1988 PONTIAC FIERO Service Repair Manual

866 CHASSIS SHEET METAL
PROPER IDENTIFICATION AND CDAlrUmNG
OF INTERIOR PWSTIC TRlM
Interior plastic trim parts are normally supplied
in only one color. It is necessary to paint most parts.
Most vinyl headlinings and soft vinyl seat cushion and
hack cover assemblies are furnished in colors.
Instructions on how to identify each paintable
plastic part, and how to apply the available paint
materials are as follows:
Paintable plastic trim components, as used on
General Motors interiors, can be divided into three
general types:
@ Polypropylene Plastic
@ ABS Plastic
@ Vinyl Plastic
Excluding the soft vinyl seat cushion and seat
back trim cover assemblies, the plastic used most
widely on the interior of bodies is "POLYPROPYL-
ENE" and, as noted later, requires special refinishing
materials and procedures. Therefore, it is important
for a painter to be able to identify each plastic in order
to paint it satisfactorily. The purpose of the following
tests is to determine the identity of a given plastic so
that the proper paint procedure and refinishing mate-
rials will be used.
TEST PROCEDURE
Polypropylene, ABS or Vinyl Plastic
From a hidden backside portion of the part,
remove a sliver of plastic with a sharp blade.
Holding the sliver with needle-nose pliers, put it
to a flame and observe whether or not any
smoke is given off when burning.
ABS PLASTIC will give off a HEAVY BLACK
SMOKE, and POLYPROPYLENE will burn
clean.
However, if a sliver gives off OTHER THAN
HEAVY BLACK SMOKE, it is either DIRTY
POLYPROPYLENE OR IS VINYL. To deter-
mine which it is, the following burn test should
be made with the hot tip of a clean copper wire.
Heat the tip of the copper wire to a "red-glow"
with a propane (gas) torch.
Touch the heated wire to a hidden portion of the
plastic in question, to get some of the plastic on
the wire.
Return the wire, with its
now plastic-coated tip,
to the flame and observe for flame color.
If the flame given off from the wire is of the
GREEN-TURQUOISE-BLUE RANGE, then
the PLASTIC IS VINYL. (Any other color
flame would indicate the material is dirty poly-
propylene.
)
PAINWING lNTERiOR PWSTIC PARTS
Before painting, always check the body number
plate of the car for the
correct trim code color number
for that model year. The body number plate is located
on the upper horizontal surface of the shroud. Interior
color is color keyed to this "Trim Combination Num-
ber" (TR) on the body plate. Each paint supplier pro-
vides an interior color chart which identifies their
stock number, color name, gloss factor and trim com-
bination number for each "conventional" interior
color. Charts listing "vinyl" interior colors are also
provided.
"CONVENTIONAL" interior acrylic colors are
designed for use only on hard trim parts, such as:
1. Steel parts (primer or sealer required on new
service parts).
2. Hard POLYPROPYLENE plastic ("Special
Primer" required
- See GM Parts Catalog).
3. Hard ABS plastic (NO primer necessary).
"VINYL" interior colors are designed for soft
and/or flexible trim parts, such as instrument panel
cover pad assemblies, upper door trim pad assem-
blies, molded headlining panels, head rests and assist
handles. These colors require a final top coat of clear
vinyl spray, with instrument panel pads requiring a
"nonglare" clear final top coat. Other trim parts
require a degree of gloss to match similar adjacent
parts.
POLYPROPYLENE PUSTIC PARTS
The system for painting polypropylene parts
involves the use of a special primer. It is essential that
the service part be first primed with a coating of spe-
cial POLYPROPYLENE PRIMER (Detroit
Autobody
#PP-2250, or equivalent) according to factory recom-
mendations on the can. Because the primer acts as a
bonding agent between the plastic and acrylic lacquer, failure to use it will result in color coat "lifting"
and/or
"peeling" problems. After priming, the part can be
color coated with conventional interior acrylic
lacquer,
PROCEDURE
1. Wash part thoroughly with a cleaning solvent ("Acryli-Clean," "Prep-Sol," or equivalent) that
will not leave any greasy film.
2. Apply a thin, wet coat of the special polypropyl-
ene primer according to label directions on can.
Wetness of primer is best determined by observ-
ing gloss reflection of spray application in ade-
quate lighting. Be sure primer application
includes all edges. Allow
the primer to flash dry
ONE (1) MINUTE MINIMUM and TEN (10)
MINUTES MAXIMUM. (If the flash period
before color coating should extend beyond ten
minutes, the primer MUST be reapplied to
avoid previously mentioned adhesion
problems
.)

