1988 PONTIAC FIERO key

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.)

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

1 Dl-2 R-4 AIR CONDITIONING COMP
4 POLE CLUTCH-
SHORT SHAFT
1. COMPRESSOR SHELL 2. ROLL PINS 3. THRUST AND BELLEVILLE WASHER 4. MAlN BEARING-FRONT 5. CLUTCH COlL TERMINALS 6. PULLEY RIM 7. PULLEY RIM MOUNTING SCREW
AND LOCKWASHER
8. RmOR BEARING 9. ROTOR BEARING RETAINER
10. SEAL SEAT RETAINER
11. SHAFT KEY 12. SHAFT NUT 13. SHAFT SEAL 14. CLUTCH DRIVE ASSEMBLY 15. ROTOR AND HUB ASSEMBLY 16. CLUTCH COlL AND HOUSING
ASSEMBLY
17. SEAL SEAT O-RING 18. FRONT HEAD 19. VALVE PLATE ASEMBLY
20. VALVE PLATE RETAINING RING
21. SHELL RETAINER 22. PISTON ASSEMBLY 23. MAlN BEARING - REAR 24. SUCTION PORT
25. DISCHARGE PORT
Fig. 4 R-4 Compressor With Six-Pole Clutch
should then be discarded and the same
amount of new
525 viscosity refrigerant oil
added to the compressor (See Refrigerant Oil
Distribution" in
the Air Conditioning Section
1 B).
Fig. 2 R-4 Compressor Cross Section Shaft Design

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 101-3
1-RETAINER RlNG
2-SHAFT SEAL
4-O-RING, SEAL SEAT
%-SHAFT SEAL KIT
6-SCREW AND WASHER
ASSEMBLY FRONT
HEAD MOUNTING
7-FRONT HEAD
8-MAIN BEARING
9-RING SEAL, FRONT
HEAD TO CYLINDER
11-O-RING, CYLINDER
TO SHELL
12-TH RUST WASHER
13-BELLEVILLE WASHER
14-THRUST WASHER KIT
15-CYLINDER AND SHAFT
ASSEMBLY
16-RETAINER RlNG
17-VALVE PLATE
18-SHIPPING PLATE
19-SCREW
20-O-RING
SUCTION-
DISCHARGE PORTS
21-PRESSURE RELIEF
VALVE
22-O-RING, PRESSURE
RELIEF VALVE
23-SHAFT NUT
24-CLUTCH HUB KEY
25-CLUTCH DRIVE
ASSEMBLY
26-RETAINER RlNG
27-ROTOR
28-ROTOR BEARING
29-ROTOR AND BEARING
ASSEMBLY
*
30-COIL AND HOUSING
ASSEMBLY
31-PULLEY RIM MOUNT-
ING SCREW
32-PULLEY RIM
I
Fig. 5 8-4 Compressor Disassembled View

