupe 2 Door Convert ~blr
Scd.ln 4 Door b W~ndow Plalli Back
Scd.jn 4 Uui,r 4 Wl,idir,r Nutchbdck
Manual Belts
Manudi Belts Wlth Bullt-In Sdfrty
blaiiual Belts Vltli Bullt-In Safety (Drlvrr Only)
Fig. 3 Vehicle Identification Number Data
PLANT CODE
GM PLANT CODES
LV.1.N. POSITION $11)
Lakrwood
Lanslnq B
Norwood
Pontlac
Tarrytown
W1:low Run
St. Therese
Lordstown
6000 SIE
6000 STE
Trans
Am
Grand
Prlx
Grand Prlx LE
G.P. Brougham
Bonnevlile
Bonnevll le LE
(V.I.N. POSITION $8)
Sunblrd GT
Grand
Am
Grand Am LE Gr~nd Am SE
CARBURETION
I
MPFI Turbo
Sed,in 7 D~,i,r Plaln Lia~.k lIl.~t~'l~li.~ck~
Seci.in 4 Utnir 6 \$lndi,w Nott'I~L,.~ck
c'<jupc 2 1101)r Nuti.Ill,.ick
Statlon W~qun 4 Uc,or
Coupe 1 l>ti~>r Notchbdck Sprcldl
Coupe 2 Door Convert ~blr
Scd.ln 4 Door b W~ndow Plalli Back
Scd.jn 4 Uui,r 4 Wl,idir,r Nutchbdck
Manual Belts
Manudi Belts Wlth Bullt-In Sdfrty
blaiiual Belts Vltli Bullt-In Safety (Drlvrr Only)
Fig. 3 Vehicle Identification Number Data
OA-4 GENERAL INFORMATION
Refer to Fig. OA-6.
5-Speed (77mm) metal tag attached to extension
ENGINE
V.I.N.
VEHICLE COMPONENT IDEN"IIFICA"T0N NUMBER LOCATION
ENGINE CODES: "EM, "F", "8"
OPTIONAL V.I.N. LOCATION
ENGINE V.I.N. LOCATION
Fig. OA-5 -- Engine V.I.N. Location
Refer to Fig. OA-6.
5-Speed (77mm) metal tag attached to extension
ENGINE
V.I.N.
VEHICLE COMPONENT IDEN"IIFICA"T0N NUMBER LOCATION
ENGINE CODES: "EM, "F", "8"
OPTIONAL V.I.N. LOCATION
ENGINE V.I.N. LOCATION
Fig. OA-5 -- Engine V.I.N. Location
GENERAL INFORMATION OA-5
-
THM 700-R4 TRANSMISSION I.D. LOCATION
1-1
IOU DAY OF THE YEAR1
I SHIFT BUILT 1
1 A & B = FIRST SHIFT 1
C 5 H - SECOND SHIFT
THM 700-R4 TRANSMISSION IDENTIFICATION NUMBER
VIN LOCATION
I
OPTIONAL VIN LOCATION
--I I
Fig. OA-6 --Transmission VIN Location
LUBRICATION POINTS
CHASSIS - SEE
MAINTENANCE SCHEDULE
ENGINE OIL AND FILTER
COOLING SYSTEM
WHEEL BEARINGS
AUTO TRANSMISSION FLUID
LOWER CONTROL ARM BALL JOINTS I I
ENGINE COMPARTMENT
STEERING LINKAGE
Fig. OA-7 Typical Lubrication Points
-
THM 700-R4 TRANSMISSION I.D. LOCATION
1-1
IOU DAY OF THE YEAR1
I SHIFT BUILT 1
1 A & B = FIRST SHIFT 1
C 5 H - SECOND SHIFT
THM 700-R4 TRANSMISSION IDENTIFICATION NUMBER
VIN LOCATION
I
OPTIONAL VIN LOCATION
--I I
Fig. OA-6 --Transmission VIN Location
LUBRICATION POINTS
CHASSIS - SEE
MAINTENANCE SCHEDULE
ENGINE OIL AND FILTER
COOLING SYSTEM
WHEEL BEARINGS
AUTO TRANSMISSION FLUID
LOWER CONTROL ARM BALL JOINTS I I
ENGINE COMPARTMENT
STEERING LINKAGE
Fig. OA-7 Typical Lubrication Points
OA-6 GENERAL INFORMATION
USING FRAME CONTACT HOIST USING FRAME CONTACT HOIST
REARWARD OF FRONT TIRE ' FORWARD OF REAR TIRE
USING SUSPENSION CONTACT HOIST
LIFTING ON REAR AXLE
USING SUSPENSION CONTACT HOIST
UNDER FRONT LOWER CONTROL ARM
520016-0A
Fig.
8 Vehicle Lifting Points "F" Model
USING FRAME CONTACT HOIST USING FRAME CONTACT HOIST
REARWARD OF FRONT TIRE ' FORWARD OF REAR TIRE
USING SUSPENSION CONTACT HOIST
LIFTING ON REAR AXLE
USING SUSPENSION CONTACT HOIST
UNDER FRONT LOWER CONTROL ARM
520016-0A
Fig.
8 Vehicle Lifting Points "F" Model
GENERAL INFORMATION OA-7
APPROXIMATE CAPACITIES
Fuel Injected Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE
5.OL V8 Oil Change
*Approximate capacity with or without oil filter change.
Crankcase capacities shown are approximate refill capacities. After refill, recheck oil as outlined in the Owner's Manual.
COOLING SYSTEM
2.8L V6 Without A/C
5.OL V8 Without A/C
Fig. OA-9 Fluid Capacties
APPROXIMATE CAPACITIES
Fuel Injected Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE
5.OL V8 Oil Change
*Approximate capacity with or without oil filter change.
Crankcase capacities shown are approximate refill capacities. After refill, recheck oil as outlined in the Owner's Manual.
COOLING SYSTEM
2.8L V6 Without A/C
5.OL V8 Without A/C
Fig. OA-9 Fluid Capacties
08-8 GENERAL INFORMATION
USE OF METRIC AND CUSTOMARY NUTS, BOLTS AND SCRERS
Some veh~cles present spec~al servlce requ~rements to the technrc~a~l due to the use of both metnc and cus-
tomary (Inch) type nuts, bolt5 and screws. Many are metnc and some are very close in d~mens~on to custom-
ary nuts. bolts and screws in the Inch system M~smatched or Incorect nut5, bolt5 and screus can result rn
damage, malfunct~on or poss~ble personal Injury Nuts. bolts and screws removed from the veh~cle 5hould be
saved for re-use uhenever poscrble. If they are not re-usable. care should be taken to select a replacement
that matches the ong~nal.
General Motors Eng~neenng Standards have ddopted a portion of the standard metnc fastener slzes defined
by SI (Systeme Internatronal) Th~s was done to reduce the number of srzes used and yet retarn the best
strength character~st~cs In each thtead size. For example. the customary 114-20 and 1/4-28 screws are replaced
by the metrlc M6.3 x I screw wh~ch has nearly the same d~ameter and 25.4 threads per inch. The thread p~tch
IS In between the customary coarse and fine thread prtches.
Metnc and customary thread notatlon d~ffer sl~ghtly. The d~fference IS ~llustrated belou.
CUSTOMARY METRIC
Thread Major Thread Major
D~ameter D~ameter
~n inches rn M~ll~meters
Number of D~stance
Threads Between Threads
in Mill~meters
Care should be taken when servlclng the veh~cle to guard agalnst cross thread~ng or Improper retention due to
interchanged metnc and inch nuts and bolts.
When obtarn~ng metnc or customary nuts, bolts, and screws locally for servrcing the vehicle. care must be
exerc~sed in selecting parts that are equrvalent to the ong~nal parts In dimensions. strength. and p~tch of
Fig. OA-10 -- Metric Information, Chart A
USE OF METRIC AND CUSTOMARY NUTS, BOLTS AND SCRERS
Some veh~cles present spec~al servlce requ~rements to the technrc~a~l due to the use of both metnc and cus-
tomary (Inch) type nuts, bolt5 and screws. Many are metnc and some are very close in d~mens~on to custom-
ary nuts. bolts and screws in the Inch system M~smatched or Incorect nut5, bolt5 and screus can result rn
damage, malfunct~on or poss~ble personal Injury Nuts. bolts and screws removed from the veh~cle 5hould be
saved for re-use uhenever poscrble. If they are not re-usable. care should be taken to select a replacement
that matches the ong~nal.
General Motors Eng~neenng Standards have ddopted a portion of the standard metnc fastener slzes defined
by SI (Systeme Internatronal) Th~s was done to reduce the number of srzes used and yet retarn the best
strength character~st~cs In each thtead size. For example. the customary 114-20 and 1/4-28 screws are replaced
by the metrlc M6.3 x I screw wh~ch has nearly the same d~ameter and 25.4 threads per inch. The thread p~tch
IS In between the customary coarse and fine thread prtches.
Metnc and customary thread notatlon d~ffer sl~ghtly. The d~fference IS ~llustrated belou.
CUSTOMARY METRIC
Thread Major Thread Major
D~ameter D~ameter
~n inches rn M~ll~meters
Number of D~stance
Threads Between Threads
in Mill~meters
Care should be taken when servlclng the veh~cle to guard agalnst cross thread~ng or Improper retention due to
interchanged metnc and inch nuts and bolts.
When obtarn~ng metnc or customary nuts, bolts, and screws locally for servrcing the vehicle. care must be
exerc~sed in selecting parts that are equrvalent to the ong~nal parts In dimensions. strength. and p~tch of
Fig. OA-10 -- Metric Information, Chart A
GENERAL INFORMATION OA-9
REUSE OF PREVAILING "TRQUE NUT AND BOLT
WASHER NYLON STRIP OR PATC
I
A. CLEAN, llNRUSTFD PREVAILING TORQllF BOLTS AND NL'TS MAY Bk. REUSED AS
FOLL.0WS I
I. CLEAN DIRT AND OTHER FORFICN MATERIAL OFF NUT AND BOLT.
2, INSPECT BOLT AND NUT TO ASSURE THERE ARE NO CRACKS. ELONGATION OR
OTHER SIGNS OF ABUSE OR OVERTIGIiTENING. LIGHTLY LUBRICATE THREADS. (IF
ANY DOUBT, REPLACE WITH NEW PREVAILING TOROLE FASTENER OF EQUAL OR
GREATER STRENGTH.)
3. ASSFMBLE PARTS AND START BOLT OR NLIT.
4. OBSERVE THAT BEFORE FASTENER SkATS. IT DEVk.LOPS PREVAILING TORQUE PER
CHART BELOW. (IF ANY DOUBT, INSTALL NliW PRFVAILIN(; TORQL'F FASTENER OF
EQUAL OR GREATER STRENGTH).
5. TIGHTEN TO TORQUE SPECIFIED IN
SERVl('k MANl'AL,
REUSE OF PREVAILING "TRQUE NUT AND BOLT
WASHER NYLON STRIP OR PATC
I
A. CLEAN, llNRUSTFD PREVAILING TORQllF BOLTS AND NL'TS MAY Bk. REUSED AS
FOLL.0WS I
I. CLEAN DIRT AND OTHER FORFICN MATERIAL OFF NUT AND BOLT.
2, INSPECT BOLT AND NUT TO ASSURE THERE ARE NO CRACKS. ELONGATION OR
OTHER SIGNS OF ABUSE OR OVERTIGIiTENING. LIGHTLY LUBRICATE THREADS. (IF
ANY DOUBT, REPLACE WITH NEW PREVAILING TOROLE FASTENER OF EQUAL OR
GREATER STRENGTH.)
3. ASSFMBLE PARTS AND START BOLT OR NLIT.
4. OBSERVE THAT BEFORE FASTENER SkATS. IT DEVk.LOPS PREVAILING TORQUE PER
CHART BELOW. (IF ANY DOUBT, INSTALL NliW PRFVAILIN(; TORQL'F FASTENER OF
EQUAL OR GREATER STRENGTH).
5. TIGHTEN TO TORQUE SPECIFIED IN
SERVl('k MANl'AL,
OA-10 GENERAL INFORMATION
METRIC BOLT AND NUT IDENTIFICATION
Common metric fastener strength property classss are 9.8 and 10.9 with the clers idsntifica$ion
embossed on the haad of each bolt. Customary (inch) strength clases range from grade 2 to 8 wi(h
line ihntificaion embosssd on each bolt head. Markings correspond to two lines lsss than the
actual grade (i.e. grade 7 bolt will exhibit 5 embossd lines on the bolt head). Some metric nuts will
be markd with single digit strength identification numbers on the nut face. The following figure
illustr&es the different strength markings.
Customary (~nch) bolts - ldent~f~cat~on marks correspond to bolt
strength
-
lncreas~ng numbers represent lncreaslng strength.
Metr~c Bolts - ldent~f~cat~on class numbers correspond to bolt
strength
-
lncreas~ng numbers represent lncreaslng strength.
MANUFACTURERS NUT STRENGTH
IDENTIFICATION IDENTI FlCATlON
POSlDRlV
Fig. OA-12 -- Metric Information, Chart C
METRIC BOLT AND NUT IDENTIFICATION
Common metric fastener strength property classss are 9.8 and 10.9 with the clers idsntifica$ion
embossed on the haad of each bolt. Customary (inch) strength clases range from grade 2 to 8 wi(h
line ihntificaion embosssd on each bolt head. Markings correspond to two lines lsss than the
actual grade (i.e. grade 7 bolt will exhibit 5 embossd lines on the bolt head). Some metric nuts will
be markd with single digit strength identification numbers on the nut face. The following figure
illustr&es the different strength markings.
Customary (~nch) bolts - ldent~f~cat~on marks correspond to bolt
strength
-
lncreas~ng numbers represent lncreaslng strength.
Metr~c Bolts - ldent~f~cat~on class numbers correspond to bolt
strength
-
lncreas~ng numbers represent lncreaslng strength.
