manualshive.com logo in svg

Pontiac Firebird 1977, Service Manual, Page: 389 / 1443

Share
Download
Pontiac Firebird 1977 Service Manual Download Page 389

Summary of Contents for Firebird 1977

Page 1: ...Released By www 78ta com Serial Number 77SER 001 1008...

Page 2: ...ble hazardous consequencesof each way Consequently Pontiac has not undertaken any such broad evaluation Accordingly anyone who uses a service procedure or tool which is not recommended by Pontiac must...

Page 3: ...g the 1977 Pontiac Models In all cases an equivalent may be used PONTlAC MOTOR DIVISION GENERAL MOTORS CORPORATION PONTIAC MICHIGAN 48053 S 7704F January 1977 Litho in U S A O General Motors Corporati...

Page 4: ...upper left instrument panel area visible through the windshield The plate has embossed numerals as shown in Fig OA 2 GOVERNMENT CERTIFICATION LABEL All models have a label on the left door end panel...

Page 5: ...BACK COUPE 17 2 DRXOUPE 1 27 4 DR SEDAN IHATCHBACK COUPE I 7 VENTURA SJ VENTURA SJ VENTURA SJ I 2 DR COUPE 27 4 DR SEDAN 69 LE MANS LE MANSSAFARI LE MANS I I4 DR SEDAN 29 STATIONWAGON 2 DR COUPE 231 C...

Page 6: ...t tumblers springs or retainers Uncoded side bar locks may be coded to match the keys used on the car by ordering the above parts separately Five types of tumblers are used to make the various combina...

Page 7: ...metric 50 customary Most of the other cars have a small metric fastener content It is most important that replacement fasteners be of the correct nominal diameter thread pitch and strength Original eq...

Page 8: ...rent strength markings When replacing metric fasteners be carful to use bolts and nuts of the same strength or greater than the original fasteners the same number marking or higher It is likewise impo...

Page 9: ...GM 280 MI GM 290 MI GM 300 MI CUSTOMARY INCH BOLTS IDENTIFICATION MARKS CORRESPOND TO BOLT STRENGTH INCREASING NUMBERS REPRESENT INCREASING STRENGTH METRIC BOLTS IDENTI FlCATlON CLASS NUMBERS CORRESP...

Page 10: ...54062 7 93750 8 33437 8 73125 9 12812 9 52500 9 92187 10 31875 10 71562 11 11250 11 50937 1190625 12 30312 l2 7OOOO Fractions 33 64 17 32 35 64 9 16 37 64 19 32 39 64 518 41 64 21 32 43 64 11 16 45 6...

Page 11: ...4 0 6 0 5 0 U S Pt 6 0 17 j7 13 Y 8 0 19 3 7 5 19 0 L at 5 0 4 0 6 0 5 0 US Pt 3 5 2 5 8 0 19 3 US Pt 4 3 L ot 4 0 3 0 5 0 4 0 U S Pt L Imp at 3 3 2 5 4 1 3 3 Imp Pt 2 0 2 9 5 0 16 0 4 2 17 5 4 2 17...

Page 12: ...nd B are the same in both schedules The Schedule I Fig OB 1 or Schedule I1 Fig OB 2 is tied to the engine family number as shown on the emission control label on the radiator support or fan shroud Som...

Page 13: ...l Veh cleoperation will be opt mum at the altltude des gnatedon the Label but will be sat sfacloryat all alr tudes SECTION A LUBRICATION AND GENERAL MAINTENANCE See Explanat on ITEM NO The exhaust eml...

Page 14: ...imeqxa w Alar s ql an wal l o u op qJ qm sau 6ua e l i d w x a l y 1 mpni ile Ile le AloiJeks ies aq IIIM i n q aqei aqj uo pajeu6 sap apni ils aql i e wnw ido aq II M uo ielado ap qaA laqei u o l a...

Page 15: ...and mileage in the maintenance schedule under the appropriate Owner Service Log column SECTION A LUBE GENERAL MAINTENANCE ITEM NO SERVICES A 1 CHASSIS Lubricate all grease fittings in front suspensio...

Page 16: ...EEL BEARINGS Clean and repack front wheel bearings with a lubricant meeting requirements of GM 6031 M A 10 MANUAL STEERING GEAR Check for seal leakage around the pitman shaft and housing If leakage is...

Page 17: ...at seat adjusters securely engage by pushing forward and backward whenever a manual seat is adjusted q SEAT BACK LATCHES Check to see that seat back latchesare holdingby pullingforward on thetop of ea...

Page 18: ...ystems can be seen SECTION C EMISSIONS SCH I C 1 SCH II C 2 THERMOSTATICALLY CONTROLLED AIR CLEANER Inspect installation to make certain that all hoses and ducts are connected and correctly installed...

Page 19: ...ions of physical damage 3 Replace any damaged or deteriorated parts SCH I C 16 SCH II C 13 AIR CLEANER ELEMENT Replace the engine air cleaner element at designatedintervals The PCV filter on all excep...

Page 20: ...50 mixture of water and a high quality Ethylene Glycol base anti freeze conforming to GM Spec 1899 M Engine Oil SE Engine Oil conforming to GM Specs GM 6136 M ENGINE OIL AND FILTER Recommendations Us...

Page 21: ...uce varnish and sludge deposits resulting from some unusual operational difficulty a thoroughly tested and approved additive G M Super Engine Oil Supplement or equivalent is available at your dealer I...

Page 22: ...MAINTENANCE LUBRICATION OB 11 I Temperature Range Anticipated Before Next Oil Change 4993 Fig 00 3Recommended SAE Viscosity Grades...

Page 23: ...on Control 7026014 PCV Filter In Air Cleaner FB 59 PFV Filter In Valve Cover FB 56 PCV Valve LA 140 CV793 LA 151 CV789C V6 231 CV770C V8 301 CV792C V8 305 35O L CV774C V8 350 P 350 R 400 403 CV679C Ca...

Page 24: ...TTACHMENT ONLY SO AS TO DISTRIBUTE LOAD AND SUPPORT VEHICLE I N A STABLE MANNER FLOOR JACK OR HOIST LlFT Fig 08 5 Lift Points F and X Series FLOOR JACK OR HOIST LlFT NOTE SUPPORTS MUST BE POSITIONED S...

Page 25: ...a year 16 RADIATOR Check coolant level at each 011 change Replace every 3 q 0 0 0 Miles or 24 Months A n BATTERY Check level periodically except Freedom Battery CRANKCASE VENTILATION ELEMENT AND AIR C...

Page 26: ...VENTILATION CONTENTS OF THIS SECTION General Description 1A 2 Heater Control Functional Test 1A 2 Diagnosis 1A 9 Heater Wiring Diagram 1A 9 Heater Trouble Diagnosis 1A 9 On Car Service Procedures 1 1...

Page 27: ...control mode lever and temperature lever efforts must be checked These efforts should not be too low below 2 Ib using pull scale or too high above 6 5 Ib or repair adjustment then be made 1 Close all...

Page 28: ...RE BY BLENDING THE TO WINDSHIELD AND INCOMING OUTSIDE AIR THRUI 20 TO FLOOR AROUND THE HEATER CORE 4240 FIG 1A 2 1977 B SERIES HEATER CONTROL POSITIONOF THlS SYSTEM SELECTOR LEVER DETERMINES AIR FLOW...

Page 29: ...TLETS IN OFF FLOW IS ABOUT 80 TO FLOOR 20 TO WIND SHIELD IN DEF FLOW IS REVERSED ANY POSITION BETWEEN OFF DEF DIVIDES ACCORDINGLY FIG 1A 4 1977 X SERIES HEATER CONTROL THIS SYSTEM ER DETERMINES FROM U...

Page 30: ...ES ADDITIONAL UNTEMPERED OUTSIDE AIR FLOW INTO CAR IS GAINED BY OPERATION OF VENT KNOBS LOCATED ALONG SIDE EACH KICK PAD F SERIES UPPER KNOB CONTROLS UPPER AIR FLOW THRU OUTLETS AT EACH END OF IIP 424...

Page 31: ...heater outlet with some air also from defroster nozzle 5 Slide the mode lever to the extreme right to the DEFROST position note effort requirements above 0 Hot air 130 F or 54 C comes mainly from the...

Page 32: ...FLOW PASSAGE UNDER I P OWER MOTOR FLOOR OUTLET CENTER UPPER I P VENT OUTLET y g T OUTLET HEAT MODE AIR FLOW TEMPERED BY HEATER CONTROL TEMP LEVER TEMP VALVE DOOR OPENED WINDSHIELD SHUT OFFVALVE DOOR...

Page 33: ...RIGHT SIDE OF HEATER CASE IF TEMP LEVER IS AT COLD INCOMING AIR WILL BE UNTEMPERED SOME DISCHARGE MAY BE FOUNDAT FLOOR OUTLET AS LEVER IS MOVED TOWORDS HEATER DEF THE BY PASSDOOR CLOSES THE AIR DEF VA...

Page 34: ...f proper operation of heater system Advise operator to use blower to force air to rear seat area Check to be sure front floor mat is under floor mat retainer at dash Insufficient heat to rear seat Obs...

Page 35: ...ng Blower motor not connected Connect wire Check ground Inoperative blower motor A B F G H Check heater fuse and wiring Replace Series blower motor operates whenever motor is necessary ignition switch...

Page 36: ...turnbuckle in opposite direction to move control lever 1 16 to 1 8 away from end of slot if eased out of detent 4 Move lever to DEFROST position Then back to OFF 5 Lever must have slight spring back I...

Page 37: ...IM PLATES SPEED0 UPPER LEVEL DUCT CLUSTER TO R R I P TRIM PLATE MUST SAFARI GRAND R R SCREWS LeMANS GRAND D C CABLE tPRlX COVER TO R R I P TRlM PLATES MUST HEATER CONTROL SAFARI GRAND LeMANS GRAND PRl...

Page 38: ...LE HEATER CASE CORE DOORS D C BATTERY DRAIN RADIATOR D C HEATER HOSES R R SCREWS NUTS A T ENGINE SIDE R R GLOVE BOX DEFROSTER SCREW DEFROSTER DUCT D C CABLES TILT I P OUTWARD R R CASE CORE SEALS STRAI...

Page 39: ...L H LOWER VENT GRILUDOOR D C CABLE I P FEED...