181-4 R-4 ABR CONDITIONING COMPRESSOR OVERHAUL
SERVICE PROCEDURES
MINOR REPAIR PROCEDURES
THE FOLLOWING OPERATIONS TO THE
R-4 COMPRESSOR CLUTCH PLATE AND 1 -SUCTION
HUB, ROTOR AND BEARING, AND COIL &
PULLEY RIM ARE COVERED AS 'WINOR" 3-DISCHARGE
BECAUSE THEY MAY BE PERFORMED
WITHOUT FIRST DISCHARGING THE
SYSTEM OR REMOVING THE
COMPRESSOR FROM THE VEHICLE. 5-~-25008-~
The two types of drive systems used on the R-4
Compressor (\I-groove type and poly-groove type)
affect only minor repair procedures and are so noted
where required. Major repair procedures are not
Fig. 6 Compressor In Holding Fixture affected by the type of drive system.
The Shaft and 2. Keep the clutch hub from turning with the
Pressure Relief Valve may also be serviced WITHOUT
REMOVING THE COMPRESSOR from the vehicle Clutch
Hub Holding Tool 5-25030/J-33027
remove, and discard the shaft nut, using Thin
but these operations are covered later in this section as
MAJOR REPAIR PROCEDURES because the Wall Socket
5-9399.
system must be discharged, evacuated and recharged
to complete service.
Illustrations used in describing these operations
show the compressor removed from the vehicle only to
more clearly illustrate the various operations.
CLUTCH HUB
When servicing the compressor, remove only the
necessary components that preliminary diagnosis
indicates are in need of service. Refer to the AIR
CONDITIONING section and Fig.
4 and Fig. 5 for
information relative to parts nomenclature and
location.
Removal and installation of external compressor
components and disassembly and assembly of internal
components must be performed on a clean workbench.
The work area, tools and parts must be kept clean at
all times.
CLUTCH PLATE AND HUB ASSEMBLY Fig. 7 Removing Shaft Nut Fig. 6 thru 10
CLUTCH PLATE AND HUB ASSEMBLY 3. Thread the Clutch Plate and Hub Assembly INSTALLATION AND REMOVAL Remover 5-33013-I3 into the hub. Hold the body
PROCEDURES FOR THE SIX-POLE of the Remover with a wrench and turn the center
CLUTCH ARE THE SAME AS THE screw into the Remover body to remove the
FOUR-POLE CLUTCH WITH THE Clutch Plate and Hub assembly.
EXCEPTION OF THE CLUTCH HUB
HOLDING TOOL. FOR FOUR-POLE 4. Shaft key
CLUTCH USE J-25030. FOR SIX-POLE
CLUTCH USE J-33027. Install or Connect
a Remove or Disconnect 1. Shaft key in hub key groove. Allow the key to
project approximately
4.8mm (3/16") out of
1. If compressor is on the car, loosen compressor keyway.
mounting brackets, disconnect the compressor
The shaft key is curved slightly to provide an
drive belt and reposition the compressor for
interference fit in the shaft key groove of the hub.
access, if necessary. If compressor has been
removed from the car, attach the compressor to 2. Be Sure the frictional surface of the clutch plate
Holding Fixture
J-'25008-8 and clamp the and
the clutch rotor are clean before installing the
Holding Fixture
in a vise. Clutch
Plate and Hub assembly.
Compressor mounting holes are metric. Use 3.
Align the shaft key with the shaft keyway and
proper metric bolts with holding fixture place the Clutch Plate and Hub assembly onto the
J-25008-A. compressor shaft.

R-4 AIR CONDITIONING COMPRESSOR - OVERHAUL 1 Dl-5
J-33013-8 HUB AND CLUTCH PLATE AND
CLUTCH DRIVE PLATE HUB ASSEMBLY
ASSEMBLY REMOVER
H60070-1 Dl-D
Fig. 8 Clutch Plate And Hub Assembly Removal
1-CLUTCH PLATE AND HUB
ASSEMBLY
2-CLUTCH ROTOR
3-SHAFT KEY
Fig.
9 Installing Shaft Key
NOTICE: To avoid internal damage to the
compressor, do not drive or pound on the clutch
hub or shaft.
4. Install the Clutch Plate and Hub Installer
J-9480-B.
5. Hold the hex portion of the Installer Body
J-9480-B with a wrench and tighten the center
screw to press the, hub onto the shaft until there
is
a .5mm - l.Omm (.020"-.040") inch air gap
between the frictional surfaces of the clutch plate
and clutch rotor.
6. Install a new shaft nut with the small diameter
boss of the nut against the crankshaft shoulder,
using Thin Wall Socket J-9399. Hold the Clutch
Plate and Hub assembly with Clutch Hub
Holding Tool
J-25030/J-33027 and tighten to 14
N-m (10 lb. ft.) torque, using a 0-60 N-m (0-25
1b.ft.) torque wrench.
7. If operation is performed with compressor on car,
connect drive belt, tighten mounting brackets and
adjust belt tension.
1-DRIVE PLATE
INSTALLER
J-9480-B
2-DRIVE PLATE
INSTALLER
BEARING
3-AIR GAP
(.02OU-.040")
4-CLUTCH PLATE
AND HUB ASM.
Fig.
10 Installing Clutch Plate & Hub Asm.
CLUTCH ROTOR AND BEARING:FOUR POLE
CLUTCH
Fig. 11 thru 28
Remove or Disconnect
1. Clutch Plate and Hub assembly
2. Rotor and Bearing assembly retaining ring, using
Snap Ring Pliers J-6083. Mark the location of the
clutch coil terminals.
Fig. 11 Removing Rotor & Bearing Asm. Retainer Ring
If only the Clutch Rotor and/or Rotor Bearing
are to be replaced, bend the lockwashers away
from the pulley rim mounting screws, andremove
the six mounting screws and special lock washers
before proceeding with Step 3. Discard the lock
washers.
3. Install Rotor and Bearing Puller
5-25031 down
into the rotor until the Puller arms engage the
recessed edge of the rotor hub. Hold the Puller
and arms in place and tighten the Puller screw
against the Puller Guide to remove the Clutch