CHASSIS SHEET METAL 2@-7
3. During the above flash time period (1 to 10 min-
utes), apply appropriate "conventional" interior acrylic lacquer color as required and allow
painted part to dry for
4 to 5 hours before install-
ing on car.
RlGlD OW HARD ABS PMS"TIC PARTS
Rigid or hard ABS plastic requires no primer.
"Conventional" interior acrylic lacquers adhere satis-
factorily to hard ABS plastics.
Procedure
1. Wash part thoroughly with a cleaning solvent
(Acrylic-Clean, Pre-Kleano, Prep-Sol or equiv-
alent) to remove any dirt or grease.
2. Apply appropriate "conventional" interior
acrylic lacquer color. Apply only sufficient
color for proper hiding to avoid washout of
"grain" effect.
3. Allow to dry and then install part.
VINYL AND FLEXIBLE (Son) ABS
PLASTIC PARTS
The outer cover or skin material of "flexible"
instrument panel cover (pad) assemblies is made of an
ABSIPVC plastic blend. The same is true of many
"padded" door trim assemblies. The soft cushion pad-
ding under the I.P. skin is urethane foam plastic. The
most widely used
"flexible" vinyls (poly vinyl chlo-
ride)
are coated fabrics, such as used in seat trim,
some door trim assemblies, molded headlining panels
and sun visors. Most head rests are "flexible" vinyls.
Examples of "hard vinyls are: door and front seat
back assist handles and coat hooks.
The paint system of vinyl and flexible ABS
plastic involves the use of interior "vinyl" color and a
clear vinyl top coat.
Procedure
1. Wash part thoroughly with a vinyl cleaning and
preparation solvent ("Vinyl Press"
- Ditzler,
"Vinyl Prep Conditioner"
- Detroit Autobody
or equivalent) to remove greasy film or silicone.
Wipe off cleaner while still wet with clean,
lint-
free cloth.
2. Immediately after wiping face dry, apply inte-
rior "vinyl" color in wet coats allowing suffi-
cient flash time between coats (see label
directions on can). Use proper "vinyl" color as
designated by interior trim combinations. Apply
only sufficient color for proper hiding to avoid
washout of "grain" effect. No primer or
primer-
sealer is required.
3. Before the final vinyl color coat has dried, apply
two coats of clear vinyl top coat spray (instru-
ment panels will require the "nonglare" clear top
coat). Do not allow the first spray coat to com-
pletely dry before spraying on the second. Use
top coat with appropriate gloss level to match adjacent similar components. This
clear coat is
necessary to control the gloss requirement and
prevent
'tracking" (rubbing-off) of the color
coat after drying.
4. Allow to dry according to label directions before
installing part.
ON-VEHICLE SERVICE
CONCEALED HEADLIGHTS
The concealed headlights used on this model are
electrically operated. When the headlights are turned
on, solid state circuitry activates the actuators. This
same circuitry senses when the actuators stop moving
and removes the ground to deactivate the actuators.
When the headlights are turned off, the actuators run
in opposite direction closing the headlight doors.
Should an electrical failure occur in the head-
light circuit, they may be raised manually by rotating
the knob on the actuator in a counterclockwise direc-
tion until the headlights are fully open. The headlights
may be lowered by rotating the knob on the actuator in
a clockwise direction until the headlights are fully
closed.
For electrical circuit information and diagnosis,
refer to Section
8A of this manual.
If it is desired to raise the headlights with the
lights off, either of the following procedures may be
used:
1. Turn the lights on. After the headlights are
open, disconnect the electrical connections at
the actuator connectors. Turn the lights off. The
headlights will now remain in the open position.
2. Turn the parking lights on. Depress the head-
light rocker switch lightly. The headlights may
then be raised "up" fully with the lights off.
Adjust
Because of the number of adjustments possible
and the number of attaching points of the concealed
headlight body assembly
(9), only those attachments
which control the adjustment desired should be loos-
ened. Make one
adjbstment at a time.
NOTICE: The headlight door does NOT have
slotted mounting holes and therefore is not
adjustable by itself. This insures proper clearance
between the headlight door and the hood and
fenders in both the raised and lowered positions.
The entire headlight body assembly must be
adjusted to achieve the desired appearance and
fit. Care should be exercised when adjusting the
headlight body assembly. Severe hammer blows could damage the die cast aluminum headlight
body assembly.
TO RAISE OR LOWER the headlight body
assembly, proceed as follows:
1. Open hood.
2. Raise headlights.