MANUFACTURERS NUT STRENGTH
IDENTIFICATION IDENTI FlCATlON
POSlDRlV
Fig. OA-12 -- Metric Information, Chart C
SI METRIC-CUSTOMARY CONVERSION TABLE
to get equivalent
by nurnber of: Multiply
to get equivalent
by number ol: Multiply
LENGTH ACCELERATION
Inch
Foot
Yard
Mile
millimeters (mm)
meters (m)
meters
kilometers (km)
TORQUE
AREA
newton-meters
(N-m)
newton-meters
millimeters2 (mm2)
centimeters2 (cm2 )
meters' (m2)
meters2
POWER
Horsepower
VOLUME PRESSURE OR STRESS
3.377
6.895
mm3
cm3
liters (I)
liters
liters
meters3 (ma)
Inches of mercury
Poundslsq. in.
kilopascals (kPa)
kilopascals
Quart
Gallon
Yard3
ENERGY OR WORK
BTU
Foot-pound
Kilowatt-hour
joules (J)
joules
joules (J
= one W's) MASS
Pound
Ton
Ton
kilograms (kg)
kilograms (kg)
tonne (t)
Foot candle
FORCE
FUEL PERFORMANCE
Kilogram
Ounce
Pound
newtons (N)
newtons
newtons
Mileslgal
Gallmile
kilometerslliter (km/l)
literslkilometer (Ilkm)
TEMPERATURE VELOCITY
1.609 Degree Fahrenheit degree Celsius (C) Mileslhour
to get equivalent
by nurnber of: Multiply
to get equivalent
by number ol: Multiply
LENGTH ACCELERATION
Inch
Foot
Yard
Mile
millimeters (mm)
meters (m)
meters
kilometers (km)
TORQUE
AREA
newton-meters
(N-m)
newton-meters
millimeters2 (mm2)
centimeters2 (cm2 )
meters' (m2)
meters2
POWER
Horsepower
VOLUME PRESSURE OR STRESS
3.377
6.895
mm3
cm3
liters (I)
liters
liters
meters3 (ma)
Inches of mercury
Poundslsq. in.
kilopascals (kPa)
kilopascals
Quart
Gallon
Yard3
ENERGY OR WORK
BTU
Foot-pound
Kilowatt-hour
joules (J)
joules
joules (J
= one W's) MASS
Pound
Ton
Ton
kilograms (kg)
kilograms (kg)
tonne (t)
Foot candle
FORCE
FUEL PERFORMANCE
Kilogram
Ounce
Pound
newtons (N)
newtons
newtons
Mileslgal
Gallmile
kilometerslliter (km/l)
literslkilometer (Ilkm)
TEMPERATURE VELOCITY
1.609 Degree Fahrenheit degree Celsius (C) Mileslhour
OA-12 GENERAL INFORMATION
DECIMAL AND METRIC EQUIVALENTS
Fractions Decimal Metric Fractions Decimal
In
. MM . In .
Metric
MM
.
Fig . OA-14
..Metric Information, Chart E
DECIMAL AND METRIC EQUIVALENTS
Fractions Decimal Metric Fractions Decimal
In
. MM . In .
Metric
MM
.
Fig . OA-14
..Metric Information, Chart E
- -
GENERAL INFORMATION OA-13
LIST OF AUTOMOTIVE ABBREVIATIONS
WHICH MAY
BE USED IN THIS MANUAL
A-6
- Axial 6 Cyl. A C Compressor
AIC - Air Conditioning
ACC - Auto'matic Climate Control
EMF - Electromotive Force PAIR - Pulse Air Injection Reaction System
EMR - Electronic Module Retard P B - Power Brakes
EOS - Exhaust Oxygen Sensor PCV - Positive Crankcase Ventilation
ESC - Electronic Spark Control PECV - Power Enrichment Control Valve
APT - Adjustable Part Throttle
AT - Automatic Transmission
ATC
- Automatic Temperature Control
ATDC
- After Top Dead Center
FMVSS - Federal Motor Vehicle Safety
BAR0 - Barometric Absolute Pressure Sensor
Ft. Lb. - Foot Pounds (Torque)
Bat.
+
- Positive Terminal FWD - Front Wheel Drive
- Four Wheel Drive
BHP - Brake Horsepower 4 x 4 - Four Wheel Drive
BP - Back Pressure
BTDC
- Before Top Dead Center HD
- Heavy Duty
HE1 - High Energy Ignition
Cat. Conv. - Catalytic Converter
CC - Catalytic Converter
- Cubic Centimeter
- Converter Clutch
CCC - Computer Command Control
HVM - Heater-Vent-Module
IAC - ldle Air Control
CCOT - Cycling Clutch (Orifice) Tube IC - Integrated Circuit
CCP - Controlled Canister Purge ID - Identification
C.E. - Check Engine - Inside Diameter
CEAB - Cold Engine Airbleed ILC - Idle Load Compensator
CEMF
- Counter Electromotive Force
I/P - Instrument Panel
CID
- Cubic
Inch Displacement ISC - Idle Speed Control
CLOOp - Closed Loop
CLCC
- Closed Loop Carburetor Control km - Kilometers
CP
- Canister Purge
kmiL - Kilometers Liter (mpg)
Cu. In. - Cubic Inch kPa - Kilopascals
CV
- Constant Velocity
Cyl.
-
Cylinder(s)
L-4 - Four Cylinder In-Line (Engine)
DBB - Dual Bed Bead L-6 - Six Cylinder In-Line (Engine)
DBM
- Dual Bed Monolith LF
- Left Front
DEFl - Digital Electronic Fuel Injection LR - Left Rear
DFI - Digital Fuel Injection
Diff. - Differential Man. Vac. - Manifold Vacuum
Distr. - Distributor MAP - Manifold Absolute Pressure
EAC - Electric Air Control Valve
EAS - Electric Air Switching Valve MPG - Miles Per Gallon
ECC - Electronic Comfort Control MPH - Miles Per Hour
ECM
- Electronic Control Module MT
- Manual Transmission
N.m - Newton Metres (Torque)
Emission Control
Fig.
014-15 -- Common Abbreviations
GENERAL INFORMATION OA-13
LIST OF AUTOMOTIVE ABBREVIATIONS
WHICH MAY
BE USED IN THIS MANUAL
A-6
- Axial 6 Cyl. A C Compressor
AIC - Air Conditioning
ACC - Auto'matic Climate Control
EMF - Electromotive Force PAIR - Pulse Air Injection Reaction System
EMR - Electronic Module Retard P B - Power Brakes
EOS - Exhaust Oxygen Sensor PCV - Positive Crankcase Ventilation
ESC - Electronic Spark Control PECV - Power Enrichment Control Valve
APT - Adjustable Part Throttle
AT - Automatic Transmission
ATC
- Automatic Temperature Control
ATDC
- After Top Dead Center
FMVSS - Federal Motor Vehicle Safety
BAR0 - Barometric Absolute Pressure Sensor
Ft. Lb. - Foot Pounds (Torque)
Bat.
+
- Positive Terminal FWD - Front Wheel Drive
- Four Wheel Drive
BHP - Brake Horsepower 4 x 4 - Four Wheel Drive
BP - Back Pressure
BTDC
- Before Top Dead Center HD
- Heavy Duty
HE1 - High Energy Ignition
Cat. Conv. - Catalytic Converter
CC - Catalytic Converter
- Cubic Centimeter
- Converter Clutch
CCC - Computer Command Control
HVM - Heater-Vent-Module
IAC - ldle Air Control
CCOT - Cycling Clutch (Orifice) Tube IC - Integrated Circuit
CCP - Controlled Canister Purge ID - Identification
C.E. - Check Engine - Inside Diameter
CEAB - Cold Engine Airbleed ILC - Idle Load Compensator
CEMF
- Counter Electromotive Force
I/P - Instrument Panel
CID
- Cubic
Inch Displacement ISC - Idle Speed Control
CLOOp - Closed Loop
CLCC
- Closed Loop Carburetor Control km - Kilometers
CP
- Canister Purge
kmiL - Kilometers Liter (mpg)
Cu. In. - Cubic Inch kPa - Kilopascals
CV
- Constant Velocity
Cyl.
-
Cylinder(s)
L-4 - Four Cylinder In-Line (Engine)
DBB - Dual Bed Bead L-6 - Six Cylinder In-Line (Engine)
DBM
- Dual Bed Monolith LF
- Left Front
DEFl - Digital Electronic Fuel Injection LR - Left Rear
DFI - Digital Fuel Injection
Diff. - Differential Man. Vac. - Manifold Vacuum
Distr. - Distributor MAP - Manifold Absolute Pressure
EAC - Electric Air Control Valve
EAS - Electric Air Switching Valve MPG - Miles Per Gallon
ECC - Electronic Comfort Control MPH - Miles Per Hour
ECM
- Electronic Control Module MT
- Manual Transmission
N.m - Newton Metres (Torque)
Emission Control
Fig.
014-15 -- Common Abbreviations
0.4-14 GENERAL INFORMATION
SERVICE PARE SlDENTlFlGATlON LABEL
The Service Parts Identification Label provides identifi- fixed to the inside of each passenger car vehicle at the
cation of vehicle equipment to assist in servicing and assembly plant.
determining replacement parts, Included on this label
will be regular production options (RPO's) as well as For additional information on the Service Parts Identifi-
standard and mandatory options. The label will be af- cation Label, see a GM Parts Catalog.
VEHICLE ---f
IDENTIFICATION
NUMBER
lGlAZ3799ER157148 1JD69
ARL A02 A65 BGY B9A B9K C60 Dl0 D35 E5Z E6E E9Z FLT GU1 JM7
<19 KG4 LC3 MX1 M31 NA5 NB1 OMX VK3 VC2 VY1 VY4 V73 Y19 ZJ7
GBJ 62L 62U 67D 671 679 7BJ 8HJ 9HJ
BBPBBBBPPB EXAMPLE -
DIS. LACQUER WA-L8240 U8240 A4721
i
BODY TYPE STYLE
OPTION CONTENT
PAINT TECHNOLO(IY
SOLUTION LACOUEH
DlSPEHSlON LACOUEH
HIGH SOLIDS EN4MEL
VINYL
FOP CCIl.Oli
IlF AI'I'LICAHLZI
\VA CERBORNE ENAI.ICL I'AINT LOULS APd[J LOLATIONS I
BASECOAT CLCAl3C04T L LfJIVEIi L:C)UY COLOII 1lilP.1
U UPI'CH f!O[IY (,OLCJII
~,lJP.ll~lPl/~ llO'J',
A hllI1ULf L!O[)Y OII ACCCNT
COLOF? ISTHIPINO CTC. I
LABEL LOCATION
Fig. OA-16 Service Parts Idcnt~frcation Label
SERVICE PARE SlDENTlFlGATlON LABEL
The Service Parts Identification Label provides identifi- fixed to the inside of each passenger car vehicle at the
cation of vehicle equipment to assist in servicing and assembly plant.
determining replacement parts, Included on this label
will be regular production options (RPO's) as well as For additional information on the Service Parts Identifi-
standard and mandatory options. The label will be af- cation Label, see a GM Parts Catalog.
VEHICLE ---f
IDENTIFICATION
NUMBER
lGlAZ3799ER157148 1JD69
ARL A02 A65 BGY B9A B9K C60 Dl0 D35 E5Z E6E E9Z FLT GU1 JM7
<19 KG4 LC3 MX1 M31 NA5 NB1 OMX VK3 VC2 VY1 VY4 V73 Y19 ZJ7
GBJ 62L 62U 67D 671 679 7BJ 8HJ 9HJ
BBPBBBBPPB EXAMPLE -
DIS. LACQUER WA-L8240 U8240 A4721
i
BODY TYPE STYLE
OPTION CONTENT
PAINT TECHNOLO(IY
SOLUTION LACOUEH
DlSPEHSlON LACOUEH
HIGH SOLIDS EN4MEL
VINYL
FOP CCIl.Oli
IlF AI'I'LICAHLZI
\VA CERBORNE ENAI.ICL I'AINT LOULS APd[J LOLATIONS I
BASECOAT CLCAl3C04T L LfJIVEIi L:C)UY COLOII 1lilP.1
U UPI'CH f!O[IY (,OLCJII
~,lJP.ll~lPl/~ llO'J',
A hllI1ULf L!O[)Y OII ACCCNT
COLOF? ISTHIPINO CTC. I
LABEL LOCATION
Fig. OA-16 Service Parts Idcnt~frcation Label
MAINTENANCE AND LUBRICATION OB-1
SECTION OB
NTENANCE AND LUBR
CONTENTS
Maintenance Schedule, Gasoline .............................................. OB-l
Maintenance Schedules I and 11 .............................................. OB-2
Owner Inspections ......................................................... OB-3
Recommended Fluids and Lubricants ......................................... OB-6
PASSENGER CAR MAINTENANCE SCHEDULE
VEHICLES WITH GASOLINE ENGINE
NORMAL CAR USE ITEM 4
The maintenance services contained in Schedules I Carburetor or Throttle Body Mounting Bolt
and 11 are based on the assumption that your car will be Torque*
used as designed:
Check torque of mounting bolts and/or nuts.
@ To carry passengers and cargo within the limits
shown on the Tire Placard located on the edge of the
ITEM 5
driver's door.
@ On reasonable road surfaces within legal driving
Engine Idle Speed Adjustment*
limits. (Engines without Idle Speed Control or Idle Air
Control) - Adjust to specifications shown on the under-
@ On unleaded gasoline.
hood label. If no specifications are shown on the label, no
adjustment is necessary. Calibrated test equipment must
EXPLANATION OF SCHEDULED MAINTENANCE
be used.
SERVICES
The services listed in Maintenance Scheduies I and ITEM 6
11 are further explained below. When the following main-
~i~~ and wheel aotation
tenance services are performed, make sure all parts are
replaced and all necessary repairs are done before driving
To equalize wear and obtain
maximum tire life,
your car. Be sure to use the proper fluid and lubricants as rotate in accordance with patterns shown in Owner's
shown in Figure OB-2. Manual.