Page 40: ...C CABLE AT DUCT VIEW A r R R KlCK PAD R R GLOVE BOX DOOR HEATER CASE CORE DOORS R R OUTLET D C BATTERY R RDUCT DRAIN RADIATOR R R DOOR SCREWS D C HEATER HOSES R R SCREWS NUTS ONENGlNE PASS SlDE R R GL...

Page 41: ...71 1 TOHEATERCONTROL t AIR DEFROST CABLE D C BATTERY VIEW B HEATER POWER FEED BLOWER MOTOR WIRE HEATER CONTROL WIRING EXISTING INSTR PANEL WIRE HA R R LOWER STRG COL TRIM PANEL FLANGE LEVER MUST ING N...

Page 42: ...R CASE NUTS AT ENGINE SIDE D C ELECT CONN R R GLOVE BOX DOOR FROM INSIDE CAR DRILL OUT R H CASE STUD WITH 1M DRILL SEAL PULL ASSEMBLY D C ELECT CONN CABLES R R SEALS R R CORE FROM CASE USE NEW SCREW...

Page 43: ...C DEFROSTCABLE R R CONTROL AT CONTROL D C CABLES AT HEATER CASE REMOVE CABLE REPAIR EPAlR CABLE OR CONSTRUCT NEW CABLE OF EQUAL LENGTH USING PARTS FROM BOWDEN CABLE REPAIR KIT USE CABLE HOUSING FROMO...

Page 44: ...res No 4 of 4 HEATER HOSES LOOSEN CLA SLIT HOSE I F BLOWER AIR INLET DUCT ASM MOTOR D C ELECTRIC CONNECTOR R R SCREWS NUTS R R MOTOR CAGE USE NEW STRIP CAULK TYPE SEALING MATERIAL 4293 iEATER BLOWER M...

Page 45: ...CABLE HOUSING FROM ORIGINAL CABLE IF POSSIBLE IN MOST INSTANCES ONLY THE WIRE PORTIONOF THE CABLE WILL REQUIRE REPLACEMENT HEATER CONTROL D C BATTERY R R I P BEZEL R R CONTROL SCREWS PULL CONTROL OUT...

Page 46: ...LECT CONNECTOR MARK MOTOR FLANGE TO CASE POSITION R R BLOWER SCREWS R R MOTOR CAGE TO R R HEATER CORE ADDITIONALLY D C HEATER HOSES R R INLET SCREWS R R CORE STRAP SCREWS REMOVE CORE USE NEW STRIP CAU...

Page 47: ...CE MANUAL L H TEMPERATURE VALVE DOOR 0 R R FRT MODULE COVER D C CABLE HEATER CORE VENT VALVE DOOR nap CARI F 1 1 HEATER OUTLET VALVE DOOR VAL I R R MODULE R R DOOR R R R R DO0R R R DOOR Fig 1A 26 1977...

Page 48: ...L H LOWER VENT CABLE R R CABLE SCREWS NUT I I CENTER UPPER VENT CABLE D C CABLE AT MODULE R R CABLE SCREW NUT C P...

Page 49: ...L OUT LE AT MODULE PULL CONTROL OUT D C HARNESSES AND TEMP CABLE LE SCREWINUT D C CABLE AT MODULE CONTROL BLOWER SPEED R R CABLE SCREWINUT PULL CONTROL OUT D C HARNESS 3653 R R SWITCH SCREWS Fig 1A 24...

Page 50: ...HEATER HOSES R R HOSE CLAMPS HEATER CORE R R HEATER HOSES D C ELECTRICAL CONNECTORS R R FRONT MODULE COVER SCREWS R R CORE HEATER 3654 CTORS...

Page 51: ...Fig 1A 25 1977 B Series Heater Exterior Service Procedures...

Page 52: ...es A C Diagnostic Connector 1B 23 B Series C60 C65 Air Conditioning Electrical Diagnosis 1B 23 On Car Service Procedures 1B 26 Precautionary Service Measures 1B 26 Discharging Adding Oil Evacuating an...

Page 53: ...DESCRIPTION COOLING IS OFFERED WlTH THE CONDITIONED AIR DISTRIBUTED THRU I P OUTLETS A T HI BLOWER SPEED LIMITED AIR FLOW DISTRIBUTED THRU I OR WJSHLD OUTLETS WHENEVER IGNITION IS I N A RUN OR ON POS...

Page 54: ...Compressor is installed its oil must first be drained and measured to leaveonly that like amount drained and measured in the oil compressor 3 ON AN R 4 COMPRESSOR SYSTEM WITH SIGNS OF ABUNDANT OIL LE...

Page 55: ...TIFIER 151A 18 BLK 1518 12 BLK ENGINE 9 HARN LINE 1 5 1 A E 1 8 GRO CONN 2Z 18 GRN DK THRIHW 1 59 18 GRN OK 66 18 GRN LT I 150 18BLK L 2 12 RED 678 18 GRN LTIBLK IGNITION IAD AF k c 50 14 BRN 508 14 B...

Page 56: ...RED 5 2 1 2 RED IAlC YARN 7THROTTLE 678 18 GRN LTI8LK 59A 18 GRN DK 150A 12 ELK r RECrlFlER T A AIC WIRE HARN LINE WNN 150A 14 ELK COMP WIRE HARN LD7 WIRING GRD FUSE BLOCK 44 18 GRN DK 8A 18 GRA HEADL...

Page 57: ...LK THRIHW 2 E l 0 REDS 2D 12 R E D 2 12 RED W C HARN l 4 4 THROTTLE SOLENOID 8 GRN LTIELK GRN DK 12 ELK A C WIRE HARN LINE CONN 150A 14 ELK LD7 WIRING GRD IGNITION 508 14 ERN 508 14 ERN 8 1 8 GRA ED20...

Page 58: ...1 2 10 RED AIC POWER FEED TO ENGINE HARM1 I i s n x SERIES AIR CONDITIONING WIRING FOR ENGINE CODES LX6 I V 1 5 1 1 LD7 1 C 2311 U 7 I Y S11 LG3 l U 3051 w 18 LT GRN COMPRESSOR WIRING L 14 BLK RECTIF...

Page 59: ...DBL BLK STR 0 16 GRN LT DBL BLKSTR A h 16GRN LT GRNLT m glYl I PRESSURE CUT OUT SW LX6 ONLY L 11 ONLY I c 1 6 G R N L T 16 GRN DK SGL WHT STR 1 6 G R N D K RECTIFIER y LX6ONLYl 1977 ASTRE AIR CONDITI...

Page 60: ...R O L E COMP CUT OUT L X I L11 L16 G R i 16 GRN LTIBLK PRESSURE CUTQUT SW 10 RED TO M R ACC FEED CONN 1877 SUNBIRD AIR CONDITIONING WIRING FOR ENGINE CODES LX8 W 1511 L11 8 140 LD7 l C 2311 BLOWER DEL...

Page 61: ...ASM DEFROST POSIT1 POSITION b I P OUTLETS Fig 1B 8 1977 Typical A C Air Flows WATER CONTROL VALVE VACUUM a n o M M c T CART or L o w n MODE VACUUM MOSE ASY u m n MODE AIR INLET IRECIICI DIAPHIIAGM LEV...

Page 62: ...RATOR CORE HEATER CORE 1 BLOWER MOTOR UPPER LOWER 1 DIVERTER VALVES AIR INLET VALVE MODE DOORS RECIRC DOOR TEMP V V E DOOR HEAT MODE I 9 DEFROST NOTE PORT 3 HAS VACUUM FROM PORT 7 IN ANY MODE WHEN TEM...

Page 63: ...EVAPORATOR AIR INLET CHECK VALVE DASH GROMMET RECIRC DIAPHRAGM...

Page 64: ...G 18 13 VACUUM TANK EVAP BLWR ASM VACUUM TEE DASH PANEL GROMMET Fig 18 12 1977 X Series C60 A C Vacuum Diagram BLACK rl AIR INLET VALVE CONTROL ASM PANEL 1 0 DEF 0 H T R 0 0 NORM Fig 18 13 1977 Astre...

Page 65: ...SWITCH V HPV i LPL ORIFICE METERS THE LIQUID R 12 INTO EVAPORATOR REDUCING ITS PRESSURE AND WARM BLOWER AIR ACROSS EVAPORATOR CORE CAUSES BOILING OFF OF LIQUID INTO VAPOR LPV LEAVES EVAPORATOR AS LOW...

Page 66: ...be heated for charging purposes by placing in not over 125 F 51 C water or being wrapped with warm wet rags NEVER HEAT ABOVE 12YF 51 C OR USE BLOW TORCH RADIATOR OR STOVE to heat the container Welding...

Page 67: ...and near the connection to eliminate the possibility of dirt entering the system Both sides of the connection should be capped plugged or taped as soon as possible to prevent the entrance of dirt fore...

Page 68: ...ame direction until squeal stops At this point the tester is ready for use To check operation remove cap from reference leak remove sensor probe from brackets and hold electrode cage near the referenc...

Page 69: ...outlet 4 Start engine and run a t 2000 R P M 5 After one minute the minimum drop in temperature of the air from the center outlet should be as follows slide mode lever to OFF set blower switch to HI a...

Page 70: ...WN MAIN FUSE I FUSE BLOWN 1 FUSE O K I CHECK C C O T SYSTEM WIRING DIAGRAM TO COMPRESSOR IF CLUTCH IS STILL NOT ENGAGED REMOVE CLUTCH REPAIR I CHECK FOR OPEN CIRCUIT I REPLACE FUSE AS PER SERVICE MANU...

Page 71: ...UTLET AND CHECK SYSTEM TO THESE I 1 TURN ENGINE OFF ALL SERlESl 2 CLOSE ALL DOORS WINDOWS ALL 3 HOOD UP ENGINE EXHAUST SUITABLY VENTILATED ALL 4 SLIP FAN CLUTCH SPRING OUT FROM ITS LOCATING NOTCH BY H...

Page 72: ...BE ORIFICE I CHECK COMPRESSORCYCLING REPAIR OR REPLACE REPLACE ACCUMULATOR ASM AND piziq I EVACUATE RE CHARGE SYSTEM I I I SYSTEM SYSTEM DEFECTIVE THERMOSTATIC I0 K I0 K I SWITCH I REPLACE I CHECK COM...

Page 73: ...outlet Temperature too low Check duct work for proper installation Check blower operation Inspect TEMP lever and cable for proper operation Check heater hoses for function On A B and G Series check w...