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1B1-7
I
1-J-29886 DRIVER
HANDLE
2-J-9481 -A PULLEY BEARING AND
PULLEY INSTALLER
3-ROTOR BEARING
I
4-ROTOR AND
HUB ASM.
Fig.
16 Installing Clutch Rotor Bearing
Fig.
17 Installing Rotor and Bearing Asrn. (On Car)
E. Install the retainer ring.
F. Reassemble the Clutch Plate and Hub with
the shaft key onto the shaft with Installer
J-9480-B until .5 to l.Omm (.020" to ,040")
air gap is obtained.
G. Install shaft lock nut. Torque to 14 N-m (10
lb. ft.).
On Bench
Reassemble the Rotor and Bearing assembly to
the front head of the compressor using Rotor
&
Bearing Installer J-26271-A. With Installer
assembled to the Universal Handle, J-29886,
force will be applied to the inner race of the
bearing and the face of the rotor when installing
the assembly onto the front head of the
compressor. 8.
Tighten pulley rim mounting screws to
11 N.m
(100 inch-pounds) torque and lock screw heads in
place by bending special lock washers, similar to
original crimp and lock bends on washers.
9. Reinstall Clutch Plate and Hub assembly as
described in "Clutch Plate and Hub"
Replacement procedures.
1 -J.25031
GUIDE
2-J-25031
ROTOR 81
BEARING
PULLER
3-POLY GROOVE
PULLEY
ROTOR
5. Install rotor and bearing assemblv retainer ring,
Fig. 19 Removing Clutch Rotor Asrn. - Poly-Groove
Drive
CLUTCH ROTOR AND EBEARING:SIX POLE
CLUTCH
Fig. 2 1 thru 28
I Remove or Disconnect -. using Snap Ring Pliers j-6083. I
1. Clutch plate hub assembly 6. Apply sealer (Loctite RC-75, Loctite 601 or 2. Rotor and bearing assembly retaining ring using equivalent) to threads of pulley rim mounting
Snap Ring Pliers 5-6083 screws. Instal1 screws and new 'pecial lock 3.
Install Pulley Rotor and Puller Guide J-2503 1 to
washers but do not torque the screws.
the front head and install
5-33020 Pulley Rotor
7. Rotate the pulley rim and rotor to insure that and Bearing Puller down into the inner circle of
pulley rim is rotating "in-line." If pulley rim is slots in the rotor. Turn the J-33020 puller
distorted (does not rotate in-line), adjust or clockwise in the slots to engage the puller tangs
replace pulley rim.
with the segments between the slots in the rotor.

1 -J-29886 DRIVER
HANDLE
2-J-26271-A ROTOR
& BEARING
ASSEMBLY
INSTALLER
Fig. 20 Installing Rotor
& Bearing Assembly,
Poly-Groove Type (On Bench)
4. Hold the J-33020 Puller in place and tighten the
puller screw against the Puller Guide to remove
the pulley rotor and bearing assembly.
5. To prevent damage to the pulley rotor during
bearing removal, the rotor hub must be properly
supported.
Remove the forcing screw from J-33020 Puller
and with the puller tangs still engage in the rotor
slots, invert the assembly onto a solid flat surface
or blocks.
Fig. 22 Pulley Rotor and Bearing Puller Installation
I 1-LATCH ASM 3-SPRING I 1 2-25 N-rn (18 LB.FT.1 4-HOOD ASM I
Fig. 23 Pulley Rotor and Bearing Removal
1 -CLUTCH
COl L
2-PULLEY BEARING
3-POLY GROOVE
PULLEY ROTOR
4-RETAINER 5-CLUTCH DRIVE
6-SHAFT KEY
7-SHAFT NUT