1988 PONTIAC FIERO Service Repair Manual

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

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.

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

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

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'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

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