ITEM 1
Engine Oil and Oil Filter Change*
ALWAYS USE SFICC OR SF/CD ENERGY CON-
SERVING OILS OF PROPER VISCOSITY
- Also.
always change oil and filter as soon as possible after
driving in a dust storm. See your Owner's Manual for
further details.
ITEM 2
Chassis Lubrication
Lubricate all grease fittings in suspension and steer-
ing linkage. Lubricate
transmissionltransaxle shift
linkage, parking brake cable guides, underbody contact
points and linkage. Also lubricate clutch cross shaft lever
every
30,000 miles (50 000 km) on rear-wheel-drive cars
only.
ITEM 3
Carburetor Choke and Hoses*
If your car is equipped with a carburetor, verify that
choke and vacuum break work properly and are within
specifications. Correct any binding caused by damage or
gum on the choke shaft. Inspect hoses for proper hookup,
cracks, chafing or decay. Correct as necessary.
Vacuum or A.I.R. Pump Drive Belt Inspection*
When a separate belt is used to drive the
vacuum or
A.I.R. pump, inspect it for cracks, fraying, wear and
proper tension. Adjust or replace as needed.
ITEM
8
Cooling System Service*
Drain, flush and refill system with new coolant. See
your Owner's Manual for further details.
ITEM 9
Wheel Bearing Repack (Rear-Wheel-Drive Cars
Only Except Corvette)
Clean and repack front wheel bearings at each brake
relining or 15,000 miles
(25 000 km), whichever comes
first, when car is used in such service as police, taxi or
door-to-door delivery. If you do not use your car in such
service, clean and repack bearings at each brake relining
or 30,000 miles (50 000 km), whichever comes first.
Corvette models do not require wheel bearing repack.
SECTION OB
NTENANCE AND LUBR
CONTENTS
Maintenance Schedule, Gasoline .............................................. OB-l
Maintenance Schedules I and 11 .............................................. OB-2
Owner Inspections ......................................................... OB-3
Recommended Fluids and Lubricants ......................................... OB-6
PASSENGER CAR MAINTENANCE SCHEDULE
VEHICLES WITH GASOLINE ENGINE
NORMAL CAR USE ITEM 4
The maintenance services contained in Schedules I Carburetor or Throttle Body Mounting Bolt
and 11 are based on the assumption that your car will be Torque*
used as designed:
Check torque of mounting bolts and/or nuts.
@ To carry passengers and cargo within the limits
shown on the Tire Placard located on the edge of the
ITEM 5
driver's door.
@ On reasonable road surfaces within legal driving
Engine Idle Speed Adjustment*
limits. (Engines without Idle Speed Control or Idle Air
Control) - Adjust to specifications shown on the under-
@ On unleaded gasoline.
hood label. If no specifications are shown on the label, no
adjustment is necessary. Calibrated test equipment must
EXPLANATION OF SCHEDULED MAINTENANCE
be used.
SERVICES
The services listed in Maintenance Scheduies I and ITEM 6
11 are further explained below. When the following main-
~i~~ and wheel aotation
tenance services are performed, make sure all parts are
replaced and all necessary repairs are done before driving
To equalize wear and obtain
maximum tire life,
your car. Be sure to use the proper fluid and lubricants as rotate in accordance with patterns shown in Owner's
shown in Figure OB-2. Manual.
ITEM 1
Engine Oil and Oil Filter Change*
ALWAYS USE SFICC OR SF/CD ENERGY CON-
SERVING OILS OF PROPER VISCOSITY
- Also.
always change oil and filter as soon as possible after
driving in a dust storm. See your Owner's Manual for
further details.
ITEM 2
Chassis Lubrication
Lubricate all grease fittings in suspension and steer-
ing linkage. Lubricate
transmissionltransaxle shift
linkage, parking brake cable guides, underbody contact
points and linkage. Also lubricate clutch cross shaft lever
every
30,000 miles (50 000 km) on rear-wheel-drive cars
only.
ITEM 3
Carburetor Choke and Hoses*
If your car is equipped with a carburetor, verify that
choke and vacuum break work properly and are within
specifications. Correct any binding caused by damage or
gum on the choke shaft. Inspect hoses for proper hookup,
cracks, chafing or decay. Correct as necessary.
Vacuum or A.I.R. Pump Drive Belt Inspection*
When a separate belt is used to drive the
vacuum or
A.I.R. pump, inspect it for cracks, fraying, wear and
proper tension. Adjust or replace as needed.
ITEM
8
Cooling System Service*
Drain, flush and refill system with new coolant. See
your Owner's Manual for further details.
ITEM 9
Wheel Bearing Repack (Rear-Wheel-Drive Cars
Only Except Corvette)
Clean and repack front wheel bearings at each brake
relining or 15,000 miles
(25 000 km), whichever comes
first, when car is used in such service as police, taxi or
door-to-door delivery. If you do not use your car in such
service, clean and repack bearings at each brake relining
or 30,000 miles (50 000 km), whichever comes first.
Corvette models do not require wheel bearing repack.
OB-2 MAINTENANCE AND LUBRICATION
Select and follow Schedule I or Schedule I1 based on how you use your car:
SCHEDULE I
Follow Schedule I if your car is mainly operated under one or moreof the following Idling andlor low speed operation in stop-and-go traffic.
conditions: Towing a trailer.
@ When most trips are less than 4 miles (6 kilometers).
Operating in dusty areas.
When most trips are less than
10 miles (16 kilometers) and outside temperatures
Schedule
I should also be followed if the car is used for delivery service,
remain below freezing. police, taxi or other commercial applications.
TO BE SERVICED
Every
30.000 miles
I50 000 km)
Every 30,000 miles I50 000 km) or 36 months
Every
30,000 miles 150 000
km)
SCHEDULE ll
Follow Schedule II only if none of the driving conditions specified in Schedule I apply.
TO BE SERVICED
At
7 500 miles 12 500 km
on1
FOOTNOTES:
I
*An Emission Control Service
ttThe U.S. Environmental Protection Agency has determined that the failure to perform this
maintenance item will not nullifv the emission warrantv or limit recall liabilitv orior to the
completion of vehicle useful life. General Motors, however, urges that all recommended main-
tenance services be performed at the indicated intervals and the maintenance be recorded in
section C of the owner's ma~ntenance schedule.
Figure OB-1 Maintenance Schedules I and I1 - Gasoline Vehicles
Select and follow Schedule I or Schedule I1 based on how you use your car:
SCHEDULE I
Follow Schedule I if your car is mainly operated under one or moreof the following Idling andlor low speed operation in stop-and-go traffic.
conditions: Towing a trailer.
@ When most trips are less than 4 miles (6 kilometers).
Operating in dusty areas.
When most trips are less than
10 miles (16 kilometers) and outside temperatures
Schedule
I should also be followed if the car is used for delivery service,
remain below freezing. police, taxi or other commercial applications.
TO BE SERVICED
Every
30.000 miles
I50 000 km)
Every 30,000 miles I50 000 km) or 36 months
Every
30,000 miles 150 000
km)
SCHEDULE ll
Follow Schedule II only if none of the driving conditions specified in Schedule I apply.
TO BE SERVICED
At
7 500 miles 12 500 km
on1
FOOTNOTES:
I
*An Emission Control Service
ttThe U.S. Environmental Protection Agency has determined that the failure to perform this
maintenance item will not nullifv the emission warrantv or limit recall liabilitv orior to the
completion of vehicle useful life. General Motors, however, urges that all recommended main-
tenance services be performed at the indicated intervals and the maintenance be recorded in
section C of the owner's ma~ntenance schedule.
Figure OB-1 Maintenance Schedules I and I1 - Gasoline Vehicles
F CARLINE
ITEM 10
TransmissionRransaxle Service
The manual transmission or transaxle fluid does not
require changing. (Corvette only.) Change fluid in over-
drive unit every 30,000 miles (50 000 km).
For automatic transmissions or transaxles, change
both the fluid and filter every 15,000 miles (25 000 km) if
the car is mainly driven under one or more of these
conditions:
@ In heavy city traffic where the outside temperature
regularly reaches 90ยฐF (32ยฐC) or higher.
@ In hilly or mountainous terrain.
@ Frequent trailer pulling.
@ Uses such as found in taxi, police car or delivery
service.
If you do not use your car under any of these condi-
tions, change both the fluid and filter every 100,000 miles
(160 000 km). See you Owner's Manual for further
details.
ITEM 11
Spark Plug Service*
Replace spark plugs with type listed in your Owner's
Manual.
ITEM 12
Spark Plug Wire Inspection*
Clean wires and inspect for burns, cracks or other dam-
age. Check the wire boot fit at distributor and at spark plugs.
Replace wires as needed.
ITEM 13
Positive Crankcase Ventilation
(PCV) Valve
Inspection*
Inspect valve for proper function. Replace valve if
necessary as well as any worn, plugged or collapsed
hoses.
ITEM 14
EGR System Service*
Conduct EGR System Service as referenced in the
EGR System Chart shown in the appropriate 6E Section.
Also, refer to your GM maintenance schedule booklet for
specific applications.
ITEM 15
Air Cleaner and
PCV Filter Replacement*
On 1.6 and 2.0 liter engines, replace every 50,000
miles (80 000 km). On all other engines, replace every
30,000 miles (50 000 km). Replace more often under
dusty conditions. Ask your dealer for the proper replace-
ment interval for your driving conditions.
MAINTENANCE AND LUBRICATION
08-3
ITEM 16
Engine Timing Check*
Adjust timing to underhood label specifications. If
no specifications are shown, no adjustment is needed.
ITEM 17
Fuel Tank, Cap and Lines Inspection*
Inspect fuel tank, cap and lines (including fuel rails
and injection assembly, if so equipped) for damage or
leaks. Inspect fuel cap gasket for an even filler neck
imprint or any damage. Replace parts as needed.
ITEM 18
Thermostatically Controlled Air Cleaner
Inspection*
If your car is equipped, inspect all hoses and ducts
for proper hookup. Make sure valve works properly.
OWNER INSPECTIONS AND SERVICES
Listed below are inspections and services which
should be made by either you or a qualified technician at
the intervals shown to help ensure proper safety, emission
performance and dependability of your car. Take any
problems promptly to your dealer or another qualified
technician for service advice. Whenever repairs are neces-
sary, have them completed at once. For your safety and
that of others, any safety-related parts that could have
been damaged in an accident should be inspected and all
needed repairs should be done before operating your car.
Be sure to use the proper fluids and lubricants as shown in
Figure OB-2.
WHILE OPERATING YOUR VEHICLE
Automatic transmissionltransaxle shift indi-
cator operation
- Make sure the indicator points to the
gear chosen.
Horn operation
- Blow the horn occasionally to
make sure it works. Check all button locations.
I
Brake system operation -- Be alert to abnormal
sounds, increased brake pedal travel or repeated pulling to
one side when braking. Also, if a brake warning light
comes on or flashes, or the anti-lock warning light (if
equipped) comes on or remains on, something may be
wrong with part of the brake system. Have it inspected and
repaired at once.
Exhaust system operation
- Be alert to any
changes in the sound of the system or any smell of fumes.
These are signs the system may be leaking or overheating.
.
Have it inspected and repaired at once. Also see "Engine
Exhaust Gas Caution (Carbon Monoxide)" and "Catalytic
Converter" in your Owner's Manual.
*An Emission Control
Service
ITEM 10
TransmissionRransaxle Service
The manual transmission or transaxle fluid does not
require changing. (Corvette only.) Change fluid in over-
drive unit every 30,000 miles (50 000 km).
For automatic transmissions or transaxles, change
both the fluid and filter every 15,000 miles (25 000 km) if
the car is mainly driven under one or more of these
conditions:
@ In heavy city traffic where the outside temperature
regularly reaches 90ยฐF (32ยฐC) or higher.
@ In hilly or mountainous terrain.
@ Frequent trailer pulling.
@ Uses such as found in taxi, police car or delivery
service.
If you do not use your car under any of these condi-
tions, change both the fluid and filter every 100,000 miles
(160 000 km). See you Owner's Manual for further
details.
ITEM 11
Spark Plug Service*
Replace spark plugs with type listed in your Owner's
Manual.
ITEM 12
Spark Plug Wire Inspection*
Clean wires and inspect for burns, cracks or other dam-
age. Check the wire boot fit at distributor and at spark plugs.
Replace wires as needed.
ITEM 13
Positive Crankcase Ventilation
(PCV) Valve
Inspection*
Inspect valve for proper function. Replace valve if
necessary as well as any worn, plugged or collapsed
hoses.
ITEM 14
EGR System Service*
Conduct EGR System Service as referenced in the
EGR System Chart shown in the appropriate 6E Section.
Also, refer to your GM maintenance schedule booklet for
specific applications.
ITEM 15
Air Cleaner and
PCV Filter Replacement*
On 1.6 and 2.0 liter engines, replace every 50,000
miles (80 000 km). On all other engines, replace every
30,000 miles (50 000 km). Replace more often under
dusty conditions. Ask your dealer for the proper replace-
ment interval for your driving conditions.
MAINTENANCE AND LUBRICATION
08-3
ITEM 16
Engine Timing Check*
Adjust timing to underhood label specifications. If
no specifications are shown, no adjustment is needed.
ITEM 17
Fuel Tank, Cap and Lines Inspection*
Inspect fuel tank, cap and lines (including fuel rails
and injection assembly, if so equipped) for damage or
leaks. Inspect fuel cap gasket for an even filler neck
imprint or any damage. Replace parts as needed.
ITEM 18
Thermostatically Controlled Air Cleaner
Inspection*
If your car is equipped, inspect all hoses and ducts
for proper hookup. Make sure valve works properly.
OWNER INSPECTIONS AND SERVICES
Listed below are inspections and services which
should be made by either you or a qualified technician at
the intervals shown to help ensure proper safety, emission
performance and dependability of your car. Take any
problems promptly to your dealer or another qualified
technician for service advice. Whenever repairs are neces-
sary, have them completed at once. For your safety and
that of others, any safety-related parts that could have
been damaged in an accident should be inspected and all
needed repairs should be done before operating your car.