Page 74: ...en trouble shooting the refrigerant system refer to Fig 1B 20 C C O T A C System Diagnostic Procedure THERMOSTATIC SWITCH DIAGNOSIS 1 Install Gage Set and set up the vehicle as described under Perform...

Page 75: ...sistor 4 No low or MI Speed Faulty resistor 5 No blower except 2 to G in high or max A C 3 volts or more Faulty relay Under 3 volts Faulty resistor or wire from resistor to relay 6 No high blower 9 to...

Page 76: ...in all Faulty A C control 15 Compressor clutch a 6 to G 10 volts or more Faulty clutch or inoperative ground or compressor blower OK clutch harness A C control in norm b 8 to G Under 10 volts Go to st...

Page 77: ...the air that enters the system If for any reason caps are removed but the connections are not made parts should be resealed as soon as possible Sealingcaps should be removed from sub assembliesjust pr...

Page 78: ...4 If pressure is found on the high side of the system attempt to discharge high side using same procedure as used for low side This condition indicates a restriction and high side components should be...

Page 79: ...lB 28 1977 PONTIAC SERVICE MANUAL Fig 18 23 Discharging the 1977 C C O T A C System with J 23500 01 Station...

Page 80: ...e reached at or near sea level For each 1 000 feet above sea level specification should be lowered by one inch of mercury vacuum At 5 000feet elevation only 23 24 of vacuum is required If prescribed v...

Page 81: ...on Accumulator fitting and remove jumper wire from thermostatic switch Reconnect thermostatic switch 8 Leak check system with J 23400 Electronic Leak Detector 9 With system fully charged and leak chec...

Page 82: ...y may be performed WITHOUT FIRST PURGING THE SYSTEM OR REMOVING THE COMPRESSOR from the vehicle The Compressor ShaftSealassemblyand Pressure Relief Valve may also be serviced WITHOUT REMOVING THE COMP...

Page 83: ...18 32 1977 PONTIAC SERVICE MANUAL Fig 1B 27 Exploded View of A 6 Compressor...

Page 84: ...wrench and tighten center screw to remove Clutch Plate and Hub assembly Fig 1B 30 4 Remove square drive key from shaft or drive plate hub 5 Remove hub spacer retainer ring using Snap Ring Pliers J 54...

Page 85: ...under the hex nut on the tool This tool has a left hand thread on the body Fig 1B 34 approximately 3 32 spke between the frictional faces of the clutch drive plate and pulley CAUTI0N Make certain key...

Page 86: ...lley retainer ring using Snap Ring Pliers J 6435 26 Fig 1B 36 3 Pry out absorbent sleeve retainer and remove absorbent sleeve from compressor neck 4 Place Puller Pilot J 9395over end of compressor sha...

Page 87: ...at outer edge is recessed 1 32 from compressor neck face 8 Install clutch plate and hub assembly as described in Compressor Clutch Plate and Hub Asm Replacement Procedure A 6 COMPRESSOR PULLEY BEARING...

Page 88: ...on on compressor front head casting 4 Remove coil housing retaining ring using Snap Ring Pliers J 6435 26 Fig 1B 42 5 Lift Coil and Housing assembly off compressor Replace 1 Position coil and housing...

Page 89: ...HE HOOD INSULATOR The seal is designed to seep some oil for lubrication purposes Only change a shaft seal when a leak is detected by the following procedure When refrigerant system components other th...

Page 90: ...neck foreign material and be sure these areas are perfectly clean before installing new parts Inspection SEALS SHOULD NOT BE REUSED ALWAYS USE A NEW SEAL KIT ON REBUILD see Fig 1B 44 Be extremely care...

Page 91: ...terline 9 Position the new metal sleeveretainer so that itsflange face will be against the front end of the sleeve Pulley Puller Pilot J 9395 see Fig 1B 37 may be used to install the retainer Press an...

Page 92: ...from the compressor at this time All oil must be drained into a container sothat TOTAL amount can be measured A liquid measuring cup may be used for this purpose Drained oil should then be discarded...

Page 93: ...ead and compressor shell assembly up leaving internal mechanism resting on Internal Assembly Support Block CAUTION To prevent damage to shaft DO NOT TAP ON END OF COMPRESSOR SHAFT to remove internal m...

Page 94: ...remove piston previously identified as No 1 with balls and shoe discs from axial plate a Inspect the Teflon piston rings for nicks cuts or metal particles imbedded in exposed ring surface and replace...

Page 95: ...bearings are all 1 2 NEEDLE BEAR1 INSTALLER J 9 NEEDLE BEARING BLOCK J 21352 Fig 18 62 Installing 1977 A 6 Needle Bearing 17 Wash all parts to be re used with trichlorethylene naphtha stoddard solven...

Page 96: ...24 total preload between the seats and the axial plate at the tightest place through the 360 degree rotation of the axial plate at the tightest plate The bronze shoe discs are provided in 0005 variati...

Page 97: ...of the piece part number See Shoe Disc Size Chart in Fig 1B 68 Once a proper selection of the shoe has been made the MATCHED COMBINATION OF SHOE DISCTO REAR BALLAND SPHERICAL CAVITY IN PISTON MUST BE...

Page 98: ...LEEVE J 8001 2 lbCLAMP J 8001 3 J 8001 1 21 Fig 18 70 Gaging 1977 A 6 Rear Thrust Race Fifteen 15 thrust races are provided in increments of 0914 0005 one half thousandths thichess and one ZERO gage t...

Page 99: ...the Ring Installer and DO NOT STORE THE INSTALLER GUIDE IN THE RlNG INSTALLER as the Ring Installer Segment Retainer 0 Ring J 24608 3 will be stretched and possibly weakened during storage This could...

Page 100: ...r of petroleum jelly to the numbered shoe discs chosen in the Gaging Procedure and install all balls and shoe discs in their proper place in the piston assembly 3 Rotate the axial plate so that the hi...

Page 101: ...ement then carefuily place the ear cylinder half over the shaft and start the pistonsinto the cylinderbore Fig 1B 82 Fig 18 79 Installing 2nd 1977 A 6 Piston 0 Ring t Discharge Bushing Gossover Tube 0...

Page 102: ...scharge cross over tube Fig 1B 85 5 Install front discharge valve plate assembly aligning holes with dowel pins and proper openings in front suction reed plate Fig 1B 86 Fig 18 83 Installing 1977 A 6...

Page 103: ...r end of discharge cross over tube See Fig 1B 80 16 Install rear suction reed over dowel pins with slot TOWARDS sump REAR DISCHARGE FRONT DISCHARGE VALVE PLATE VALVE PLATE 4953 Fig 18 67 Front and Rea...

Page 104: ...ressor mounting holes should be in alignment with the compressor sump Make certain that suction screen does not drop out of place when lowering rear head into position Fig 1B 94 If rear head assembly...

Page 105: ...he R 4 Compressor Clutch covered later in this section as Major Repair Procedures Plate and Hub Rotor and Bearing and Coil Pulley Rim because the system MUST FIRST BE PURGED of are covered as Minor be...

Page 106: ...essor shaft Fig 1B 102 5 Hold the hex portion of the J 9480 1 body with a wrench and tighten the center screw to press the hub onto the shaft until there is a 020 040 inch air gap between the friction...

Page 107: ......

Page 108: ...ub Fig 1B 108 The Installer will apply force to the outer race of the bearing 3 Using a center punch with a 45 angle point stake 0 45 055 the bearing in three places 120 apart as shown in Fig 1B 107 b...

Page 109: ...lock nut Torque to 12 ft lbs 4 REPLACE ROTOR BEARING ASM ON BENCH J 9480 1 HUB A N D D R I V E PLATE ASM INSTALLER ig 18 102 Installing 1977 R 4 Clutch Plate Hub Asm Reassemble the rotor and bearing a...

Page 110: ...Tighten pulley rim mounting screws to 100 inch pounds torque and lock screw heads in place by bending special lock washers Fig 1B 110 9 Reinstall clutch plate and hub assembly according to its proced...

Page 111: ...e lock washers 3 Slide the pulley rim off the rotor and hub assembly The pulley rim and the clutch coil Fig 1B 111 are replaceable at this point Replace 1 Assemble the clutch coil pulley rim and the c...

Page 112: ...et of clean paper orderliness in the work area and a place for all parts being removed and replaced is of great importance as is the use of the proper clean service tools Any attempt to use make shift...

Page 113: ...tangs of the J 9392 Tool Remove the seal assembly by pulling straight out from the compressor shaft Discard the seal 8 Remove the sealseat O ringfrom the compressor neck using Tool J 9553 Fig 1B 115...

Page 114: ...ement procedure 8 Re install compressor belt and tighten bracketry 9 Evacuate and Charge the Refrigerant System according to the DISCHARGING EVACUATING AND CHARGING PROCEDURES FOR C C O T A C SYSTEMS...

Page 115: ...viscosity refrigerant oil and install on valve 5 Install pressure relief valve 6 Evacuate and Charge Refrigerant System according to above procedures R 4 COMPRESSOR FRONT HEAD AND OR O RING Remove 1 P...

Page 116: ...st washer on the compressor shaft with the thrust washer tang pointing up Fig 1B 124 Fig 18 124 Replacing 1977 R 4 Thrust and Belleville Washers 4 Install the new belleville washer on the shaft with t...

Page 117: ...trap away from the cylinder and position the strap high enough to clear the cylinder as the shell is removed Fig 1B 127 3 Assemble the front head to the cylinder using a new O ring seal according to p...

Page 118: ...for equal alignment of the shell around the cylinder Tighten the fixture screws finger tight 7 Using a wrench alternately tighten each bolt approximately 1 4 turn to push the compressor shell over th...

Page 119: ...uller down into rotor until puller arms engage recessed edge of rotor hub Hold puller and arms in place and tighten puller screw against Puller Guide Fig 1B 105 to remove rotor and bearing asm clutch...

Page 120: ...sert end of J 9480 1Clutch Plate and Hub Asm Installer through spacer and thread tool onto end of compressor shaft Fig 1B 102 13 Hold hex portion of J 9480 1 body with a wrench and tighten center scre...

Page 121: ...ther assembly or processing is required a shipping plate or Test Plate J 9625 should be installed to keep out air dirt and moisture until the compressor is installed 1977 C60 TEMPERATURE CABLE ADJUSTM...