26-8 CHASSIS SWEET METAL
3. Remove headlight bezel.
4. If necessary, move battery rearward to gain
access to rear screw.
5. Lower headlights.
6. Loosen two body screws and adjust headlight
body.
7. If a satisfactory appearance is still not obtained,
remove lower air deflector to gain access to
number 1 and number 2 screws.
8. Loosen two body screws and adjust headlight
body.
9. Repeat procedure, if necessary, to obtain a satis-
factory appearance.
10. Re-position battery and tighten hold-down
screw to specifications.
11. Install lower air deflector.
12. Install headlight bezel.
TO SET FRONT TO REAR
GAP between
headlight door and hood, proceed as follows:
1. Open hood.
2. Raise headlights.
3. Remove headlight bezel.
4. Lower headlights.
5. Loosen two body assembly screws and adjust
headlight body assembly.
6. If a satisfactory appearance is still not obtained,
remove lower air deflector to gain access to two
lower screws.
7. Loosen two lower screws and adjust headlight
body assembly.
8. Repeat procedure, if necessary.
9. Install lower air deflector.
10. Install headlight bezel.
TO SET SIDE-TO-SIDE GAP between head-
light door and hood and headlight door and fender,
proceed as follows:
Open hood.
Raise headlights. Remove headlight bezel.
If necessary, move battery rearward to gain
access to rear screw.
Lower headlights.
Loosen three body screws and adjust headlight
body.
If a satisfactory appearance is still not obtained,
remove lower air deflector to gain access to two
lower screws.
Loosen two lower screws and adjust headlight
body.
Repeat procedure, if necessary.
Re-position battery and tighten hold-down
screw to specifications.
Install lower air deflector.
Install headlight bezel. TO
SET CONTOUR of headlight door to hood,
proceed as follows:
1. Open hood.
2. Raise headlights.
3. Remove headlight bezel.
4. Lower headlights.
5. Loosen two (2) screws and adjust headlight
body assembly.
6. If a satisfactory appearance is still not obtained,
remove lower air deflector to gain access to two
lower screws.
7. Loosen two lower screws and adjust headlight
body assembly.
8. Repeat procedure, if necessary.
9. Install lower air deflector.
10. Install headlight bezel.
HEADLIGHT BODY ASSEMBLY
Remove or Disconnect
1. Rear headlight door attaching screws.
2. Raise headlight doors.
3. Headlight bezel attaching screws.
4. Front headlight door attaching screws and
remove headlight door.
5. Electrical connection at bulb.
6. Lower air deflector (one side only).
7. Headlight body assembly attaching screws and
disconnect electrical connection at actuator
connector.
8. Link.
9. Actuator crank arm.
10. Actuator retaining screws and remove actuator.
11. Unhook headlight capsule lower retaining
spring and remove headlight capsule assembly.
12. Headlight body assembly attaching brackets and
fasteners.
Install or Connect
1. Headlight body assembly attaching brackets and
fasteners.
2. Headlight capsule lower retaining spring and
install headlight capsule
3. Acuator retaining screws and install actuator.
4. Actuator crank arm.
5. Link.
6. Headlight body assembly attaching screws and
connect electrical connection at actuator
connector.
7. Lower air deflector (one side only).
8. Electrical connection at bulb.
9. Front headlight door attaching screws and install
headlight door.