Be sure to use the proper fluids and lubricants as shown in
Figure OB-2.
WHILE OPERATING YOUR VEHICLE
Automatic transmissionltransaxle shift indi-
cator operation
- Make sure the indicator points to the
gear chosen.
Horn operation
- Blow the horn occasionally to
make sure it works. Check all button locations.
I
Brake system operation -- Be alert to abnormal
sounds, increased brake pedal travel or repeated pulling to
one side when braking. Also, if a brake warning light
comes on or flashes, or the anti-lock warning light (if
equipped) comes on or remains on, something may be
wrong with part of the brake system. Have it inspected and
repaired at once.
Exhaust system operation
- Be alert to any
changes in the sound of the system or any smell of fumes.
These are signs the system may be leaking or overheating.
.
Have it inspected and repaired at once. Also see "Engine
Exhaust Gas Caution (Carbon Monoxide)" and "Catalytic
Converter" in your Owner's Manual.
*An Emission Control
Service
OB-4 MAINTENANCE AND LUBRICATION
Tire and wheel operation - Be alert to a vibra-
tion of the steering wheel or seat at normal highway
speeds. This may mean a wheel balance is needed. Also, a
pull right or left on a straight, level road may show the
need for
a tire pressure adjustment or wheel alignment.
Steering system operation
- Be alert to
changes in steering action. An inspection is needed when
the steering wheel is harder to turn or has too much free
play or if unusual sounds are noted when turning or
parking.
Headlight aim operation
- Take note of light
pattern occasionally. If beam aim doesn't look right,
headlights should be adjusted.
AT EACH FUEL
FILL
Engine oil level check - Check engine oil level
and add if necessary. See your Owner's Manual for further
details.
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Engine coolant level and condition - Check
engine coolant level in coolant reservoir tank and add if
necessary. Replace if dirty or rusty. See your Owner's
Manual for further details.
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Windshield washer fluid level check -- Check
washer fluid level in container and add if necessary.
Hood latch operation
- When opening hood on
cars equipped with hoods that open from the front, note
the operation of secondary latch. It should keep hood from
opening all the way when primary latch is released. Make
sure that hood closes firmly.
AT LEAST
MONTI-ILY
Tire and wheel inspection and pressure
check--
Check tires for abnormal wear or damage. Also,
check for damaged wheels. Keep pressures as shown on
Tire Placard on the driver's door (include spare unless it is
a stowaway). Pressure should
b\: checked when tires are
"cold". See "Tires" in Owner's Manual for further
infomation.
Light operation check - Check operation of
license plate light, side-marker lights, headlights includ-
ing high beams, parking lights, taillights, brake lights.
turn signals, backup lights, instrument panel and interior
lights and hazard warning flashers.
Fluid leak check - After the car has been parked
for a while, inspect the surface beneath the car for water,
oil, fuel or other fluids. Water dripping from the air
conditioning system after use is normal. If you notice fuel
leaks or fumes, the cause should be found and corrected at
once.
AT LEAST TWICE A YEAR
(FOR EXAMPLE,
EVERY SPRING AND FALL)
Power steering pump fluid level check --
Check power steering pump fluid level in accordance with
Owner's Manual instructions and keep at proper level.
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Brake master cylinder reservoir fluid
level
check ---- Check fluid and keep at proper level. Note: It is
normal for the brake fluid level to go down slightly as the
brake pads wear
- so be sure to keep reservoir filled.
NOTICE: A large loss in this system may indicate a
problem. Have
it inspected and repaired at once.
Clutch system service --- manual
transmis-
sionltransaxle --- For cars equipped with hydraulic
clutch system, check the reservoir fluid level and add fluid
as required. All others, check clutch pedal free travel and
adjust as necessary. See your Owner's Manual for further
details. ~
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Weatherstrip Lubrication - Clean surface and
then apply a thin film of silicone grease with a clean cloth.
EACH
TIME OIL IS CHANGED
Automatic and manual transmissionltrans-
axle fluid level check - Check transmission/transaxle
fluid level and add as required. (Corvette only) if equipped
with manual transmission - check fluid in the overdrive
unit and add as required.
NOTICE: A large loss in this system may indicate a
problem. Have
it inspected and repaired at once.
Brake systems inspection
- For convenience,
the following should be done when wheels are removed
for rotation: Inspect lines and hoses for proper hookup,
binding, leaks, cracks, chafing, etc. Inspect disc brake
pads for wear and rotors for surface condition. Also in-
spect drum brake linings for wear and cracks. Inspect
other brake parts, including drums, wheel cylinders, park-
ing brake, etc. at the same time. Check parking brake
adjustment.
INSPECT BRAKES MORE OFTEN IF
DRIVING
HABITS OR CONDITIONS RESULT IN FREQUENT
BRAKING.
Steering, suspension and front drive axle
boot and seal inspection
- Inspect front and rear
suspension and steering system for damaged, loose or
missing parts, signs of wear or lack of lubrication. Inspect
power steering lines and hoses for proper hookup, bind-
ing, leaks, cracks, chafing, etc. (On cars equipped with
manual steering gear, check for seal leakage.) On
front-
wheel-drive cars, clean then inspect drive axle boot seals
for damage, tears or leakage. Replace seals if necessary.
Exhaust system inspection
- Inspect complete
system. Inspect body near the exhaust system. Look for
broken, damaged, missing or out-of-position parts as well
as open seams, holes, loose connections or other condi-
tions which could cause a heat buildup in the tloor pan or
could let exhaust fumes seep into the trunk or passenger
compartment.
Tire and wheel operation - Be alert to a vibra-
tion of the steering wheel or seat at normal highway
speeds. This may mean a wheel balance is needed. Also, a
pull right or left on a straight, level road may show the
need for
a tire pressure adjustment or wheel alignment.
Steering system operation
- Be alert to
changes in steering action. An inspection is needed when
the steering wheel is harder to turn or has too much free
play or if unusual sounds are noted when turning or
parking.
Headlight aim operation
- Take note of light
pattern occasionally. If beam aim doesn't look right,
headlights should be adjusted.
AT EACH FUEL
FILL
Engine oil level check - Check engine oil level
and add if necessary. See your Owner's Manual for further
details.
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Engine coolant level and condition - Check
engine coolant level in coolant reservoir tank and add if
necessary. Replace if dirty or rusty. See your Owner's
Manual for further details.
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Windshield washer fluid level check -- Check
washer fluid level in container and add if necessary.
Hood latch operation
- When opening hood on
cars equipped with hoods that open from the front, note
the operation of secondary latch. It should keep hood from
opening all the way when primary latch is released. Make
sure that hood closes firmly.
AT LEAST
MONTI-ILY
Tire and wheel inspection and pressure
check--
Check tires for abnormal wear or damage. Also,
check for damaged wheels. Keep pressures as shown on
Tire Placard on the driver's door (include spare unless it is
a stowaway). Pressure should
b\: checked when tires are
"cold". See "Tires" in Owner's Manual for further
infomation.
Light operation check - Check operation of
license plate light, side-marker lights, headlights includ-
ing high beams, parking lights, taillights, brake lights.
turn signals, backup lights, instrument panel and interior
lights and hazard warning flashers.
Fluid leak check - After the car has been parked
for a while, inspect the surface beneath the car for water,
oil, fuel or other fluids. Water dripping from the air
conditioning system after use is normal. If you notice fuel
leaks or fumes, the cause should be found and corrected at
once.
AT LEAST TWICE A YEAR
(FOR EXAMPLE,
EVERY SPRING AND FALL)
Power steering pump fluid level check --
Check power steering pump fluid level in accordance with
Owner's Manual instructions and keep at proper level.
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Brake master cylinder reservoir fluid
level
check ---- Check fluid and keep at proper level. Note: It is
normal for the brake fluid level to go down slightly as the
brake pads wear
- so be sure to keep reservoir filled.
NOTICE: A large loss in this system may indicate a
problem. Have
it inspected and repaired at once.
Clutch system service --- manual
transmis-
sionltransaxle --- For cars equipped with hydraulic
clutch system, check the reservoir fluid level and add fluid
as required. All others, check clutch pedal free travel and
adjust as necessary. See your Owner's Manual for further
details. ~
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Weatherstrip Lubrication - Clean surface and
then apply a thin film of silicone grease with a clean cloth.
EACH
TIME OIL IS CHANGED
Automatic and manual transmissionltrans-
axle fluid level check - Check transmission/transaxle
fluid level and add as required. (Corvette only) if equipped
with manual transmission - check fluid in the overdrive
unit and add as required.
NOTICE: A large loss in this system may indicate a
problem. Have
it inspected and repaired at once.
Brake systems inspection
- For convenience,
the following should be done when wheels are removed
for rotation: Inspect lines and hoses for proper hookup,
binding, leaks, cracks, chafing, etc. Inspect disc brake
pads for wear and rotors for surface condition. Also in-
spect drum brake linings for wear and cracks. Inspect
other brake parts, including drums, wheel cylinders, park-
ing brake, etc. at the same time. Check parking brake
adjustment.
INSPECT BRAKES MORE OFTEN IF
DRIVING
HABITS OR CONDITIONS RESULT IN FREQUENT
BRAKING.
Steering, suspension and front drive axle
boot and seal inspection
- Inspect front and rear
suspension and steering system for damaged, loose or
missing parts, signs of wear or lack of lubrication. Inspect
power steering lines and hoses for proper hookup, bind-
ing, leaks, cracks, chafing, etc. (On cars equipped with
manual steering gear, check for seal leakage.) On
front-
wheel-drive cars, clean then inspect drive axle boot seals
for damage, tears or leakage. Replace seals if necessary.
Exhaust system inspection
- Inspect complete
system. Inspect body near the exhaust system. Look for
broken, damaged, missing or out-of-position parts as well
as open seams, holes, loose connections or other condi-
tions which could cause a heat buildup in the tloor pan or
could let exhaust fumes seep into the trunk or passenger
compartment.
MAINTENANCE AND LUBRICATION OB-5
Throttle linkage inspection -- Inspect for inter-
ference, binding, damaged or missing parts.
Engine drive belts inspection
- Inspect all
belts for cracks, fraying and wear. Adjust or replace as
needed.
Rear axle service (if equipped)
- Check gear
lubricant level and add if needed. For cars equipped with a
limited slip rear axle, fluid does not require changing
(except Caprice and Corvette - change fluid and required
additive at first
7,500 miles (12 500 km). See your
Owner's Manual or "Recommended Fluids
& Lubricants
Chart" in this section.
IF YOU USE YOUR GAR TO
PULL A TRAILER,
CHANGE GEAR LUBRICANT EVERY 7,500 MILES
(12 500
KM).
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Power antenna
- Clean and then lubricate power
antenna mast. The proper lubricant as shown in Figure
OB-2 should be used.
AT LEAST ONCE A YEAR
Lap and shoulder belts condition and opera-
tion
- Inspect belt system, including webbing, buckles,
latch plates, retractors, guide loops and anchors.
Moveable head restraint operation - On cars
with moveable restraints, make sure restraints stay in the
desired position. (See adjustment instructions in your
Owner's Manual.)
Seatback latch and recliner operation on
cars equipped
with recliner seat --- Be sure
seat-
backs latch on those cars with folding seats using mechan-
ical latches. Make sure the recliner is holding by pushing
and pulling on the top of the seatback while it is reclined.
See your Owner's Manual for seat operating information.
Spare tire and jack storage- Be alert to rattles
in rear of car. Make sure the space tire, all jacking equip-
ment, any tire inflator and any covers or doors are securely
stowed at all times. Oil jack ratchet or screw mechanism
after each use.
Key lock service
- Lubricate key lock cylinder at
least annually.
Body lubrication service
- Lubricate all body
door hinges including the tailgate or hatchback lid (if
equipped). Also lubricate the body hood, fuel door and
rear compartment hinges and latches including interior
glove box and counsel doors, and any folding seat
hardware.
"Fansmissionltransaxle neutral or clutch
starl switch operation
CAUnON: Before pedorming the follow-
ing safety switch check, be sure to have
enough room around the car. Then, firmly
apply both the parking brake (see your
Owner's Manual for procedure) and the
regular brakes. Do not use the accelerator
pedal. If the engine starls, be ready to turn
off the ignition promptly. Take these pre-
cautions because the car could move
without warning and possibly cause per-
sonal injury or properly damage. On auto-
matic transmissionltransaxle cars, try to
starl the engine in each gear. The starler
should crank only in "Park" or "Neutral."
On manual transmissionltransaxle cars,
place the shiR lever in "Neutral," push the
clutch halfway and try to starl. The starler
should crank only when the clutch is fully
depressed.
Steering column lock operation
- While
parked, try to turn key to "Lock" in each gear range. The
key should turn to "Lock" only when gear is in "Park" on
automatic or "Reverse" on manual
transmissionltransax-
le. On cars with key release lever, try to turn key toULock"
without depressing the lever. The key should turn to
"Lock" only with the key lever depressed. On all vehicles,
the key should come out only in "Lock."
Parking brake and transmissionltransaxle
"Park" mechanism operation
CAUT1ON:Before checking the holding
ability of the parking brake and automatic
transmissionltransaxle "Park" mecha-
nism, park on a fairly steep hill with
enough room for movement in the down-
hill direction. To reduce the risk of person-
al injury or property damage, be prepared
to apply the regular brakes promptly if the
car begins to move.
To check the parking brake, with the engine running and
transmission/transaxle in "Neutral." slowly remove foot
pressure from the regular brake pedal (until the car is held
by only the parking brake).
To check the automatic transmissionltransaxle "Park"
mechanism holding ability, release all brakes after shift-
ing the transmissionltransaxle to "Park."
ljnderbody flushing - At least every spring,
tlush from the underbody with plain water any corrosive
materials used for ice and snow removal and dust control.
Take care to thoroughly clean any areas where mud and
other debris can collect. Sediment packed in closed areas
of the vehicle should be loosened before being flushed.