Page 122: ...CONDITIONING 16 71 MODE ACTUATORS DIAPHRAGMS eR R A C MODULE R R PANEL SCREWS EVAPORATOR CORE 1 CAGE R R DOOR AIR INLET VALVE DOOR R R A C MODULE TOP COVERISCREEN R R DOOR 3627 Fig 18 132 1977 B Serie...

Page 123: ...18 72 1977 PONTIAC SERVICE MANUAL...

Page 124: ...NUTS HEATER AIR DISTRIBUTOR OUTLET R R GLOVE BOX R R MODULE DISTRIBUTOR DUCT MIX BOX R R DISTRIBUTOR OUTLET SCREWS LOWER HORIZONTAL A C DUCTS R H R R HUSH PANEL R R DUCT SCREWS L H OUTLET DUCT R R I...

Page 125: ...SH PANEL R R GLOVE BOX D C VACUUM HARNESS R R DIAPHRAGM NUTS AIR DISTRIBUTOR DUCT MIX BOX R R GLOVE BOX I R R DUCT MIX BOX SCREWS R R SWITCH SCREWS R R SWITCH SCREWS Fig 1B 133 1977 B Series A C Inter...

Page 126: ...MODULE TOP R MODULE TOP COVER R CORE LY NEW SEALING MATERIAL WATER VALVE 3LOWER MOTOR RESISTOR RADIATOR COOLANT l R SCREWS D C VACUUM HARNESS l C WIRING R R HOSE CLAMPS HIGH BLOWER RELAY R R SCREWS 7...

Page 127: ...R R MOTOR SCREWS R R IMPELLER R R SCREWS D C NEG BATTERY CABLE D E C AIC SYSTEM R R HOOD R R R H WISHLD WIPER ARM R R MODULE LEAF SCREEN SEAL TOP COVERIBLOWER MOTOR AS ASM R R SWITCH R R EVAPORATOR C...

Page 128: ...R R SCREW CENTER I P A C OUTLET BEZEL R R GLOVE BOX A R R SCREWS a RETAINER 9 w LeMANS LeMANS SPORT L H I P A C ADAPTER OUTLET TRIM PLATE R R TRIM PLATE 2 J J p LOWER DUCT ASM R R SCREWS VIEW A Fig 1...

Page 129: ...TRlM PLATE CENTER OUTLET EXTENSION DUCT R R SCREWS OUTLET R R RIVETS COLD AIR DUCT R R GLOVE BOX R R SCREWS L H OUTLET EXTENSION DUCT R R SCREWS R R GLOVE BOX R R UPPER LOWER I P TRlM PLATES R R SCREW...

Page 130: ...PORATOR CASE R R GLOVE BOX R R COLD AIR DUCT HEATER DISTRIBUTOR R R LOWER DEFROSTER DUCT SCREW R R COREICASE RET SCREW TO PULL ASM FREE FROM COWL D C TEMP CABLE VACUUM HOSES FROM ASM REMOVE CORE AND C...

Page 131: ...R R HEATER CASE R R GLOVE BOX LEMANS LEMANS SPORT D C VACUUM HOSE R R HEATER DISTRIBUTOR R R SCREWS R R SCREWS D C VACUUM HOSE CONTROL VACUUM HARNESS INSTALL VACUUM CONTROL PUSH ON NUTS SNAP IN FLAG...

Page 132: ...OUT PEEL OFF PROTECTIVE D C ELECT CONN CONTROL BLOWER SWITCH PULL CONTROL OUT L OFF PROTECTIVE LEMANS LEMANS CONTROL WIRING P FEED SAFARI GRAND LEMANS GRAND PRlX WIRING SET UP I STEP 2 L OFF PROTECTIV...

Page 133: ...E CORES BLOWER AND DUCT ASM FOR BLOWER CASE R R USE HEATER SECTION 1A R R IN ADDIT TO D C ELECT CONN COOLING TUBE ACCUMULATOR FOR EVAP CASE CORES AND DUCT ASM D EC A C SYSTEM DdZC ALL ELECT CONN COOL...

Page 134: ...WlTH STING DASH HlGH BLOWER RELAY D C ELECT CONN p L W R R SCREWS BLOWER RESISTOR D C ELECT CONN R R SCREW A BLOWER TERMINAL VlEW A IS WIRE USED WlTH RADIO ONLY HlGH BLOWER FEED n L VIEW B r0COMPRESSO...

Page 135: ...R COMPRESSOR REMOVALS REPLACEMENTS VIEW A R 4 COMPRESSOR SEE C C O T REFRIGERANT OIL DISTRIBUTION FOR COMPRESSOR REMOVALS REPLACEMENTS TIGHTEN PRIOR TO TIGHTENING MUFFLER OR COMPRESSOR MOUNTING CONDEN...

Page 136: ...LE R R UPPER LOWER I P I P CENTER OUTLET DUCT R R STRG COL TRlM PANEL R R GLOVE BOX DOOR R R LOWER R H DUCT R R I P TRlM PANEL R R CENTER I P DUCT OUTLET R R DUCT THRU GLOVE BOX GLOVE COMPT DOOR OUTLE...

Page 137: ...ENDER SKIRT SCREWS TO PRY OUT SKIRT FOR ACCESS TO R R LOWER HEATER HOSE CLAMP REM OTHER HOSE R R HEATER CORE UNDERHOOD NUTS R R CASE INSIDE CAR SCREWS R R CONSOLE TAPE ASM D C TEMP CABLE AT HEATER CAS...

Page 138: ...LOVE BOX R R SCREWS D CCABLEAT HEATERCASE D C VAC HOSE A C CONTROL REPAIR ADJUST SEE TEMPERATURE CABLE ADJUST REPAIR CABLE OR CONSTRUCT NEW A C CONTROL CABLE OF EQUAL LENGTH USING D CBATTERY PARTS FRO...

Page 139: ...IAC SERVICE MANUAL PLENUM AIR INLET DOORIDIAPHRAGM LOOSEN REPOSITION COWL SCREEN RECIRC DIAPHRAGMIDOOR R R KICK PAD D C VAC HOSES R R SCREWS VIEW D Fig 18 146 1977 F Series A K Interior Service Proced...

Page 140: ...MATERIAL MARK CAPILLARY TUBE LOCATION ON INLET PlPE FOR BLOWER CASE R R USE HEATER SECTION 1A R R INADDIT TO D C ELECT CONN COOLING TUBE D E C A C SYSTEM USE NEW STRIP CA ADD 3 0 2 OIL FOR EXPANSION T...

Page 141: ...CT CONN AND D EC A C SYSTEM ALL FREON HOSES ARE TO BE INSTALLED WITH NO TWlST ASSEMBLED INTO THEM EFRIGERANT NOTE AFTER REMOVING SHIPPING PLATE ON REAR ROTATE THE PLATE SLlGH COAT ALL 0RINGSWlTH CONDE...

Page 142: ...TO R R ANY REFRIGERANT LINEICOMPONENT VIEW B D C ANY ELECT CONN AND D EC AtC SYSTEM ALL FREON HOSES ARE TO BE INSTALLED WITH NO TWIST ASSEMBLED INTO THEM...

Page 143: ...R DIST DUCT HOSE D C ELECT CONN R R SCREWS TEMP CABLE VACUUM VALVE PULL CONTROL D C VACUUM HARNESS OUTLET DEFLECTOR R R SCREWS VIEW B CENTER AIR OUTLET CENTER OUTLET ADAPTER CENTER OUTLET ADAPTER NOTE...

Page 144: ...ER 7TS FROM BOWDEN CABLE REPAIR KIT USE CABLE Ei HOUSING FROM ORIGINAL CABLE I F POSSIBLE IN MOST INSTANCES ONLY THE WIRE PORTION ENGINE CODE C 2311 R I ICarrrrr I z Yn8 301 A c CONTROL WIRING A C CON...

Page 145: ...ASKET IR DISTRIBUTOR DUCT D C BATTERY DRAIN COOLANT D C HEATER HOSES NEC TO BLOCK OUT FENDER SKIRT TO REACH LOWER HOSE AND STUD NUT R R CASE STUD NUTS FROM ENGINE COMPT SIDE R R GLOVE BOX R R R H KICK...

Page 146: ...NEL VIEW D w VlEW E DooRL uT PLENUM AIR INLET OOR DIAPHRAGM VlEW C D SEAL BEFORE TORQUING BOTTOM VAC CONTROL ARM IN HOUSING HOLD VALVE CLOSED WITH 2 LBS WIN LOAD PANEL VIEW B 4734 Fig 18 153 1977 X Se...

Page 147: ...LECT CONN COOLING OIL ADDITION TUBE D E C A C SYSTEM R R SCREWS IL O RINGSWHEN tEINSTALLING NUTS USE NEW STRIP CAULK TYPE LER MATERIAL 02 OIL FOR EVAP CORE REPL TRANSDUCER HOSE CONNECTS DlRECTLY TO HE...

Page 148: ...A h MUFFLER HOSE FITTING NOTE TO R R ANY REFRIGERANT LINE COMPO ASM SET UP FOR ENGINE NENT D C ANY ELECTRIC CONNECTOR AND D E C A C SYSTEM ALL REFRIGERANT HOSES ARE TO BE INSTALLED WITH NO TWIST ASSE...

Page 149: ...N ON INLET PIPE R R CLAMP SCREWS BRACKET ENGINE HARNES VlEW B VIEW A 1 7 9 c q VlEW D DO NOT CRIMP CAPILLARY TUBE BLOWER WIRING WlTH C 2311 R 3501 Y 301 COMPRESSOR LOW PRESSURE TO RESISTOR 1 r POWER L...

Page 150: ...R COLD AIR DUCT HEATER DEF DUCT R R ALSO R R DIST DUCT CONTROL SELECTOR DUCT ASM A C CONTROL D C BATTERY R R LOWER L H DUCT R R I P CLUSTER BEZEL ASH TRAYIRETAINER R R CONTROL CLUSTER SCREWS R R DIST...

Page 151: ...TAINERS SCREWS SELECTOR DUCT HEATER CORE DOORS ASM D C BATTERY D C HEATER HOSES R R ENGINE SIDE ASM NUTS R R GLOVE BOX R R R H OUTLET FLEX HOSE R R L H OUTLET DUCT LOWER STRG COLUMN R R IIP BEZEL ASH...

