1988 PONTIAC FIERO cooling

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

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

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

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.

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.)

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.

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.

AIR CONDITIONING 1B-1
SECTION 1B
R COND
When performing air conditioning diagnosis on vehicles equipped with a catalytic converter, it will be necessary to
WARM the engine to a NORMAL operating temperature BEFORE attempting to idle the engine for periods greater
than five
(5) minutes. Once the engine attains normal idle, diagnosis and adjustments can be made.
CONTENTS
.................. General Description .................................. 1B-1 Accumulator Assembly Service .1B-19
.......................... C.C.O.T. A!C System ................................ 1B-1 On-Vehicle Sewice ..... 1B-20
....................................... System Components - Functional ................. 1B-2 Blower Motor .1B-20
..................................... System Components - Control ..................... 1B-3 Hi-Blower Relay 1B-20
...................................... Relays and Switches ................................... 1B-3 Blower Resistor 1B-20
Diagnosis ................................................. 1B-5 Controller, Blower Switch or Vacuum
................................................ Testing the Refrigerant System ...................... 1B-5 Valve .lB-20
Insufficient Cooling "Quick-Check Temperature Control Cable ....................... .1B-20
.................................... Procedure.. ............................................. 1B-5 Vacuum
Harness .lB-20
C.C.O.T. A/C System Diagnostic Control Wiring Harness ........................... .1B-20
..... ................................. Procedure.. ............................................. 1B-8 Heater
Core .. .lB-21
................................ Leak Testing ........................................... 1B-12 Lower Heater Outlet 1B-21
............................... Service Procedures ................................. .1B-12 Heater Module Case .lB-21
.......................... O-Ring Replacement ................................ .1B- 12 Pressure Cycling Switch .1B-21
....................................... Handling Refrigerant- 12 ............................ .1B- 13 Vacuum Tank .lB-21
Discharging, Adding Oil, Evacuating Liquid Line .......................................... .1B-23
and
Charging Procedures - AIC Accumulator ......................................... .1B-23
.................................... Systems .............................................. .1B-14 Evaporator Core .1B-24
In-Line Air Conditioning Evaporator Case .................................... .1B-24
.......................................... Filter
Installation.. .................................. .1B- 18 Compressor .lB-24
.............................................
................ Expansion Tube (Orifice) Service .1 B- 19 Condenser IB-24
GENERAL DESCRIPTION
All engines are equipped with a fixed displace- evaporator temperature. The pressure cycling switch
ment (R-4) air conditioning compressor. This
com- is the freeze protection device in the system and
pressor may cycle on and off under normal air
senses refrigerant pressure on the suction side of the
conditioning demand. system. This switch is located on a standard
Schrader- -
All air conditioning systems that use the fixed
displacement R-4 compressor are referred to as
C. C.O.T. (Cycling Clutch, Orifice Tube) type sys-
tems. This is the same system that has been used on
all General Motors vehicles in the past several years.
The C.C.O.T. NG System
The Cycling Clutch Orifice Tube (C.C.O.T.)
refrigeration system is designed to cycle a compressor
on and off to maintain desired cooling and to prevent
evaporator freeze. Passenger compartment comfort is
maintained by the temperature lever on the controller.
Control of the refrigeration cycle (on and off
operation of the compressor) is done with a switch
which senses low-side pressure as an indicator of type
valve low-side fitting. During air temperatures
over 10°C
(50°F), the equalized pressures within the
charged
A/C system will close the contacts of the
pressure switch. When an air conditioning mode
(max, norm, bi-level, defrost) is selected, electrical
energy is supplied to the compressor clutch coil. AS
the compressor reduces the evaporator pressure
to
approximately 175 kPa (25 psi), the pressure switch
will open, de-energizing the compressor clutch.
As
the system equalizes and the pressure reaches approxl-
mately 315 kPa (46 psi), the pressure switch contacts
close, re-energizing the clutch coil. This cycling
coy
tinues and maintains average evaporator discharge air
temperature at approximately 1°C (33°F). Because of
this cycling, some slight increases and decreases of
engine speedlpower may be noticed under certain con-
ditions. This is normal as the system is designed
to
cycle to maintain desired cooling, thus preventing
evaporator freeze-up.