Engine cooling system service
- Inspect
coolant and freeze protection. If dirty or rusty, drain, flush
and refill with new coolant. Keep coolant at the proper
mixture as specified in your Owner's Manual. This pro-
vides proper freeze protection. corrosion inhibitor level
and engine operating temperature. Inspect hoses and re-
place if cracked. swollen or deteriorated. Tighten hose
clamps. Clean outside of radiator and air conditioning
condensor. Wash radiator filler cap and neck.
To help
ensure proper operation. a pressure test of both the cooling
system and cap is also recommended. (See maintenance
schedule charts in Figure
OB-l for the recommended
coolant change interval.)
Throttle linkage inspection -- Inspect for inter-
ference, binding, damaged or missing parts.
Engine drive belts inspection
- Inspect all
belts for cracks, fraying and wear. Adjust or replace as
needed.
Rear axle service (if equipped)
- Check gear
lubricant level and add if needed. For cars equipped with a
limited slip rear axle, fluid does not require changing
(except Caprice and Corvette - change fluid and required
additive at first
7,500 miles (12 500 km). See your
Owner's Manual or "Recommended Fluids
& Lubricants
Chart" in this section.
IF YOU USE YOUR GAR TO
PULL A TRAILER,
CHANGE GEAR LUBRICANT EVERY 7,500 MILES
(12 500
KM).
NOTICE: A large loss in this system may indicate a
problem. Have it inspected and repaired at once.
Power antenna
- Clean and then lubricate power
antenna mast. The proper lubricant as shown in Figure
OB-2 should be used.
AT LEAST ONCE A YEAR
Lap and shoulder belts condition and opera-
tion
- Inspect belt system, including webbing, buckles,
latch plates, retractors, guide loops and anchors.
Moveable head restraint operation - On cars
with moveable restraints, make sure restraints stay in the
desired position. (See adjustment instructions in your
Owner's Manual.)
Seatback latch and recliner operation on
cars equipped
with recliner seat --- Be sure
seat-
backs latch on those cars with folding seats using mechan-
ical latches. Make sure the recliner is holding by pushing
and pulling on the top of the seatback while it is reclined.
See your Owner's Manual for seat operating information.
Spare tire and jack storage- Be alert to rattles
in rear of car. Make sure the space tire, all jacking equip-
ment, any tire inflator and any covers or doors are securely
stowed at all times. Oil jack ratchet or screw mechanism
after each use.
Key lock service
- Lubricate key lock cylinder at
least annually.
Body lubrication service
- Lubricate all body
door hinges including the tailgate or hatchback lid (if
equipped). Also lubricate the body hood, fuel door and
rear compartment hinges and latches including interior
glove box and counsel doors, and any folding seat
hardware.
"Fansmissionltransaxle neutral or clutch
starl switch operation
CAUnON: Before pedorming the follow-
ing safety switch check, be sure to have
enough room around the car. Then, firmly
apply both the parking brake (see your
Owner's Manual for procedure) and the
regular brakes. Do not use the accelerator
pedal. If the engine starls, be ready to turn
off the ignition promptly. Take these pre-
cautions because the car could move
without warning and possibly cause per-
sonal injury or properly damage. On auto-
matic transmissionltransaxle cars, try to
starl the engine in each gear. The starler
should crank only in "Park" or "Neutral."
On manual transmissionltransaxle cars,
place the shiR lever in "Neutral," push the
clutch halfway and try to starl. The starler
should crank only when the clutch is fully
depressed.
Steering column lock operation
- While
parked, try to turn key to "Lock" in each gear range. The
key should turn to "Lock" only when gear is in "Park" on
automatic or "Reverse" on manual
transmissionltransax-
le. On cars with key release lever, try to turn key toULock"
without depressing the lever. The key should turn to
"Lock" only with the key lever depressed. On all vehicles,
the key should come out only in "Lock."
Parking brake and transmissionltransaxle
"Park" mechanism operation
CAUT1ON:Before checking the holding
ability of the parking brake and automatic
transmissionltransaxle "Park" mecha-
nism, park on a fairly steep hill with
enough room for movement in the down-
hill direction. To reduce the risk of person-
al injury or property damage, be prepared
to apply the regular brakes promptly if the
car begins to move.
To check the parking brake, with the engine running and
transmission/transaxle in "Neutral." slowly remove foot
pressure from the regular brake pedal (until the car is held
by only the parking brake).
To check the automatic transmissionltransaxle "Park"
mechanism holding ability, release all brakes after shift-
ing the transmissionltransaxle to "Park."
ljnderbody flushing - At least every spring,
tlush from the underbody with plain water any corrosive
materials used for ice and snow removal and dust control.
Take care to thoroughly clean any areas where mud and
other debris can collect. Sediment packed in closed areas
of the vehicle should be loosened before being flushed.
Engine cooling system service
- Inspect
coolant and freeze protection. If dirty or rusty, drain, flush
and refill with new coolant. Keep coolant at the proper
mixture as specified in your Owner's Manual. This pro-
vides proper freeze protection. corrosion inhibitor level
and engine operating temperature. Inspect hoses and re-
place if cracked. swollen or deteriorated. Tighten hose
clamps. Clean outside of radiator and air conditioning
condensor. Wash radiator filler cap and neck.
To help
ensure proper operation. a pressure test of both the cooling
system and cap is also recommended. (See maintenance
schedule charts in Figure
OB-l for the recommended
coolant change interval.)
NOTE: Fluids and lubricants identified below by name, part number or specification may be obtained from your GM dealer.
Figure 00-2 Recommended Fluids and Lubricants
USAGE
Engine Oil
Engine Coolant
Brake and Hydraul~c Clutch Systems
Parking Brake Cables
Power Steering System
Manual Steerlng Gear (reclrculat~ng ball)
Automatic Transrn~ssionRransaxle and 5 Speed Manual Transm~ss~ons
Manual Transm~ssion (rear-wheel-drive) 4 Speed
Manual Transm~ss~onRransaxle Shin Linkage
Key Lock Cylinders
Automatic Transmlss~onfrransaxle Shlft Llnkage
Clutch Llnkage Plvot Po~nts
Floor Sh~n L~nkage
Power Antenna Mast (3-mast sect~on-type only)
Chass~s Lubr~cation
Standard D~fferent~al Rear Axle
L~m~ted-Sl~p D~flerent~al Rear Axle
W~ndsh~eld.Washer Solvent
Hood Latch Assembly
a) Plvots and Sprlng Anchor
b) Release Pawl
Front Wheel Bearings (rearqwheel-drive)
Hood and door hlnges, statlon wagon tailgate hlnge or hatchback Ild and
Ilnkage, headl~ght door assembl~es, statlon wagon rear foldrng seat, fuel door
hlnge, rear compartment Ihd hlnges
Weatherstr~ps
FLUlDlLUBRlCANT
GM Goodwrench Motor 011 or equivalent for API Se~lce, SFICC or SFICD of the
recommended v~scos~ty
M~xture of water and good qual~ty ethylene glycol base antllreeze conforming to GM spec
1825M (GM Part No 1052753)
Delco Supreme 11 Fluld (GM Part No 1052535) or DOT-3 Fluld
Chass~s grease meetlng requirements of GM-6031M (GM Part No 1052497)
GM power steerlng flu~d, Part No 1052884 or equivalent
Use lubricant meetlng requirements of GM-4673M (GM Part No 1052182)
DEXR0N'-II Automat~c Transm~ss~on Flu~d (GM Part No 1051855) Camaro and Flreblrd
(5 Speed)
Corvette overdr~ve unlt - DEXRON a.II All others SAE-80W-90 GL-5 gear lubr~cant
(GM Part No 1052271)
Chass~s grease meetlng requirements of GM-6031M (GM Part No 1052497)
Black Key Lock Cyl~nders - light oil (GM Par1 No. 1052949)
All other Key Lock Cyl~nders - sllicone lubrlcant (GM Part No 1052277)
Eng~ne 011
Eng~ne 011
Eng~ne 011
Llght 011 (GM Part No 1052949)
Chass~s grease meetlng requirements of GM-6031M (GM Part No 1052497)
SAE 80W or SAE 80W-90 GL-5 (SAE 80W GL-5 In Canada) gear lubricant (GM Part No
1052271)
For Camaro only - Use SAE BOW190 GL-5+ Hypold 011 (GM Part No 1050010), 11 equ~pped
wl5 7L (L98) Englne or 5 OL (LB9) engine wmpeed manual transm~ss~on and disc brakes
All other applications - Use SAE 80W or SAE 80W-90 GL-5 Gear Lubr~cant (GM Part No
1052271)
GM Opt~kleen Washer Solvent (GM Part No 1051515) or equ~valent
a) Eng~ne 011
b) Chass~s grease meet~ng requirements of GM.6031M (GM Part No 1052497)
Lubricant GM Part No 1051344 grease or equivalent
Eng~ne 011
S~l~cone Grease (GM Part No 1052863) or equivalent
Figure 00-2 Recommended Fluids and Lubricants
USAGE
Engine Oil
Engine Coolant
Brake and Hydraul~c Clutch Systems
Parking Brake Cables
Power Steering System
Manual Steerlng Gear (reclrculat~ng ball)
Automatic Transrn~ssionRransaxle and 5 Speed Manual Transm~ss~ons
Manual Transm~ssion (rear-wheel-drive) 4 Speed
Manual Transm~ss~onRransaxle Shin Linkage
Key Lock Cylinders
Automatic Transmlss~onfrransaxle Shlft Llnkage
Clutch Llnkage Plvot Po~nts
Floor Sh~n L~nkage
Power Antenna Mast (3-mast sect~on-type only)
Chass~s Lubr~cation
Standard D~fferent~al Rear Axle
L~m~ted-Sl~p D~flerent~al Rear Axle
W~ndsh~eld.Washer Solvent
Hood Latch Assembly
a) Plvots and Sprlng Anchor
b) Release Pawl
Front Wheel Bearings (rearqwheel-drive)
Hood and door hlnges, statlon wagon tailgate hlnge or hatchback Ild and
Ilnkage, headl~ght door assembl~es, statlon wagon rear foldrng seat, fuel door
hlnge, rear compartment Ihd hlnges
Weatherstr~ps
FLUlDlLUBRlCANT
GM Goodwrench Motor 011 or equivalent for API Se~lce, SFICC or SFICD of the
recommended v~scos~ty
M~xture of water and good qual~ty ethylene glycol base antllreeze conforming to GM spec
1825M (GM Part No 1052753)
Delco Supreme 11 Fluld (GM Part No 1052535) or DOT-3 Fluld
Chass~s grease meetlng requirements of GM-6031M (GM Part No 1052497)
GM power steerlng flu~d, Part No 1052884 or equivalent
Use lubricant meetlng requirements of GM-4673M (GM Part No 1052182)
DEXR0N'-II Automat~c Transm~ss~on Flu~d (GM Part No 1051855) Camaro and Flreblrd
(5 Speed)
Corvette overdr~ve unlt - DEXRON a.II All others SAE-80W-90 GL-5 gear lubr~cant
(GM Part No 1052271)
Chass~s grease meetlng requirements of GM-6031M (GM Part No 1052497)
Black Key Lock Cyl~nders - light oil (GM Par1 No. 1052949)
All other Key Lock Cyl~nders - sllicone lubrlcant (GM Part No 1052277)
Eng~ne 011
Eng~ne 011
Eng~ne 011
Llght 011 (GM Part No 1052949)
Chass~s grease meetlng requirements of GM-6031M (GM Part No 1052497)
SAE 80W or SAE 80W-90 GL-5 (SAE 80W GL-5 In Canada) gear lubricant (GM Part No
1052271)
For Camaro only - Use SAE BOW190 GL-5+ Hypold 011 (GM Part No 1050010), 11 equ~pped
wl5 7L (L98) Englne or 5 OL (LB9) engine wmpeed manual transm~ss~on and disc brakes
All other applications - Use SAE 80W or SAE 80W-90 GL-5 Gear Lubr~cant (GM Part No
1052271)
GM Opt~kleen Washer Solvent (GM Part No 1051515) or equ~valent
a) Eng~ne 011
b) Chass~s grease meet~ng requirements of GM.6031M (GM Part No 1052497)
Lubricant GM Part No 1051344 grease or equivalent
Eng~ne 011
S~l~cone Grease (GM Part No 1052863) or equivalent
HEATING AND VENTILATION 1A-1
SECTION 1A
NG AND VENT
CONTENTS
General Description ................................. 1A-1
Diagnosis - Heater Trouble ...................... 1A-5
Insufficient Heating or Defrosting .............. 1A-5
Blower Electrical ......................................... 1A-7
....... Improper Air DeliveryINo Mode Shift 1 A-8
Too Much Heat .......................................... 1A-9
....................................................... Controls 1A-10
............................................... Blower Noise 1A-11
....................................... On-Vehicle Sewice 1A-13
.......................... Heater Control Assembly 1 A- 13
....................................... Blower Switch 1A- 13
.................................. Temperature Cable 1 A- 13
.......................................... Heater Core 1 A- 13
................................. Vent Control Cable 1 A- 13
Lower Heater Outlet ................................ 1A-14
........................................ Blower Motor 1A-14
GENERAL DESCRIPTION
The base heater system is designed to provide
heating, ventilation, windshield defrosting and on some
cars, side window defogging. Ram air ventilation is
provided on some cars by two (2) outboard vent valves
installed in the plenum. These vent valves are
controlled by push-pull controls mounted in the
instrument panel. When either of these valves are
opened, air will enter the passenger compartment from
the pressurized plenum and be directed to the floor of
the vehicle.
/& VENTILATION
1-FRONT INLET GRILLE
2-BODY LOCK PILLAR EXHAUST VALVE
Fig. 2 Interior Body Air
& Exit - Typical Hatchback
Models
The power-vent, heat, and defrost provisions of
the base system are controlled within the heater
module. The module itself is composed of two (2)
components
- a blower air inlet and a heater defroster.
The blower air inlet is mounted to the front of the cowl
and the heater defroster assembly is mounted to the
rear of the cowl. A gasket is used between the two to
prevent air, water and noise entrance into the
passenger compartment. Air distribution is through a
heater outlet, defroster duct, power-vent duct work
and outlets.