Page 152: ...R R SCREW ANTI DIESELING RELAY VIEW A USE BAT IGN RECEPTACLES IN FUSE BLOCK AR COURTESY LAMP OPT FEED DEFROSTER DUCT RELAYS USED WITH ENGINE CODE J 151 ANTI DIESELING RELAY D C ELECT CONN R R SCREWS R...

Page 153: ...R MOTOR CAGE ASSEMBLY D C HEATER HOSES D C ALL ELECT CONN D C REFRIGERANT LINES R R ACCUM R R EVAP ASM NUTS SCREWS TRANSFER PARTS SEE THERMOSTATIC SWITCH USE NEW STRIPCAULK TYPE SEALING MATERIAL ADD...

Page 154: ...CUSTOM AIR CONDITIONING 18 101 Fig 18 161 1977 Astre Series A C Exterior Service Procedures No 2 of 3...

Page 155: ...RESSOR LOW PRESSURE CUT OFF SWITCH D C ELECT CONN D E C A C SYSTEM R R SWITCH D C ELECT CONN R R SCREWS MUFFLER HOSE FITTING ASM RADIATOR CONDENSER D E C A C SYSTEM R R SCREWS ADD 10 2 OIL FOR 525 VIS...

Page 156: ...TYPE LOOSEN L H I P CLUSTER SCREWS SEALING MATERIAL ADD 3 02 OIL FOR R R R H LAP COOLER CONT D EVAP CORE REPL DUCT EXTENSION MODULAR DUCT DUCT EXTENSION MODULAR DUCT ASM D C BATTERY R R I P PAD MODU...

Page 157: ...EN CABLE REPAIR T O REMOVE D C BATTERY KIT USE CABLE HOUSING FROM ORIGINAL CABLE I F LOWER STRG COL TIPZIP PAD POSSIBLE I N MOST INSTANCES ONLY THE WIRE PORTION OUTWARD OF THE CABLE WILL REQUIRE REPLA...

Page 158: ...I DIESELING RELAY USE BAT IGN RECEPTACLES PULL CONTROL I N FUSE BLOCK D C ELECT CONN R R SCREW ANTI DIESELING RELAY D C ELECT CONN RELAYS USED WITH ENGINE CODE V 151 TIME DELAY RELAY D C ELECT CONN V...

Page 159: ...1B 106 1977 PONTIAC SERVICE MANUAL Fig 18 166 1977 Sunbird Series VC Exterior Service Procedures No 1 of 3...

Page 160: ...TOR VlEW F NGlNE CODE C 231 LOWER WIRING COMPRESSOR LOW PRESSURE CUT OFFSWITCH THERMOSTATIC SWITCH COMPRESSOR LOW PRESSURE CUT OFF SWITCH INLET ASSEMBLY TO COMPRESSOR F NECESSARY CONNECTION BLOWER MOT...

Page 161: ...OMPRESSOR SEE C C O T REFRIGERANT OIL DISTRIBUTION FOR NOTE TO R R ANY REFRIGERANT LINE COMPONENT D C ANY ELECT CONN AND D E C A C SYSTEM b d h CONDENSER VISCOSITY REFRIGERANT mmn MET COVER PLATE A c...

Page 162: ...RACKET ALTITUDE AND CALIFORNIA THI BLOWER CONNECTOR 1 ENGINE HARNESS FEED A C HARNESS CONNECTOR TO MUFFLER PIPE WATER HOSE CT TO IDLE STOP ENGINE CODES R 350 K 403 LENOID LEAD A C WIRING COMPRESSOR Wl...

Page 163: ...S COMPRESSOR MOUNTING BOLT A C COMPRESSOR TO MUFFLER PIPE IDLE STOP DISCHARGE LINE A C HARNESS CONNECTOR LEAD IS CUT OFF ON ENGINE CODE R 350 MANUAL TRANS CARS WIDE OPEN THROTTLE SWITCH COMPRESSOR WIR...

Page 164: ...PRESSOR CONNECTION CALIFORNIA LOCATION ENGINE CODE C 231 COMPRESSOR WIRING TAPE EXCEPT C LOCATION LIQUID LINE ENGINE CODE B 140 COMPRESSOR FOR ASTRE GROUNDWIRE BATTERY CABLE BOLT 81 LOCK W R 4 COMPRES...

Page 165: ...COMPRESSOR MOUNTING FOR ENGINE CODE B 140 i BRACKET 7 8 14TTERY CABLE ON ASTRE SUNBIRD 4753 Fig 18 17 2 1977 Compressor Mounting No 1 of 4 Engine Codes 8 14 0 and V 15 1 R 4 COMPRESSOR MOUNTING A 6 C...

Page 166: ...MOUNTING FOR ENGINE CODE C 231 ON A B 81F SERIES REAR BRACKET SOR MOUNTING CODES U 305 REAR BRACKET REAR BRACE ONT BRACKET SUPPORT VIEW A WITH POWER STEERING VIEW B Fig 18 173 1977 Compressor Mounting...

Page 167: ...977 PONTIAC SERVICE MANUAL OMPRESSOR MOUNTING EMISSION HOS ROUTED AS SHOWN FOR ENGINE CODES P 350 2 400 ON A B F G SERIES 4755 Fig 16 175 1977 Compressor Mounting No 4 of 4 Engine Codes Y 301 P 350 an...

Page 168: ...Compressor Holding Fixture 15 J 9397 Compressing Fixture 16 J 25030 Clutch Hub Holding Too 17 J 9399 9116 Thin Wall Socket 18 J 9401 Hub and Drive Plate Assembly Remover 19 J 9480 01 Hub and Drive Pla...

Page 169: ...C Control lever efforts must be checked These efforts should not be too low below 2 lb using pull scale or too high about 6 5 lb or repair adjustments then be made 1 Slide mode lever to OFF Set blower...

Page 170: ...ease as the switch lever is moved down through each position 9 Slide the mode lever to MAX Blower comes on HI speed Air exits from the A C outlets only Air noise is heard from the right front corner o...

Page 171: ...ure doors threaded operating rod toward Re install programmer yourself to hear door seating in full heat position Connect sensor hose and vacuum harness Snap temperture doors threaded operating rod in...

Page 172: ...CTLY BEHIND IN THE FUU MOTOR LlNK TRAVEL 10 12 VACUUM INDUCED IN THIS DIRECTION LOCKS MOTOR IN FULL HEAT POSITION 4798 hot if LlNK 4799 Fig 1C 5 1977 B Series C65 Programmer Front View Fig 1C 6 1977 B...

Page 173: ...URE LEVER SET AT 75O PRlX TYPE I P ADJUST THE TURNBUCKLE UNTIL THE EYELET LINES UP WlTH THE PIN LEVER END A T THE PROGRAMMER 3 SLIP THE CABLE END OVER THE PIN AND PUSH THE TEMPERATURE LEVER TO 65O LEF...

Page 174: ...1C 6 1977 PONTIAC SERVICE MANUAL 4989 1C Fig 1C 8 1977 A and G Series C65 Service Procedures View E of Fig 1C 7 No 2 of 2...

Page 175: ...rame which supports the front end sheet metal front suspension engine and other mechanical components Unitized construction demands that underbody components be properly aligned to assure correct susp...

Page 176: ...st be equal within 1 4 inch 1 Measure X X If not equal frame horn or front suspension crossmember is misaligned 2 Measure Y Y If not equal center portion of frame is misaligned 3 Measure Z Z If not eq...

Page 177: ...MENSIONS ARE IN INCHES STATION WAGON 3150 Fig 2A 3 B Series Frame Dimensions BODY MOUNTS given in each illustration The various tv es of bodv mounts and their a lication FRAME BRACES are shown in i gs...

Page 178: ...75 118 COUPE C syMMETRKAsourCENTER lOO l 2 STA WG 101314 SEDAN 8 4 G SERIES 127 112 123 112 COUPE 141 1 4COUPE 145 I 4SEDAN G SERIES 152 13 16STAWG 89 114 COUPE RH TO 19 27 32 10 5 8 DATUM 1 COUPE W B...

Page 179: ...R S L T U V Fig 2A 5 Frame Body Mounts A B and G Series BOLT 343205 343205 343205 330982 BLUEIYELLOW 330953 BEIGE 488610 GRAY 371740 PINKIGREEN 356941 VIOLETIYELLOW 356941 VIOLETIYELLOW 371741 REDIGO...

Page 180: ...ION THRU BODY MOUNT L H SIDE SHOWN R H SIDE THE SAME BODY MOUNT CUSHIONIINSULATOR USAGE SERIES F Fig 2A 6 Frame Body Mounts F and X Series X EXC 4 CYL ENGINE X 4 CYL ENGINE 1 MOUNT 377801 377801 UPPER...

Page 181: ...Y MOUNTS 2A 7 VlEW A TYP BOTH SIDES VlEW B TYP BOTH SIDES 3152 Fig 2A 7 Frame Braces B Series BOLT BRACE BOTH SIDES LBOLT 70 LB FT BRACE T WASHER A VlEW B NUT BOTHSIDES 65 LB FT 3155 Fig 2A 8 Frame Br...

Page 182: ...E ENGINE REAR C BRACES CROSSMEMBER E B FT FRAME ENGINE FRONT CROSSMEMBER __ I BRACE 7 VlEW A VlEW D BRACE NUT 55 LB FT VIEW B NUT 55 LB y FT 55 LB FT VIEW E VIEW C TYPICAL BOTH SIDES TYPICAL BOTH SIDE...

Page 183: ...AME 3RACE I BOLT CROSSMEMBER DIRECTION OPT 55 LB FT WASHER BOLT VlEW A DIRECTION OPT 55 LB FT BOTH SIDES ALL ENGINES VlEW B BOTH SIDES EXC V 6 ENGINE R H SlDE V 6 ENGINE 30 LB FT VlEW C LH SlDE V 6 EN...

Page 184: ...gh the orifice and into the piston tube This controlled passage of the fluid provides the energy absorbing action The hydraulic fluid that is forced from the cylinder tube into the piston tube displac...

Page 185: ...TEST IS NOT RECOMMENDED BECAUSE PERSONAL INJURY OR I I B INSPECTION AFTER COLLISION b Using a suitable measuring device note original position of unit then use press to compress unit at least 3 8 c Re...

Page 186: ...ing process Proper care of these bumpers is recommended to prolong their beauty and the protection of the surface finish Occasional washing and scrubbing with soap and water using soft fiber brushes i...