10. Headlight bezel attaching screws.
11. Lower headlight doors.
12. Rear headlight door attaching screws.
ACTUATOR
Remove or Disconnect
1. Battery.
2. Raise headlight door manually.
3. Headlight bezel attaching screws.
4. Pry off link assembly.
5. Actuator crank arm attaching screw. Support the
crank
arm during removal so as not to damage
the actuator.
6. Actuator electrical connector.
7. Actuator attaching screws and remove actuator.
Install or Connect
1, Actuator attaching screws and install actuator.
2, Actuator electrical connector.
3. Actuator crank arm attaching screw.
4. Link assembly.
5. Headlight bezel attaching screws.
6. Battery.
HOOD HINGE
Hood hinges are fastened to the fender panel.
Two gas struts are used (one at each hinge); both ends
of which are fastened to the front portion of the hinge
assembly. This construction provides hold-open
power. Several struts are used depending upon hood
material and configuration. Make certain both struts
have the same color coding if the struts are to be
replaced.
FENDER PANEL
An outer fender panel with a plastic inner panel
is used. Care should be used in handling raw fenders
due to the lack of fender rigidity prior to installation.
See the illustrated service procedures for installation.
Remove or Disconnect
1. Raise car part way on hoist.
2. Lower air deflector attaching screws and push-
in retainer to wheelhouse and remove both sides
of air deflector.
3. Fascia to fender attaching nuts.
4. Wheelhouse to fender inner panel attaching
screws.
5. Lower fender brace attaching screws.
6. Lower rear fender attaching screw.
7. Hood hinge to fender attaching screws and prop
hood open.
-
8. The upper fender attaching screws.
CHASSIS SHEET METAL 2C-9
9. Antenna escutcheon from fender.
10. Side marker lamp electrical connection and
remove the fender from the vehicle.
11. Strip the fender of the side marker lamp, fender
wheelhouse, fasteners and moldings.
install or Conned
To install, reverse removal procedure.
FRONT END PANEL
Remove or Disconnect
1. Raise car part way on hoist.
2. Lower air deflector attaching screws and push-
in retainer to wheelhouse and remove both sides
of air deflector.
3. Fascia to fender attaching nuts.
4. Fascia to reinforcement push-in retainers.
5. Lower car.
6. Parking lamp attaching screws.
7. Upper reinforcement attaching screws and
remove front end panel.
8. Left and right grilles.
9. Front end panel reinforcement attaching screws
and fasteners from fascia.
Install or Conned
To install, reverse removal procedure.
FIREBIRD AERO ACCESSORIES
BOOR LOWER AIR
DEFLECmR
Remove or Disconnect
1. All door trim pad hardware.
2. Loosen bottom and sides of door trim pad. Do
not remove pad.
3. Gently lift bottom of door trim pad to gain
access to nuts.
4. Three nuts (Acl) from inside door panel.
5. Two external nuts (#2) from door panel.
6. Deflector.
NOTICE: If studs that are attached to the deflec-
tor come out with the nut, they can be reinstalled
in the deflector. Remove nut from stud and rein-
stall stud in deflector.
Install or Conned
To install, reverse removal procedure.

2C-10 CHASSIS SHEET METAL
ROCKER PANEL AIR DEFLECTOR
Remove or Disconnect
1. Five top screws (#I).
2. Hoist car.
3. Seven bolts holding rocker panel rubber
air
deflector
(#2) and remove.
4. Seven screws holding rocker deflector to bottom
of rocker panel
(#3).
5. Two screws holding rear rocker deflector to rear
wheel opening
(#4).
6. Five
push type fasteners at the lower rear of the
wheel well splash shield, lift shield to gain
access to the two forward nuts.
7. Two nuts (#5) from rocker deflector front to
fender.
8. Rocker deflector.
9. Nine screws holding rocker panel deflector
support.
10. Support.
Install or Connect
To install, reverse removal procedure.
REAR BUMPER FASCIA EXTENSION
Remove or Disconnect
1. Hoist car,
2. Drill out
eight fascia extension to fascia rivets
(#I) (four each side). Four
bolts from fascia extension to lower quar-
ter panel
(#2).
Five (each side) push clips from fascia to sup-
port
(443).
Four screws from rear fascia extension to fender
(#4).
Lower car.
Right side trunk trim and spare tire.
Rear trim panel.
Left trim panel.
Right and left side fascia and fascia extension
nuts (six each side)
(#5).
Right and left tail lamp wing nuts and remove
housing.
Seven fascia push nuts and disconnect electrical
connector for license plate
(#6).
Rear bumper fascia from car.
Twelve (six each side) fascia extension to fascia
retaining nuts and remove fascia extension
(#7).
Install or Connect
To install, reverse removal procedure.

CHASSIS SHEEP METAL 26-11
1-MOLDING R&L 4-SCREEN R&L
2-EXTRACTOR R&L 5-REAR FLANGE
3-RETAINER
Figure 2 Front Fender Ornamentation

2C-12 CHASSIS SHEET METAL
1. HOOD ASM.
2. INSULATOR
3. SEAL ASM.
4. RETAINER
5. SPRING
6. LATCH ASM.
7. BOLTISCREW
8. STRIKER
9. FRT. END PANEL SUPPORT
10. CABLE
11. PRESS END OF CABLE INTO
EXISTING
CLIP
12. BUMPER
13. ADJUSTMENT SCREW
14. FENDER ASSEMBLY
15.
10 N-rn (89 LBS. IN.)
16. WELD NUT
17. ROD ASSEMBLY
18. HINGE
19. RETAINER
Figure 3 Hood and Fenders

CHASSIS SHEET METAL 26-13
1-REINFORCEMENT ASM. 5-FRAME 8-FRONT DEFLECTOR
6-FRONT FENDER ASM. 9-FASCIA,
FRONT END PANEL ASM.
3-BOLTISCR EW 7-LOWER DEFLECTOR
4-NUT
Figure 4 Front End Trim