The three modes of the base heater system (vent,
heat, defrost) are controlled by the functional
assemblies within the heater module. These assemblies
are defined below:
1. Motor & Fan Assembly (Blower).
Provides and regulates air flow from the air inlet
for further processing and/or distribution.
2. Heater Core.
Transfers heat from engine coolant to inlet air,
heating the inlet air.
3. Temperature Valve.
Regulates the amount of air passing through the
heater core, controlling the temperature and mix
of heated and ambient air.
4. Mode (Defroster) Valve.
Regulates the flow and distribution of processed
air to the distribution (heater or defroster) ducts.
5. Vent Valve.
Regulates the flow of non-processed (outside) air
into the passenger compartment.
The operation of these assemblies is controlled by
the levers and switch on the control head. Depending
on model application, two (2) or three
(3) indexed
snap-in cables are attached to the module and control
levers.
The temperature cable has the slider-type,
self-adjust feature. As the temperature lever of the
control head is cycled through its full range of travel,
the cable clip will assume a position assuring that the
temperature valve will seat in both extreme positions.
The vent and/or defrost cables also have the
SECTION 1A
NG AND VENT
CONTENTS
General Description ................................. 1A-1
Diagnosis - Heater Trouble ...................... 1A-5
Insufficient Heating or Defrosting .............. 1A-5
Blower Electrical ......................................... 1A-7
....... Improper Air DeliveryINo Mode Shift 1 A-8
Too Much Heat .......................................... 1A-9
....................................................... Controls 1A-10
............................................... Blower Noise 1A-11
....................................... On-Vehicle Sewice 1A-13
.......................... Heater Control Assembly 1 A- 13
....................................... Blower Switch 1A- 13
.................................. Temperature Cable 1 A- 13
.......................................... Heater Core 1 A- 13
................................. Vent Control Cable 1 A- 13
Lower Heater Outlet ................................ 1A-14
........................................ Blower Motor 1A-14
GENERAL DESCRIPTION
The base heater system is designed to provide
heating, ventilation, windshield defrosting and on some
cars, side window defogging. Ram air ventilation is
provided on some cars by two (2) outboard vent valves
installed in the plenum. These vent valves are
controlled by push-pull controls mounted in the
instrument panel. When either of these valves are
opened, air will enter the passenger compartment from
the pressurized plenum and be directed to the floor of
the vehicle.
/& VENTILATION
1-FRONT INLET GRILLE
2-BODY LOCK PILLAR EXHAUST VALVE
Fig. 2 Interior Body Air
& Exit - Typical Hatchback
Models
The power-vent, heat, and defrost provisions of
the base system are controlled within the heater
module. The module itself is composed of two (2)
components
- a blower air inlet and a heater defroster.
The blower air inlet is mounted to the front of the cowl
and the heater defroster assembly is mounted to the
rear of the cowl. A gasket is used between the two to
prevent air, water and noise entrance into the
passenger compartment. Air distribution is through a
heater outlet, defroster duct, power-vent duct work
and outlets.
The three modes of the base heater system (vent,
heat, defrost) are controlled by the functional
assemblies within the heater module. These assemblies
are defined below:
1. Motor & Fan Assembly (Blower).
Provides and regulates air flow from the air inlet
for further processing and/or distribution.
2. Heater Core.
Transfers heat from engine coolant to inlet air,
heating the inlet air.
3. Temperature Valve.
Regulates the amount of air passing through the
heater core, controlling the temperature and mix
of heated and ambient air.
4. Mode (Defroster) Valve.
Regulates the flow and distribution of processed
air to the distribution (heater or defroster) ducts.
5. Vent Valve.
Regulates the flow of non-processed (outside) air
into the passenger compartment.
The operation of these assemblies is controlled by
the levers and switch on the control head. Depending
on model application, two (2) or three
(3) indexed
snap-in cables are attached to the module and control
levers.
The temperature cable has the slider-type,
self-adjust feature. As the temperature lever of the
control head is cycled through its full range of travel,
the cable clip will assume a position assuring that the
temperature valve will seat in both extreme positions.
The vent and/or defrost cables also have the
1A-2 HEATING AND VENTILATION
520003-1 A
Fig. 3 Interior Body Air & Exit - Typical Sedan, Station Wagon
self-adjusting feature. Blower speeds are controllable in
all modes (VENT, HEAT, DEFROST) by the switch
on the control head.
The power-vent ventilation feature is available in
the vent mode. Outside air enters the plenum and is
driven by the blower to the temperature valve. In the
cold position of the temperature valve, air bypasses the
heater core to the vent valve opening and enters the
passenger compartment through the vent duct and
outlets
in the center of the instrument panel. If some
heated air is desired, the temperature valve may be
opened. This allows mixed (tempered) air to flow out
the center vent opening. Blending air between modes
can be done by varying the mode selector.
Varying the selector between "Heat" and
"Defrost" will allow more air or less air to be directed
out either the defroster outlet or the heater outlet. The
closer the mode selector is positioned to the "Heater"
position, the larger the amount of air coming out the
heater outlet. The closer the mode selector is
positioned to "Defrost," the larger the amount of air
going to the windshield. The temperature of this air is
governed by the temperature lever position.
Side window defogging, if so equipped, is
provided via ducts in the outboard corners of the
instrument panel. Maximum air flow from these vents
will be in "Heater" mode with reduced air flow in
"Defrost" mode.
Varying the mode selector between "Heater" and
"Vent" positions varies the proportion of air coming
out the heater outlet and the center vent outlets. With
the selector in some midway position, air coming out
the center vent outlets will be ambient temperature,
while air out the heater outlet will be mixed warm air,
its temperature depending on temperature lever
position.
In the heat and defrost mode, outside air is driven by
the blower to the temperature valve which, depending
upon its position as controlled by the operator, distributes
all or some portion of the inlet air through the heater core.
The vent valve will prevent air entry into the vent duct and
direct this ambient air to the mix portion of the heater
module. The air is thus heated, mixed, and then directed
into either the defroster duct or the heater outlet by the
position of the mode valve and control lever.
A small
amount of air is bled to the side window defogger system.
520003-1 A
Fig. 3 Interior Body Air & Exit - Typical Sedan, Station Wagon
self-adjusting feature. Blower speeds are controllable in
all modes (VENT, HEAT, DEFROST) by the switch
on the control head.
The power-vent ventilation feature is available in
the vent mode. Outside air enters the plenum and is
driven by the blower to the temperature valve. In the
cold position of the temperature valve, air bypasses the
heater core to the vent valve opening and enters the
passenger compartment through the vent duct and
outlets
in the center of the instrument panel. If some
heated air is desired, the temperature valve may be
opened. This allows mixed (tempered) air to flow out
the center vent opening. Blending air between modes
can be done by varying the mode selector.
Varying the selector between "Heat" and
"Defrost" will allow more air or less air to be directed
out either the defroster outlet or the heater outlet. The
closer the mode selector is positioned to the "Heater"
position, the larger the amount of air coming out the
heater outlet. The closer the mode selector is
positioned to "Defrost," the larger the amount of air
going to the windshield. The temperature of this air is
governed by the temperature lever position.
Side window defogging, if so equipped, is
provided via ducts in the outboard corners of the
instrument panel. Maximum air flow from these vents
will be in "Heater" mode with reduced air flow in
"Defrost" mode.
Varying the mode selector between "Heater" and
"Vent" positions varies the proportion of air coming
out the heater outlet and the center vent outlets. With
the selector in some midway position, air coming out
the center vent outlets will be ambient temperature,
while air out the heater outlet will be mixed warm air,
its temperature depending on temperature lever
position.
In the heat and defrost mode, outside air is driven by
the blower to the temperature valve which, depending
upon its position as controlled by the operator, distributes
all or some portion of the inlet air through the heater core.
The vent valve will prevent air entry into the vent duct and
direct this ambient air to the mix portion of the heater
module. The air is thus heated, mixed, and then directed
into either the defroster duct or the heater outlet by the
position of the mode valve and control lever.
A small
amount of air is bled to the side window defogger system.
HEAPING AND VENTILA"T0N 1A-3
1, LEFT AND RIGHT SIDE WINDOW 3. POWER VENTIHEAT 5. LEFT AND RIGHT RAM AIR
DEFOG OUTLETS* OUTLETS VENT OUTLETS*
2. LEFT AND RIGHT DEFROSTER 4. RAM AIR VENT
OUTLETS CONTROLS*
* NOT ON ALL MODELS
J10001-1A-F
Fig. 4 Heater Ventilation System - Typical
1-THIS POSITION ALLOWS OUTSIDE AIR FLOW 3-THIS POSITION ALLOWS ABOUT 80% AIR
TO FLOOR OUTLET. (ADDITIONAL VENTED FLOW TO WINDSHIELD AND 20% TO FLOOR.
AIR CAN BE DISTRIBUTED INSIDE CAR BY
OPERATING VENT KNOBS.)
4-TEMPERATURE LEVER POSITION WILL
REGULATE OUTLET AIR TEMPERATURE BY
2-POSITION OF THIS SYSTEM SELECTOR BLENDING THE INCOMING OUTSIDE AIR
LEVER DETERMINES AIR FLOW FROM THROUGHIAROUND THE HEATER CORE.
FLOOR, INSTRUMENT PANEL OR WIND-
SHIELD OUTLET
- IN "HEATER", FLOW IS 5-THE FAN CONTROL LEVER (OFF
- HI) PRO.
ABOUT
80% TO FLOOR AND 20% TO
WIND- VIBES SPEED CONTROL OF THE FAN.
SHIELD OUTLETS (AND SlDE WINDOW DE-
FOGGERS).
Fig. 5 Heater Control - Typical
1, LEFT AND RIGHT SIDE WINDOW 3. POWER VENTIHEAT 5. LEFT AND RIGHT RAM AIR
DEFOG OUTLETS* OUTLETS VENT OUTLETS*
2. LEFT AND RIGHT DEFROSTER 4. RAM AIR VENT
OUTLETS CONTROLS*
* NOT ON ALL MODELS
J10001-1A-F
Fig. 4 Heater Ventilation System - Typical
1-THIS POSITION ALLOWS OUTSIDE AIR FLOW 3-THIS POSITION ALLOWS ABOUT 80% AIR
TO FLOOR OUTLET. (ADDITIONAL VENTED FLOW TO WINDSHIELD AND 20% TO FLOOR.
AIR CAN BE DISTRIBUTED INSIDE CAR BY
OPERATING VENT KNOBS.)
4-TEMPERATURE LEVER POSITION WILL
REGULATE OUTLET AIR TEMPERATURE BY
2-POSITION OF THIS SYSTEM SELECTOR BLENDING THE INCOMING OUTSIDE AIR
LEVER DETERMINES AIR FLOW FROM THROUGHIAROUND THE HEATER CORE.
FLOOR, INSTRUMENT PANEL OR WIND-
SHIELD OUTLET
- IN "HEATER", FLOW IS 5-THE FAN CONTROL LEVER (OFF
- HI) PRO.
ABOUT
80% TO FLOOR AND 20% TO
WIND- VIBES SPEED CONTROL OF THE FAN.
SHIELD OUTLETS (AND SlDE WINDOW DE-
FOGGERS).
Fig. 5 Heater Control - Typical
1A-4 HEATING AND VENTILATION
1-DEFROSTER OUTLET 7-PURGE DOOR OPENS TO ALLOW 11-AIR DOOR CLOSES OFF HEATER
AIR FLOW INTO CAR UNDER I.P. AND DEFROSTER OUTLETS WHEN
2-BLENDED AIR WHEN SYSTEM SELECTOR LEVER SYSTEM SELECTOR LEVER IS
IS MOVED TO "OFF" MOVED TO "OFF"
3-HEATER CORE
8-UNTEMPERED AIR 12-DEFROSTER DOOR MOVES BY
4-BLOWER OPERATION OF HEATER
9-WARMED AIR CONTROLS SYSTEM SELECTOR
5-DASH PANEL LEVER
10-TEMPERATURE DOOR MOVES BY
6-OUTSIDE AIR FROM COWL OPERATION OF TEMPERATURE
"ON SOME MODELS ALSO
PLENUM CHAMBER LEVER ON HEATER CONTROL
SUPPLIES SIDE WINDOW
DEFOGGING DUCTS.
.
-.
Fig. 6 Typical Heater System Air Flow
1-DEFROSTER OUTLET 7-PURGE DOOR OPENS TO ALLOW 11-AIR DOOR CLOSES OFF HEATER
AIR FLOW INTO CAR UNDER I.P. AND DEFROSTER OUTLETS WHEN
2-BLENDED AIR WHEN SYSTEM SELECTOR LEVER SYSTEM SELECTOR LEVER IS
IS MOVED TO "OFF" MOVED TO "OFF"
3-HEATER CORE
8-UNTEMPERED AIR 12-DEFROSTER DOOR MOVES BY
4-BLOWER OPERATION OF HEATER
9-WARMED AIR CONTROLS SYSTEM SELECTOR
5-DASH PANEL LEVER
10-TEMPERATURE DOOR MOVES BY
6-OUTSIDE AIR FROM COWL OPERATION OF TEMPERATURE
"ON SOME MODELS ALSO
PLENUM CHAMBER LEVER ON HEATER CONTROL
SUPPLIES SIDE WINDOW
DEFOGGING DUCTS.
.
-.