Page 187: ...LAMP FRAME HANGER BAR R R BUMPER ASM E A UNIT R R NUTS BOLTS AT FRAME TORQUE 80 110 LB FT BUMPER GUARD D C PARKITURN SIGNAL LAMP R R BUMPER ASM R R NUTS ERGY ABSORBING UNlT D C PARK TURN SIGNAL LAMPS...

Page 188: ...RBING UNlT R R BUMPER ASM R R NUTS BOLTS AT FRAME TOROUE 45 60 LB FT INNER BAR REINFORCEMENT BUMPER GUARD D C REAR END WIR R R BUMPER ASM R R ASM BY 4 NUTS AT EACH E A UNIT R R SCREWS D C WIRING BUMPE...

Page 189: ......

Page 190: ...NFORCEMEN R R NUTS BOLTS FRAME 7 TORQUE 52nm 38LB FT PAD BRACKET REAR BUMPER FACE BAR EXC WAGON R R 4 NUTS AT EACH E A UNlT BUMPER MOUNTING BRACKET R R INNER REINF ATTACH NUTSBOLTS R R BUMPER GUARDS I...

Page 191: ...PRY OFF SNAP ON TORQUE 52n rn 38 LB FT PAD BRACKET REAR BUMPER FACE BAR WAGON0 R R 4 NUTS AT EACH E A UNlT BUMPER MOUNTING BRACKET BUMPER RUB R R INNER REINF ATTACH NUTS BOLTS R R BUMPER R R BUMPER G...

Page 192: ...MENT 7 HANGER BAR rFRAME HANGER BAR R R BUMPER ASM R R BUMPER ASM E A UNIT R R NUTS SCREWS TO LWR R R NUTS BOLTSAT FRAME REINF AND FACE BAR R R BPR FILLER LOWER REINFORCEMENT R R BUMPER ASM R R BUMPER...

Page 193: ...28 10 1977 PONTIAC SERVICE MANUAL R R NUTS 3372 Fig 28 1 1 Exploded Service Procedures G Series Rear Bumper...

Page 194: ...FRONT REAR BUMPERS 26 11 Fig 2B 12 Exploded Service Procedures F Series Rear Bumper...

Page 195: ...T EACH E A UNlT BUMPER MOUNTING BRACKET R R HOOD RELEASE CABLEIBRACKET R A INNER REINF ATTACH NUTS BOLTS R R BUMPER GUARDS R R RUB STRIP R R LICENSE PLATEIMOUNTING TORQUE E A UNlT NUTS 45 60 LB FT I B...

Page 196: ...MPER FACE BAR R R ASM BY 4 NUTS AT EACH E A UNlT BUMPER MOUNTING BRACKET R R INNER REINF ATTACH NUTS BOLTS R R BUMPER GUARDS R R RUBSTRIP TORQUE E A UNlT NUTS 45 60LB FT BUMPER RUB STRIP BUMPER GUARD...

Page 197: ...res H Series Rear Bumper REINFORCEMENT FRAME HANGER BAR R R BUMPER R R BUMPER A M R RENERSORBER R R FENDER BRACE BOLT R R 5 ENERSORBER TO FRAME HANGER BAR NUTS 55 FT LBS R R 14 BOLTS 30 FT LBS ATTACHI...

Page 198: ...FRONT 81 REAR BUMPERS 28 15 Fig 28 17 Exploded Service Procedures HM07 Rear End 81 HM Series Rear Bumper...

Page 199: ...1977 PONTIAC SERVICE MANUAL 2B 16 AND REINFORCE BOTTOM OF BRACKET A SERIES FRONT X SERIES FRONT OF BRACKET OF G SERIES FRONT SCREW 0974 Fig 28 19 Front License Plate Mounting Locations...

Page 200: ...reinforcement Further rigidity is obtained by the insertion of reinforcement braces and brackets strategically located so as not to interfere with adjustments or service repair conditions ADJUST Slot...

Page 201: ...release for All Series RELEASING THE HOOD on the A HM F and X Seriesis achieved by reaching through the opening in the LH bumper cooling slot and pulling outward on the release rod The hood on the H S...

Page 202: ...omote paint adhesion a light scuff sanding of the surface with 400 grit sandpaper is recommended 3 Repeat cleaning of the surface 4 Color coat with acrylic lacquer for proper color match 5 Allow to dr...

Page 203: ...nd insure a smooth surface a light scuff sandingwith W grit sandpaper wet or dry is recommended 3 Repeat cleaning of the surface NOTE Under no circumstances should acrylic lacquer paint be used in ref...

Page 204: ...POLYPROPYLENE 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 T...

Page 205: ...oneOnly Aquamarine Met 4984 Bahia Green Met 4966 Berkshire Green Met 4967 Cream Gold 4890 Goldenrod Yellow 3893 Mojave Tan 4891 Buckskin Met 4997 Fiesta Orange 4909 Brentwood Brown Met 4968 Roman Red...

Page 206: ...ABS plastic requires no primer Conventional interior acrylic lacquers adhere satisfactorily to hard ABS plastics PROCEDURE 1 Wash part thoroughly with a cleaning solvent Acrylic Clean Pre Kleano Prep...

Page 207: ...2C 8 1977 PONTIAC SERVICE MANUAL Fig 2C 3 Exploded Service Procedures A Series Front End...

Page 208: ...R R HINGE SCREWS HOOD INSULATOR PAD R R PLASTIC RETAINERS FRONT FENDER R 81R WHEEL BLOCK UP HOOD FENDER SKIRT R R WHEEL R 81R SCREWS A T COWL RAD SUPT LOOSEN SKIRT AT REAR FRONT GUSSETS R R SCREWS Fig...

Page 209: ...2C 10 1977 PONTIAC SERVICE MANUAL Fig 2C 5 Exploded Service Procedures B Series Front End...

Page 210: ...CHASSIS METAL PLASTICS PAINT AND REPAIR 2C 11 CO NERINGLAMP BEZEL D C WIRING B I ad R R NUTS Fig 2C 6 Exploded Service Procedures B Series Fenders and Hood...

Page 211: ...AME INSULATORS HOOD LOCK R R NUTS SCREWS A T FENDERS SKIRTS I D C CABLE TRANSFER PARTS f R R SCREWS r ie COUPLING TOWARDS FRONT END PANEL R R PARK T SICNAL HEADLAMPS 0 0 D POP UPSPRING R R NUTS SCREWS...

Page 212: ...CHASSIS METAL PLASTICS PAINT AND REPAIR 2C 13 Fig 2C 8 Exploded Service Procedures G Series Fenders and Hood...

Page 213: ......

Page 214: ...LIGNMENT SHIMS USED TRANSFER PARTS PUSH ONTYPE AIR EXTRACTOR R R WHEEL LOOSEN SKIRT AT REAR BLOCK SKIRT OUT FROM R R EXTRACTOR NUTS FENDER SKIRT R R WHEEL R R SCREWS AT FENDER COWL RAD SUPT ACTOR PROC...

Page 215: ...2C 16 1977 PONTlAC SERVICE MANUAL PARTS 3352 Fig 2C 1 1 Exploded Service Procedures X Series Front End...

Page 216: ...CHASSIS METAL PLASTICS PAINT AND REPAIR 2C 17 Fig 2C 12 Exploded Service Procedures X Series Fenders and Hood...

Page 217: ......

Page 218: ...HOOD RELEASE HANDLE BRACKET D C HANDLE FROM BRACKET I R R BRACKET BOLT L R R SCREWS BOLTS D C CABLE FROM LOCK VIEW B D C C CLIP LAMP HOUSING R R SPRING FRONT END PANEL R R GRILLE EMBLEMS R R GRILLE R...

Page 219: ...VICE MANUAL SAFETY LATCH R R SCREWS 77 H HOODS HOOD SPRING ROTATE HOOD R R HOOD HINGE SCREWS TO COWL R R INSULATOR PAD R R SAFETY LATCH R R HOOD SPRING R RETAINERS ASTRE R R RETAINERS Fig 2C 15 H Seri...

Page 220: ...NT AND REPAIR 2C 21 INSTALL APPLIQUE ALONG CENTER OF HOLES I N FENDER SEE VIEW A FOR TYPICAL CLIP INSTALLATION MOLDING ATTACHMENT TYPICAL FOR LOCATING APPLIOUE Fig 2C 16 A Series and B S e r i e s Woo...

Page 221: ...77 PONTIAC SERVICE MANUAL ALIGN STRIPE TO MIRROR R H MIRROR TYPICAL MOLDING DECAL SECTION A A DOOR MOLDING DOOR DIMENSION TAKEN FROM TOP OF DOOR DECAL SECTION 0 E Fig 2C 17 A Series and G Series Strip...

Page 222: ...IN VlEW C 13 0 MM 1 5 IN CONSTANT 11 0 MM 1 4 IN BELOW PARALLEL WlTH CREASE LlNE NOTE POSITION MOLDINGS AS FOLLOWS GRAND SAFARI FENDER 2 5 MM 1 IN FORWARD OF REAR EDGE OF FENDER QUARTER PANEL 2 5 MM...

Page 223: ...2C 24 1977 PONTIAC SERVICE MANUAL Fig 2C 19 F Series Esprit Stripe Decals and Moldings...

Page 224: ...ER PAPER TO FRONT ALIGN DECAL CARRIER PAPER ACCENTCOLOR ENDS OF STRIPES TO BE FLUSH I EDGE OF R R DECK LID 126 FROM EDGE OF DECK LID DECAL CARRIER PAPER TO LINE UP WITH PONTIAC PLATE 90 CONSTANT FROM...

Page 225: ...2C 26 1977 PONTIAC SERVICE MANUAL DECK 4 Fig 2C 2 1 F Series Trans Am Decals...

Page 226: ...OR FRONT END PANEL TO FRONT FENDER SECTION B B CARRIER PAPER LTlNG AS SHOWN CATE STRIPE ON HOOD AND TO BE FLUSH AND NOTE ALL DIM RUN CONSTANT TO PEAK LINE FRONT END PNL NS TAKEN ON FLUSH AND TURN SURF...

Page 227: ...M E 1 TRIES TO BE WRAPPED AT P A M L EWES...