Fig. 6 Typical Heater System Air Flow
HEATING AND VENTILATION 1A-5
@ INSUFFICIENT HEATING OR DEFROST lNG
OF THE HEATER
IF PROBLEM NOT RESOLVED THEN
HECK FOR AIRFLOW OUT DEFROSTER
VENT OUTLETS
INSTALL THE RADIATOR CAP. WITH ENGINE WARM,
DRIVE THE VEHICLE AT
48
KPH(3OMPH). WITH A THER-
MOMETER, CHECK THE AMBIENT AIR TEMPERATURE
CONTINUED AT TOP OF NEXT PAGE
Fig. 7 Insufficient Heating or Defrosting Diagnosis Procedure
(7 of 2)
@ INSUFFICIENT HEATING OR DEFROST lNG
OF THE HEATER
IF PROBLEM NOT RESOLVED THEN
HECK FOR AIRFLOW OUT DEFROSTER
VENT OUTLETS
INSTALL THE RADIATOR CAP. WITH ENGINE WARM,
DRIVE THE VEHICLE AT
48
KPH(3OMPH). WITH A THER-
MOMETER, CHECK THE AMBIENT AIR TEMPERATURE
CONTINUED AT TOP OF NEXT PAGE
Fig. 7 Insufficient Heating or Defrosting Diagnosis Procedure
(7 of 2)
1A-6 HEATING AND VENTILATION
CHECK VEHICLE FOR
COLD AIR LEAKS AT DASH,
HEATER CASES AND FROM
VENTS. CHECK
UNDERSEAT FOR
OBSTRUCTIONS.
w
TEN FOR DOOR SLAM PRIOR TO THE END
CHECK THE TEMPERA-
TURE DOOR ADJUSTMENT,
CABLES, LINKAGE AND AD-
JUST TO FULL HOT. CHECK
I
WITH THE TEMPERATURE
DOOR FULL HOT, START THE
VEHICLE. CHECK THE TEMPER-
ATURE OF THE HEATER INLET
AND OUTLET HOSES BY FEEL.
THE AIR TEMPERATURE
AROUND THE HOSES MUST BE
AT LEAST 85OF.
I
WITH THE BLOWER ON
HIGH, MOVE THE TEMP-
ERATURE LEVER FROM
FULL HOT TO FULL
COLD AND LISTEN FOR
AIRFLOW CHANGE.
CHECK THE TEMPER-
ATURE DOOR AD-
JUSTMENT, CABLES,
CONTROL, LINKAGE &
BETWEEN THE
COOLANT REPLACE.
Fig. 8 Insufficient Heating or Defrosting Diagnosis Procedure (2 of 2)
CHECK VEHICLE FOR
COLD AIR LEAKS AT DASH,
HEATER CASES AND FROM
VENTS. CHECK
UNDERSEAT FOR
OBSTRUCTIONS.
w
TEN FOR DOOR SLAM PRIOR TO THE END
CHECK THE TEMPERA-
TURE DOOR ADJUSTMENT,
CABLES, LINKAGE AND AD-
JUST TO FULL HOT. CHECK
I
WITH THE TEMPERATURE
DOOR FULL HOT, START THE
VEHICLE. CHECK THE TEMPER-
ATURE OF THE HEATER INLET
AND OUTLET HOSES BY FEEL.
THE AIR TEMPERATURE
AROUND THE HOSES MUST BE
AT LEAST 85OF.
I
WITH THE BLOWER ON
HIGH, MOVE THE TEMP-
ERATURE LEVER FROM
FULL HOT TO FULL
COLD AND LISTEN FOR
AIRFLOW CHANGE.
CHECK THE TEMPER-
ATURE DOOR AD-
JUSTMENT, CABLES,
CONTROL, LINKAGE &
BETWEEN THE
COOLANT REPLACE.
Fig. 8 Insufficient Heating or Defrosting Diagnosis Procedure (2 of 2)
HEATING AND VENTILATION 1A-7
@ BLOWER ELECTRICAL
LOCATE SHORT IN THE
FOLLOWING WIRES:
1. FROM THE FUSE PANEL
2. FROM THE BLOWER
SPEED SWITCH TO THE
HEATER RESISTOR BLOCK.
3. FROM THE HEATER RE-
SISTOR BLOCK. CONNECT A
JUMPER LEAD FROM THE BAT-
TERY POSITIVE TERMINAL TO
ANY
WlRE TERMINAL IN THE
CONNECTOR. USE
12 VOLT
TEST LIGHT TO CHECK FOR
VOLTAGE AT THE CORRES-
PONDING WIRE ON THE
USE THE
12 VOLT
TEST LIGHT TO
CHECK THE POWER
FEED TERMINAL ON
THE BLOWER
SPEED SWITCH
TEST LAMP DOES
BLOWER SPEED SWITCH.
REPAIR OPEN IN FEED
WlRE FROM RESISTOR TO
BLOWER MOTOR.
Fig. 9 Blower Electrical Diagnosis
@ BLOWER ELECTRICAL
LOCATE SHORT IN THE
FOLLOWING WIRES:
1. FROM THE FUSE PANEL
2. FROM THE BLOWER
SPEED SWITCH TO THE
HEATER RESISTOR BLOCK.
3. FROM THE HEATER RE-
SISTOR BLOCK. CONNECT A
JUMPER LEAD FROM THE BAT-
TERY POSITIVE TERMINAL TO
ANY
WlRE TERMINAL IN THE
CONNECTOR. USE
12 VOLT
TEST LIGHT TO CHECK FOR
VOLTAGE AT THE CORRES-
PONDING WIRE ON THE
USE THE
12 VOLT
TEST LIGHT TO
CHECK THE POWER
FEED TERMINAL ON
THE BLOWER
SPEED SWITCH
TEST LAMP DOES
BLOWER SPEED SWITCH.
REPAIR OPEN IN FEED
WlRE FROM RESISTOR TO
BLOWER MOTOR.
Fig. 9 Blower Electrical Diagnosis
1 A-8 HEATIN,G AND VENVILAVIBN
@ IMPROPER AIR DELIVERY OR NO MODE SHlFT
WITH THE VEHICLE ON AND THE ENGINE WARM, RUN THE FOLLOWING FUNC-
I TIONAL CHECKS. CHECK CABLES FOR EXCESSIVE EFFORT OR BINDING.
POWER
VENT
OUTLET
HEATER
OUTLET
DEFR.
OUTLET
MODE SIDE
WINDOW
DEFOGGER
OUTLET
VENT NO
AIRFLOW
NO
AIRFLOW
NO
AIRFLOW AIRFLOW No I
I I
COLD HIGH HIGH VENT AMBIENT
AIRFLOW
NO
AIRFLOW
NO
AIRFLOW AIRFLOW No I
HEATER
DEFROSTER
COLD HIGH HIGH
TO HOT
COLD HIGH HIGH
TO HOT
NO
AIRFLOW
COLD TO
HOT
AIRFLOW
MINIMUM
COLD TO
HOT
AIRFLOW
MINIMUM
COLDTO HOT
AIRFLOW
COLD TO
HOT
AIRFLOW
MINIMUM
COLD TO HOT
AIRFLOW
MINIMUM
COLD TO
AIRFLOW
N
0
AIRFLOW
CONNECTED & CABLE SHEATH RETAINED
G20025.1A
Fig. 10 Improper Air Delivery Or No Mode Shift Diagnosis
@ IMPROPER AIR DELIVERY OR NO MODE SHlFT
WITH THE VEHICLE ON AND THE ENGINE WARM, RUN THE FOLLOWING FUNC-
I TIONAL CHECKS. CHECK CABLES FOR EXCESSIVE EFFORT OR BINDING.
POWER
VENT
OUTLET
HEATER
OUTLET
DEFR.
OUTLET
MODE SIDE
WINDOW
DEFOGGER
OUTLET
VENT NO
AIRFLOW
NO
AIRFLOW
NO
AIRFLOW AIRFLOW No I
I I
COLD HIGH HIGH VENT AMBIENT
AIRFLOW
NO
AIRFLOW
NO
AIRFLOW AIRFLOW No I
HEATER
DEFROSTER
COLD HIGH HIGH
TO HOT
COLD HIGH HIGH
TO HOT
NO
AIRFLOW
COLD TO
HOT
AIRFLOW
MINIMUM
COLD TO
HOT
AIRFLOW
MINIMUM
COLDTO HOT
AIRFLOW
COLD TO
HOT
AIRFLOW
MINIMUM
COLD TO HOT
AIRFLOW
MINIMUM
COLD TO
AIRFLOW
N
0
AIRFLOW
CONNECTED & CABLE SHEATH RETAINED
G20025.1A
Fig. 10 Improper Air Delivery Or No Mode Shift Diagnosis
HEATING AND VENTILATION 1A-9
@TOO MUCH HEAT
TEMPERATURE LEVER
TO CONTROL END OF
LOW THE ENGINE
PERATURE DOOR TO WARM UP. WITH
TEMPERATURE HEATER DEFROST-
ER & VENT DOOR
BLOWER INLET & REPAIR
Fig.
11 Too Much Heat Diagnosis.
@TOO MUCH HEAT
TEMPERATURE LEVER
TO CONTROL END OF
LOW THE ENGINE
PERATURE DOOR TO WARM UP. WITH
TEMPERATURE HEATER DEFROST-
ER & VENT DOOR
BLOWER INLET & REPAIR
Fig.
11 Too Much Heat Diagnosis.
----
1A-10 HEATING AND VENTILATION
@ CONTROLS
CHECK CABLES FOR ROUTING, KINKEC CABLES,
WIRING INTERFERENCE OR OTHER INSTRUMENT
PANEL INTERFERENCE.
REMOVE CABLE
FROM DOOR(S)
CAUSING BINDING
AND CYCLE DOOR(ยง)
MANUALLY. CHECK
FOR DOOR BINDING
MOVES ON HIGH BLOWER
WlTH A LONGER CABLE AND
ADD A LOOP TO THE CABLE
ROUTING TO INCREASE CONTROL
EFFORT, CHECK INSTRUMENT
PANEL INTERFERENCES WlTH
NEW CABLE ROUTING TO INSURE
PROPER OPERATI
INSTALLATION
I
SEAL OK
SHAFT ALIGNMENT, BENT
Fig. 12 Heater Controls Diagnosis
1A-10 HEATING AND VENTILATION
@ CONTROLS
CHECK CABLES FOR ROUTING, KINKEC CABLES,
WIRING INTERFERENCE OR OTHER INSTRUMENT
PANEL INTERFERENCE.
REMOVE CABLE
FROM DOOR(S)
CAUSING BINDING
AND CYCLE DOOR(ยง)
MANUALLY. CHECK
FOR DOOR BINDING
MOVES ON HIGH BLOWER
WlTH A LONGER CABLE AND
ADD A LOOP TO THE CABLE
ROUTING TO INCREASE CONTROL
EFFORT, CHECK INSTRUMENT
PANEL INTERFERENCES WlTH
NEW CABLE ROUTING TO INSURE
PROPER OPERATI
INSTALLATION
I
SEAL OK
SHAFT ALIGNMENT, BENT
Fig. 12 Heater Controls Diagnosis
HEATING AND VENTILATION 1 A-1 1
~ @ BLOWER NOISE
SIT IN THE VEHICLE WlTH THE DOORS AND WINDOWS CLOSED. WlTH THE IGNITION ON
AND THE ENGINE OFF, START WITH THE BLOWER ON HIGH, IN VENT MODE AND THE
TEMPERATURE LEVER ON FULL COLD. CYCLE THROUGH BLOWER SPEEDS, MODES AND
TEMPERATURE DOOR POSITIONS TO FIND WHERE THE NOISE OCCURS AND WHERE THE
SYSTEMS AND MODES (USUALLY DEFROSTER) MAY BE WORSE THAN OTHERS. CHECK
ANOTHER VEHICLE IF POSSIBLE (SAME MODEL) TO DETERMINE IF THE NOISE IS
TYPICAL OF THE SYSTEM AS DESIGNED.
INDICATE THE TYPE OF NOISE AND WHERE IT OCCURS:
A-WHINE, B-CLICKTTICK, C-SQUEALISCREECH, D-FLUTTER, E-RUMBLE,
F-SCRAPING, G--AIR RUSH, H-OTHER, DESCRIBE
I
BLOWER SPEED REDUC- MAY OCCUR AT COLD AM- DOOR COMBINATIONS BUT CAN
0
CONTINUED AT TOP OF NEXT PAGE
G20009-1 A
Fig. 13 Blower Noise Diagnosis (1 of 2)
~ @ BLOWER NOISE
SIT IN THE VEHICLE WlTH THE DOORS AND WINDOWS CLOSED. WlTH THE IGNITION ON
AND THE ENGINE OFF, START WITH THE BLOWER ON HIGH, IN VENT MODE AND THE
TEMPERATURE LEVER ON FULL COLD. CYCLE THROUGH BLOWER SPEEDS, MODES AND
TEMPERATURE DOOR POSITIONS TO FIND WHERE THE NOISE OCCURS AND WHERE THE
SYSTEMS AND MODES (USUALLY DEFROSTER) MAY BE WORSE THAN OTHERS. CHECK
ANOTHER VEHICLE IF POSSIBLE (SAME MODEL) TO DETERMINE IF THE NOISE IS
TYPICAL OF THE SYSTEM AS DESIGNED.
INDICATE THE TYPE OF NOISE AND WHERE IT OCCURS:
A-WHINE, B-CLICKTTICK, C-SQUEALISCREECH, D-FLUTTER, E-RUMBLE,
F-SCRAPING, G--AIR RUSH, H-OTHER, DESCRIBE
I
BLOWER SPEED REDUC- MAY OCCUR AT COLD AM- DOOR COMBINATIONS BUT CAN
0
CONTINUED AT TOP OF NEXT PAGE
G20009-1 A
Fig. 13 Blower Noise Diagnosis (1 of 2)
1A-12 HEATING AND VENTILATION
EXAMINE BLOWER FAN FOR WEAR
SPOTS, CRACKED BLADES OR
HUB, LOOSE FAN RETAINING
NUT AND ALIGNMENT. EXAMINE
BLOWER CASE FOR WEAR SPOTS.
REPAIRIREPLACE
ASNECESSARY
ANDRECHECK
ALL MODES
BUT NOT ALL
TEMPERATURE
POSITIONS
AND REMOVE. CHECK MATERIALS AND
HEATERIDEFROSTER REMOVE. CHECK NECESSARY AND
DOOR SEALS. VENT DOOR
CHECK SYSTEM
FOR OBSTRUC-
TIONS OR FOREIGN
MATERIALS BE-
TWEEN THE FAN
AND THE TEMPER-
ATURE DOOR.
REMOVE, REPAIR
OR REPLACE AS
NECESSARY AND
RECHECK.
Fig.
14 Blower Noise Diagnosis (2 of 2)
EXAMINE BLOWER FAN FOR WEAR
SPOTS, CRACKED BLADES OR
HUB, LOOSE FAN RETAINING
NUT AND ALIGNMENT. EXAMINE
BLOWER CASE FOR WEAR SPOTS.
REPAIRIREPLACE
ASNECESSARY
ANDRECHECK
ALL MODES
BUT NOT ALL
TEMPERATURE
POSITIONS
AND REMOVE. CHECK MATERIALS AND
HEATERIDEFROSTER REMOVE. CHECK NECESSARY AND
DOOR SEALS. VENT DOOR
CHECK SYSTEM
FOR OBSTRUC-
TIONS OR FOREIGN
MATERIALS BE-
TWEEN THE FAN
AND THE TEMPER-
ATURE DOOR.
REMOVE, REPAIR
OR REPLACE AS
NECESSARY AND
RECHECK.
Fig.
14 Blower Noise Diagnosis (2 of 2)
HEATING AND VENTILATION 1.4-1 3
ON-VEHICLE SERVICE
HEATER ELECTRICAL WIRING
The heater wiring diagrams are shown in
Electrical Diagnosis, Section 8A, and should be
referred to for diagnosis of electrical problems in the
heater system.
HEATER CONTROL ASSEMBLY AND BLOWER
SWITCH
Remove or Disconnect
1. Negative battery cable.
2.
Control/radio console trim plate.
3. Three (3) controller retaining screws and pull
controller out from console.
4. Control cables and electrical connections.
5. Blower switch from controller if either switch or
controller requires replacement. If controller is
being replaced, transfer blower switch to new
controller.
Install or Connect
1. When installing controller, install lower right
screw first to properly align controller in console.
2. Blower switch to controller.
3. Control cables and electrical connections.
4. Three (3) controller retaining screws and
controller to console.
5.
Control/radio console trim plate.
6. Negative battery cable.
TEMPERATURE CONTROL, POWER VENT,
HEATER DEFROST CABLE
Remove or Disconnect
1. Hush
panel(s) (see Section 8C):
a. Temperature cable - R.H. hush panel.
b. Heateddefrost cable - R.H. hush panel.
c. Vent cable
- L.H. hush panel.
2.
Control/radio console trim plate.
3. Three (3) controller retaining screws and pull
controller out from console.
4. Control cable requiring replacement at control
end.
5. Cable at mode control end (temperature cable:
remove cable link cover at crank location).
Install or Connect
1. When installing controller, install right lower
screw first to align control in console.
2. Cable at mode control end (temperature cable:
install cable link cover at crank location).
3. Control cable at control end.
4. Three (3) controller retaining screws and
contoller in console.
5.
Control/radio console trim plate.
6. Hush panel(s) (see Section 8C).
7. Fully cycle controls to adjust cables and check for
proper operation.
HEATER CORE
Remove or Disconnect
Battery ground cable.
Drain cooling system.
Heater inlet and outlet hoses from heater core.
Right lower hush panel (see Section
8C).
ECM attaching screw and move aside.
Right lower I.P. trim panel (see Section 8C).
Lower right I.P. carrier-to-cowl screw.
Four (4) heater case cover screws. Upper left screw
may be reached with a long socket extension through
the I.P. openings exposed by removal of the lower
right I.P. trim panel. Carefully lift the lower right
corner of the I.P. to align socket extension.
Heater case cover.
Core support plate and baffle screws.
Heater core, support plate and baffle from case.
Install or Connect
1. Heater core, support plate and baffle to case.
2. Core support plate and baffle screws.
3. Heater case cover.
4. Four (4) heater case cover screws.
5. Lower right I.P. carrier-to-cowl screw.
6. Right lower I.P. trim panel (see Section
8C).
7. ECM.
8. Right lower hush panel (see Section 8C).
9. Heater inlet and outlet hoses to heater core.
10. Refill cooling system and check for leaks.
11. Battery ground cable.
VENT CONTROL CABLE (RAM VENT)
Remove or Disconnect 1
1. Hush panel(s) (see Section 8C). R.H. cable
replacement will require removal of both L.H.
and R.H. hush panels.
2. Two (2) retaining screws and individual vent
control.
3. Unclip cable control clamp at vent duct and
disengage formed end of cable from door lever.
1
Install or Connect
1. Cable control clamp at vent duct and install
formed end of cable on door lever.
2, Two (2) retaining screws and individual vent
control.
3. Hush panel@) (see Section 8C).
4. Cycle control fully and check for proper
operation.
HEATER CONTROL
WIRING I
Remove or Disconnect
1. Negative battery cable.
ON-VEHICLE SERVICE
HEATER ELECTRICAL WIRING
The heater wiring diagrams are shown in
Electrical Diagnosis, Section 8A, and should be
referred to for diagnosis of electrical problems in the
heater system.
HEATER CONTROL ASSEMBLY AND BLOWER
SWITCH
Remove or Disconnect
1. Negative battery cable.
2.
Control/radio console trim plate.
3. Three (3) controller retaining screws and pull
controller out from console.
4. Control cables and electrical connections.
5. Blower switch from controller if either switch or
controller requires replacement. If controller is
being replaced, transfer blower switch to new
controller.
Install or Connect
1. When installing controller, install lower right
screw first to properly align controller in console.
2. Blower switch to controller.
3. Control cables and electrical connections.
4. Three (3) controller retaining screws and
controller to console.
5.
Control/radio console trim plate.
6. Negative battery cable.
TEMPERATURE CONTROL, POWER VENT,
HEATER DEFROST CABLE
Remove or Disconnect
1. Hush
panel(s) (see Section 8C):
a. Temperature cable - R.H. hush panel.
b. Heateddefrost cable - R.H. hush panel.
c. Vent cable
- L.H. hush panel.
2.
Control/radio console trim plate.
3. Three (3) controller retaining screws and pull
controller out from console.
4. Control cable requiring replacement at control
end.
5. Cable at mode control end (temperature cable:
remove cable link cover at crank location).
Install or Connect
1. When installing controller, install right lower
screw first to align control in console.
2. Cable at mode control end (temperature cable:
install cable link cover at crank location).
3. Control cable at control end.
4. Three (3) controller retaining screws and
contoller in console.
5.
Control/radio console trim plate.
6. Hush panel(s) (see Section 8C).
7. Fully cycle controls to adjust cables and check for
proper operation.
HEATER CORE
Remove or Disconnect
Battery ground cable.
Drain cooling system.
Heater inlet and outlet hoses from heater core.
Right lower hush panel (see Section
8C).
ECM attaching screw and move aside.
Right lower I.P. trim panel (see Section 8C).
Lower right I.P. carrier-to-cowl screw.
Four (4) heater case cover screws. Upper left screw
may be reached with a long socket extension through
the I.P. openings exposed by removal of the lower
right I.P. trim panel. Carefully lift the lower right
corner of the I.P. to align socket extension.
Heater case cover.
Core support plate and baffle screws.
Heater core, support plate and baffle from case.
Install or Connect
1. Heater core, support plate and baffle to case.
2. Core support plate and baffle screws.
3. Heater case cover.
4. Four (4) heater case cover screws.
5. Lower right I.P. carrier-to-cowl screw.
6. Right lower I.P. trim panel (see Section
8C).
7. ECM.
8. Right lower hush panel (see Section 8C).
9. Heater inlet and outlet hoses to heater core.
10. Refill cooling system and check for leaks.
11. Battery ground cable.
VENT CONTROL CABLE (RAM VENT)
Remove or Disconnect 1
1. Hush panel(s) (see Section 8C). R.H. cable
replacement will require removal of both L.H.
and R.H. hush panels.
2. Two (2) retaining screws and individual vent
control.
3. Unclip cable control clamp at vent duct and
disengage formed end of cable from door lever.
1
Install or Connect
1. Cable control clamp at vent duct and install
formed end of cable on door lever.
2, Two (2) retaining screws and individual vent
control.
3. Hush panel@) (see Section 8C).
4. Cycle control fully and check for proper
operation.
HEATER CONTROL
WIRING I
Remove or Disconnect
1. Negative battery cable.
1A-14 HEATING AND VENTILATION
2. Control/radio console trim plate and hush
panels.
3. Three (3) screws holding controller in console
and pull controller out far enough to disconnect
electrical connectors.
4. Blower motor and blower resistor electrical
connections.
5. Carefully pull cowl grommet from cowl and pull
wiring harness through cowl hole into engine
compartment.
Install or Connect
1. When reinstalling controller, install lower right
screw first to align controller.
2. Cowl grommet on cowl and wiring harness.
3. Blower motor and blower resistor electrical
connections.
4. Three (3) screws holding controller in console
and connect electrical connectors.
5.
Control/radio console trim plate and hush
panels.
6. Negative battery cable.
HEATER/VENTILATION/DEFROSTER DUCTS
See section 8C for removal.
LOWER (FLOOR) HEATER OUTLET
Remove or Disconnect
1. Console (see Section 8C).
2. L.H. and R.H. hush panels. (see Section 8C).
3. Two (2) floor outlet retaining screws.
4. Floor outlet from core case.
Install or Connect
1. Floor outlet to core case.
2. Two (2) floor outlet retaining screws.
3. L.H. and R.H. hush panels.
4. Console.
BLOWER MOTOR
Remove or Disconnect
1. Negative battery cable.
2. Electrical connections at blower motor and
blower resistor.
3. Blower motor cooling tube.
4. Blower motor retaining screws and remove motor/cage assembly from case.
5. Holding blower motor cage, remove cage
retaining screw and slide cage from motor shaft.
Install or Connect
1. Blower motor cage and retaining screw.
2. Blower motor retaining screws and
motor/cage
assembly in case.
3. Blower motor cooling tube.
4. Electrical connections at blower motor and
blower resistor.
5. Negative battery cable.
6. Reinstall radio capacitor in proper location, if so
equipped.
2. Control/radio console trim plate and hush
panels.
3. Three (3) screws holding controller in console
and pull controller out far enough to disconnect
electrical connectors.
4. Blower motor and blower resistor electrical
connections.
5. Carefully pull cowl grommet from cowl and pull
wiring harness through cowl hole into engine
compartment.
Install or Connect
1. When reinstalling controller, install lower right
screw first to align controller.
2. Cowl grommet on cowl and wiring harness.
3. Blower motor and blower resistor electrical
connections.
4. Three (3) screws holding controller in console
and connect electrical connectors.
5.
Control/radio console trim plate and hush
panels.
6. Negative battery cable.
HEATER/VENTILATION/DEFROSTER DUCTS
See section 8C for removal.
LOWER (FLOOR) HEATER OUTLET
Remove or Disconnect
1. Console (see Section 8C).
2. L.H. and R.H. hush panels. (see Section 8C).
3. Two (2) floor outlet retaining screws.
4. Floor outlet from core case.
Install or Connect
1. Floor outlet to core case.
2. Two (2) floor outlet retaining screws.
3. L.H. and R.H. hush panels.
4. Console.
BLOWER MOTOR
Remove or Disconnect
1. Negative battery cable.
2. Electrical connections at blower motor and
blower resistor.
3. Blower motor cooling tube.
4. Blower motor retaining screws and remove motor/cage assembly from case.
5. Holding blower motor cage, remove cage
retaining screw and slide cage from motor shaft.
Install or Connect
1. Blower motor cage and retaining screw.
2. Blower motor retaining screws and
motor/cage
assembly in case.
3. Blower motor cooling tube.
4. Electrical connections at blower motor and
blower resistor.
5. Negative battery cable.
6. Reinstall radio capacitor in proper location, if so
equipped.
CONTROL HANDLE INSTALLATION
1-UPPER DASH PANEL AND 4-INSTRUMENT PANEL ASSEMBLY 8-VENT DUCT RIGHT-HAND
PLENUM CHAMBER
5-DUCT AND VALVE ASSEMBLY 9-RIGHT-HAND VENT CONTROL
2-CONTROL CABLE ASSEMBLY
LEFT-HAND &VENT DUCT LEFT-HAND 10-LEFT-HAND VENT CONTROL
3-CONTROL CABLE ASSEMBLY 7-STEERING COLUMN COVER
RIGHT-HAND
1-UPPER DASH PANEL AND 4-INSTRUMENT PANEL ASSEMBLY 8-VENT DUCT RIGHT-HAND
PLENUM CHAMBER
5-DUCT AND VALVE ASSEMBLY 9-RIGHT-HAND VENT CONTROL
2-CONTROL CABLE ASSEMBLY
LEFT-HAND &VENT DUCT LEFT-HAND 10-LEFT-HAND VENT CONTROL
3-CONTROL CABLE ASSEMBLY 7-STEERING COLUMN COVER
RIGHT-HAND
1A-16 HEATING AND VENTILATION
1-UPPER DASH PANEL AND 6- BO LT/SC R E W
PLENUM CHAMBER
7-DUCT AND VALVE ASSEMBLY
2-INSTRUMENT PANEL ASSEMBLY
8-PLENUM CHAMBER
3-EXTENSION - SIDE VENT DUCT
9-FASTENER
4-"U" NUT
10-DUCT AND BAFFLE ASSEMBLY
5-INSU LATOR ASSEMBLY
520052-1A
Fig. 602 Ram Vent System Duct Work
1-UPPER DASH PANEL AND 6- BO LT/SC R E W
PLENUM CHAMBER
7-DUCT AND VALVE ASSEMBLY
2-INSTRUMENT PANEL ASSEMBLY
8-PLENUM CHAMBER
3-EXTENSION - SIDE VENT DUCT
9-FASTENER
4-"U" NUT
10-DUCT AND BAFFLE ASSEMBLY
5-INSU LATOR ASSEMBLY
520052-1A
Fig. 602 Ram Vent System Duct Work
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