Page 228: ...METAL PLASTICS PAINT AND REPAIR 2C 29 CENTER STRIPE AROUND FLUSH TO EDGE OF CARRIER PAPER VIEW C L H FENDER CENTERLINE OF WHEEL LALIGN STRIPE ON DOOR TO STRIPE ON FRT FENDER Fig 2C 24 H Series Wagon...

Page 229: ...S TO EDGE OF FLUSH WITH FRT NOTE ALIGN DARTS ON CARRIER PAPER EDGE OF FENDER PANEL EDGES TO LOCATE STRIPES WlTH ALIGN STRIPE ON DOOR TO STRIPE ON FRT FENDER BY NOTCHES I N LINER PAPER W1R H MIRROR LOC...

Page 230: ...Diagnosis Radial Tire Waddle Radial Tire Lead Diagnosis GENERAL DIAGNOSIS Since the problems in steering suspension wheels and tires involve several systems they must all be considered when diagnosin...

Page 231: ...used by restriction b Scored pressure plates thrust plate or rotor c Badly worn cam ring 4 Whine a Pump shaft bearing scored 5 Squeal or Chirp a Loose belt Gear Noise Squawk Cut dampener 0 ring on spo...

Page 232: ...ive f f o r t Required At Steering Wheel I Tight or frozen intermediate rod tie rod or idler socket 2 Steering gear adjusted too tight MANUAL STEERING GEAR DIAGNOSIS Excessive Play or Looseness in Ste...

Page 233: ...th Engine Running Especially During Parking 1 Steering linkage hitting engine oil pan at full turn 2 Insufficient pump pressure 3 Sticky flow control valve Excessive Wheel Kick Back or Loose Steering...

Page 234: ...ctive lock cylinder Lock Cylinder Can Be Removed Without Depressing Retainer 1 Lock cylinder with defective retainer 2 Lock cylinder without retainer 3 Burr over retainer slot in housing cover High Ef...

Page 235: ...urn To Top Tilt Position 1 Pivot pins are bound up 2 Wheel tilt spring is defective 3 Turn signal switch wires too tight Noise When Tilting Column 1 Upper tilt bumpers worn 2 Tilt spring rubbing in ho...

Page 236: ...tch is defective 3 If the flashing rate is still extremely slow refer to Section 8 Hazard Signal Lights Will Not Flash Turn Signal Functions Normally 1 Blown fuse 2 Inoperative hazard warning flasher...

Page 237: ...ssemble and re check See Note 3 CAUTION Key must be removed or cylinder placed in RUN position before removing lock cylinder Fig 3 3 Checking Buzzer Switch Pads Fig 3 4 Checking Buzzer Switch 5 Defect...

Page 238: ...e on steering gear pump or anywhere else on the left side of engine compartment 3 Growling noise especially when parking or when engine is cold 4 Loss of power when parking 5 Heavy steering effort Whe...

Page 239: ...pressures and compare with the maximum pump pressure recorded If pressure is not same at both stops as maximum pressure the gear is leaking internally and must be disassembled and repaired 8 Shut off...

Page 240: ...RlNG SEALS 7 818 TORQUE THE FITTING NUT 40FT LBS I F LEAKAGE PERSISTS REPLACE BRASS CONNECTOR AND REFACE HOSE TUBE FLARE IF LEAKAGE IS DUE TO DAMAGED THREADS CROSS THREADED REPLACE BRASS CONNECTOR RE...

Page 241: ...1 However resistance should be smooth and constant for each stroking rate 4 Compare with a known good shock 5 It is normal to detect a hissing noise orifice swish The following are considered abnorma...

Page 242: ...TlCLLSOF FOREIGN MATERIAL CLEAN hLL PARTS ANDHOUSINGS CHECK SEALS AND REPLACE DEARlNGS IF ROUGH OR NOISV GALLING METAL SMEARSOU ROLLER ENDSDUE TO OVERHEAT LUBRICANT FAILURE OR OVERLOAD WAGON S REPLACE...

Page 243: ...HT BROWh TO BLACS CAUSED BY INCORRECT LUBRICANT OR MOISTURE RE USE BEARINGS I F STAILIS CAN BE REMOVED BY LIGHT POLISHING OR I F NO EVIDENCE Of OVER HEATING IS OBSERVED CHECK SEALS AND RELATED PARTS F...

Page 244: ...ion The way in which a tire is built can produce lead in a car An example of this is placement of the belt Off center belts on radial tires can cause the tire to develop a side force while rolling str...

Page 245: ...INAL POSITION REPLACE THE TIRE YOU JUST TO REAR AND PUT REAR TlRE ON I LEAD REMAINS INSTALL A KNOWN GOOD TlRE I N PLACE OF FRONT LEAD SlDE TIRE I I LEAD REMAINS INSTALL A KNOWN GOOD TlRE IN PLACE OF O...

Page 246: ...E C T R E P A l R OR R E P L A C E Using the Charts The charts are divided into three se tions step sequence and result STEP SEQUENCE RESULT Always start at the first step and go through the complete...

Page 247: ...SHIFT TO NEUTRAL IGNITION LOCK WHEELS IN STRAIGHT AHEAD POSITION FOR FRONT WHEEL DRIVE w A IL SHIFT TO NEUTRAL AND BRACE STFFRING WHEEL NOTE CENTER TPD PLACE STAND UNDER UNDER TIRE OPPOSITE TIRE SAME...

Page 248: ...SIDE TO SIDE MOTION y USL USING FLAT END OF SPINDLE OR AXLE SHAFT i RECORD READING ON CHART L F RF L R RR REVISE RADIAL UPAND DOWN TABLE LATERAL SIDE TO SIDE RECHECK NEW ASSEMBLY PER STEPS 4 AND 5 IF...

Page 249: ...X s RECHECK PER TOGETHER STEP 4 REBALANCE I MORE THAL 1 035 INCH 1 0 88 mm LESS THAN 0351NCH 0 88 mm IF LATERAL READING FROM STEP 5 IS MORE THAN 030 1NCHl0 76 mm FOR ANY SINGLE TlRE TlRE IF LATERAL R...

Page 250: ...E SIDE MAY CAUSE ROUGHNESS NO VIBRATION BALANCE A L L TIRES NOT BALANCED I N a PREVIOUS STEPS PROBLEM IS NOT WHEELS DRIVETRAIN COMPONENTS VIBRATION SUBSTITUTION METHOD STEP SEQUENCE RESULT REPLACE THO...

Page 251: ...he vehicle When the wheels tilt outward at the top the camber is said to be positive When the wheels tilt inward at the top the camber is said to be negative The amount of tilt is measured in degrees...

Page 252: ...ctions 12 Regardless of equipment used to check alignment the vehicle must be on a level surface both fore and aft and transversely Satisfactory vehicle operation may occur over a wide range of front...

Page 253: ...ns check for damaged control arms and related parts NOTE Always tighten the thinner shim packs nut first for improved shaft to frame clamping force and torque retention TOE IN FIG 3A 3 Toe in the inwa...

Page 254: ...ber setting and the rear cam to adjust the caster setting The lower control arm is designed so that the camber setting should be made first In other words adjust camber then caster then toe in The fro...

Page 255: ...FRONT END ALIGNMENT 3A 5 Fig 3A 4 B Series Alignment Correction Chart...

Page 256: ...3A 6 1977 PONTIAC SERVICE MANUAL A Fig 3A 5 A G Series Alignment Correction Chart...

Page 257: ...FRONT END ALIGNMENT 3A 7 Fig 3A 6 F Series Alignment Correction Chart...

Page 258: ...MEASURED CASTER READING I I I I I FRONT SHlM REQUIRED AT FRONT BOLT REAR SHlM REQUIRED AT REAR BOLT EXAMPLE SHlM ADDITION OF SMALL 1 03 SHIMS OF MED 1 06 SHIMS GF LARGE 12 SHIMS 3973...

Page 259: ...FRONT END ALIGNMENT 3A 9 Fig 3A 8 X Series Alignment Correction Chart Except Power Steering...

Page 260: ...TRAILER PKG OR HANDLING PKG COUPE OR SEDAN WITH HANDLING PKG OR LT TRAILER PKG WAGON EXC TRAILER PKG OR HANDLING PKG Fig 3A 10A Trim Heights B Series 257 3mm 10 13 254 8mm 10 03 WAGON WITH TRAILER PKG...

Page 261: ...PKG TRAILER PKG OR 400 4 SPEED I I400 4 SPEED EXC HANDLING PKG OR TRAILER PKG 36 30 1 16 70 1 8 62 Y REAR 27 00 20 00 27 00 36 30 36 30 t WlTH 3 0 GALLONS FUEL IN FUEL TANK t t CURB CONDITION J t FRON...

Page 262: ...19 TO 0 06 H SERIES CROSS CAMBER 0 2 TO 1 8 1 16 OUT TO 3 16 IN 0 06 TO O lgO 2 O TO o0 o0TO 2 o0 TO 1 6 1 16 OUT TO 3 16 IN 0 06 TO O lgO TOE IN CASTER CASTER CAMBER INCHES TOTAL DEG PER WHEEL CROSS...

Page 263: ...other and move through symmetrical arcs Fig 3B1 I SERVICE PROCEDURES SUSPENSION AND STEERING LINKAGE CHECK 1 Raise car on one side at frame torque box located directly behind the front wheel so that...

Page 264: ...Installation See CAUTION on page 3B1 1 of this section I If the tie rod ends are removed lubricate the tie rod threads with EP Chassis lube and thread ends of tie rod into the adjuster tube making su...

Page 265: ...g H Series 2 Remove inner tie rods from intermediate rod as described under Tie Rod Removal 3 On H Series remove crossmember brace 4 Remove cotter pin and nut from intermediate rod ball stud attachmen...

Page 266: ...ISSIBLE TO ALIGN COTTER PIN SLOT 116 AND HOLDING NUT TURN MAXIMUM DO NOT BACK 55 LB FT OFF NUT FOR COTTER PIN INSERTION Fig 381 6 Steering Linkage A Series Manual Steering 7 COTTER PIN STEERING LINKAG...

Page 267: ...s make sure that the tie rod ends are in alignment with their ball studs by rotating both tie rod ends in the same direction as far as they will go and then torque adjuster tube clamps to specificatio...

Page 268: ...itman arm ball stud and remove nut A Series Manual Steering Only Remove cotter pin and nut and disconnect shock absorber from pitman arm 4 Remove intermediate rod from pitman arm using tool J 5504 J 2...

Page 269: ...30 Nut Steering Linkage Shock Absorber to Frame Bracket Bolt X Series With 151 Engine 40 Bolt Linkage Shock Absorber Bracket to Frame X Series With 151 Engine 30 Nut Pitman Arm to Intermediate Rod Al...

Page 270: ...and has mating spiral grooves in which steel balls circulate to provide a low friction drive between worm and nut Fig 3B2 I Teeth on the ball nut engage teeth on the pitman shaft sector The teeth on...

Page 271: ...hole in the metal portion of the seal and install a small metal screw approximately two turns Pry out seal with side cutters Installation See CAUTION on page 3B2 1 of this section 1 Drive new seal flu...

Page 272: ...n shaft Inspect the fit of the pitman shaft in bushings in side cover and housing If these bushings are worn a new side cover and bushing assembly or housing bushing should be installed Check steering...

Page 273: ...moving Pitman Shaft Seal Care should be taken to insure that the new seal is not assembled in a cocked position PITMAN SHAFT BUSHING REPLACEMENT Removal 1 Remove pitman shaft bushing in gear housing u...

Page 274: ...CING As a rule disassembly of the ball nut will not be necessary if it is perfectly free with no indication of binding or tightness when rotated on the worm However if there is any idnication of bindi...

Page 275: ...ompound to the bearing adjuster as the compound must be kept away from the wormshaft bearing l s o apply steering gear lubricant meeting GM standard GM 4673M or equivalent to the wormshaft bearings pi...

Page 276: ...ust steering gear Refer to Steering Gear Adjustment Fig 382 1 6 Checking End Clearance ADJUSTMENT SPECIFICATIONS MANUAL STEERING ADJUSTMENT TORQUE TO TURN WORM SHAFT Worm Bearing Preload 5 8 In Lbs Se...

Page 277: ...nt of these parts while turning or parking is aided by hydraulic pressure supplied by the pump Manual steering is always available at times when the engine is not running or in the event of pump or be...

Page 278: ...l orifice is part of the pressure line union A pressure relief valve inside the flow control valve limits pump pressure A magnet is installed in the pump housing attached by its magnetic force The mag...

Page 279: ...n force out pitman shaft seals Turn off engine NOTE Use suitable container to catch oil forced out of gear This method of removing the pitman shaft seals is recommended as it eliminates the possibilit...

Page 280: ...ing and the frame Before positioning the gear note the flat on the gear lower shaft must index with the flat in the coupling flange Make certain there is a minimum of 040 clearance betweeen coupling h...

Page 281: ...soft hammer and remove the pitman shaft and side cover from the housing Remove the side cover gasket and discard 5 Remove the rack piston as follows a Insert Ball Retainer Tool J 21552 into the rack p...

Page 282: ...y 1 If the needle bearing was removed place new needle bearing over Tool 5 6221 with the bearing manufacturer s identification against the tool and drive the bearing into the adjuster plug until it is...

Page 283: ...cer away from bearing washer 5 Install bearing retainer on the adjuster plug by carefully tapping on the flat surface of the retainer Fig 3B3 20 Fig 383 13Loosening Adjuster Plug Lock Nut Fig 383 1 4...

Page 284: ...the 3 teflon oil rings and 0 rings from the valve body and discard Cleaning and Inspection 1 Wash all parts in clean solvent and blow out all oil holes with compressed air 2 If the drive pin in the st...

Page 285: ...ion the teflon rings may be heated for 5 10 minutes in boiling water Dry well before installing 2 Lubricate the 3 new teflon oil rings with Powc 1 Steering Fluid No 1050017 or equivalentVand install i...

Page 286: ...l parts in clean solvent and dry with compressed air NOTCH I N FND CAP hlUST FULLY FNGAGE PIN PROJECTING INTO VALVE BODY I I Fig 383 24Installing Stub Shaft Assembly Fig 383 25Pitman Shaft and Side Co...

Page 287: ...h the lower ball return guide hole Fig 3B3 27 4 Lubricate the balls with Power Steering Fluid No 1050017or equivalent then feed 17balls into the rack piston while slowly rotating the worm counter cloc...

Page 288: ...Ibs 14 Check fluid in pump reservoir and add fluid if necessary PITMAN SHAFT NEEDLE BEARING AND SEALS Removal Fig 383 30 1 mXlSlffi 5 0ILSEAL W Vet E 2 BEARING LIP 3926 3 OIL SEAL 6 SELWASHLR 4 STEEL...

Page 289: ...ith Power Steering Fluid No 1050017 or equivalent Install the cap to body 0 ring in the valve body so it is seated against the lower shaft cap Align the NARROW NOTCH in the valve body with pin in the...

Page 290: ...g to maintain alignment of hole with mark Fig 383 44 f Using an in lb torque wrench turn the stub shaft and measure the torque Reading should be 4 6 in lbs If torque is not within this range repeat a...

Page 291: ...ided and are to be bent around the edges of the side cover This secures the gasket in the proper b Turn the stub shaft until the rack piston teeth are centered in the pitman shaft opening then install...

Page 292: ...b Rotate the torque wrench approximately 45 degrees each side of center and read near or on center highest reading Be sure over center adjustment has been backed out Fib 3B3 49 Loosen the lock nut and...

Page 293: ...pray area with Loctite Solvent or equivalent 4 Seat ball in housing using blunt nosed punch brass drift pin or similar tool as shown in Fig 3B3 50 Fig 3B3 50 Seat Ball in Housing 5 Air dry using compr...

Page 294: ...om the engine Remove gage from pump belt and position gage on generator belt and adjust to specified tension 1 Install power steering belt 2 Adjust belt Refer to Pump Belt Adjustment 3 Position high p...

Page 295: ...SEAL REPLACEMENT WITHOUT DISASSEMBLING PUMP The pump shaft oil seal can be replaced without disassembling the pump as follows 1 Remove the pump pulley as described in this section Bend a piece of 005...

Page 296: ...59 is attached as shown in Figs 3B3 60 thru 3B3 62 SHIM STOCK Fig 383 57 Removing Pump Seal SEAL a 1 Fig 383 58 Installing Pump Seal 1 Disconnect negative battery cable 2 Remove power steering pump be...

Page 297: ...Steering Pump Exploded BRACE 30 LB FT LOCK BRACKET t LOCK WASHER FT VlEW B Fig 383 60 Power Steering Pump Mounting 1 4 0 Engine 5 Remove pump assembly from engine with link Installation attached 1 Po...

Page 298: ...383 22 1977 PONTIAC SERVICE MANUAL 0 35 LB FT VIEW 6 PUMP 1 3287 Fig 383 61 Power Steering Pump Mounting 15 1 Engine...

Page 299: ...G GEAR AND PUMP 383 23 SPACER F SERIES WITH A I R NEGATIVE BATTERY CABLE A I R PUMP BRACE A B G AND X SERlE WITH A I R 1 40 LB FT 40 LB FT EXCEPT A I R EXCEPT AIC Fig 383 62 Power Steering Pump Mounti...

Page 300: ...ment 8 Bleed system Refer to Bleeding Power Steering System Fig 383 63A Power Steering Pump Mounting 301 350 Engine Code P and 400 Engines Cleaning and Inspection Carefully clean all pump parts in cle...

Page 301: ...ering gear or disassemble gear and clean internal parts Disassembly Refer to Figures 3B3 65 thru 3B3 69 for pump disassembly and assembly Fluid Level 1 Run engine until power steering fluid reaches no...

Page 302: ...aintain fluid leveljust above internal engine for two or three minutes then shut engine off pump casting Fluid with air in it will have a light tan or red e Road test car to make sure steering functio...

Page 303: ...I N RESSURE LINE TO CONTACT RETURN PIPE AS SHOWN PRESSURE LINE VIEW B RETURN HOSE PRESSURE L I N 0 LB FT AGAINST PRESSURE P STEERING GEAR X SERIES WITH 151 ENGINE E G R VALVE POWER STEER11 VIEW A 140...

Page 304: ...POWER STEERING B HOSES MUST BE INSTALLED TO CLEAR EACH PRESSURE OTHER VIEW A AND ALL SURROUNDING PARTS MIN CLEARANCE 5 0 EXCEPT AS OTHERWISE NOTED RETURN HOSE MUST NOT BE TWISTED DURING INSTALLATION H...

Page 305: ...D OR DISTORT PIPES TO F A C l L I T A T E I N S T A L L A T I O N AFTER TIGHTENING NUT PlPE TO BE AGAINST GEAR AS SHOWN HOSES MUST BE INSTALLED TO CLEAR EACH OTHER AND ALL SURROUNDING PARTS MINIMUM CL...

Page 306: ...MP POWER STEERING GEAR G SERIES WlTH 301 350 400 ENGlNES PIPE TO REST AGAINST A SERIES WITH GEAR AS SHOWN 301 350 400 ENGINES RETURN HOSE PUMP ASM PUMP AFTER NUT I TIGHTENED T O SPECIFIED TORQUE HOSES...

Page 307: ...WlTH 350 AND 403 ENGINES POSITION PRESSURE HOSE PlPE AGAINST POWER STEERING BRACE AS SHOWN B SERIES WlTH 350 AND 403 ENGINES NON HOME PLANT POSITION PRESSURE HOSE PlPE AGAINST SIDE COVER AS SHOWN VIE...

Page 308: ...383 32 1977 PONTIAC SERVICE MANUAL LFRAME ASM Fig 383 64E Hose Routing 305 350 L V8 Engines...

Page 309: ...D BEFOUL INSTALLATION Fig 3B3 65 Remove and Replace Reservoir DISASSEMBLY ASSEMBLY 1 REFER TO VIEW A FOR REMOVING 1 INSTALL END PLATE LUBRICATE RETAINING RING WITH POWER STEERING FLUID 2 REMOVE PARTS...

Page 310: ...TE 3 9 5 8 Fig 383 67Remove and Replace Rotating Group DISASSEMBLY ASSEMBLY 1 REMOVE PARTS AS SHOWN 1 INSTALL DRIVE SHAFT SEAL AS SHOWN IN V IEW A AND INSTALL PARTS AS SHOWN USE NEW 0 RINGS AND SEALS...

Page 311: ...ALL GEAR 605MODEL Rectangular side cover held in place with four bolts 7 LARGE GEAR 800 808 MODEL Key No Part Namm 1 HOUSING STEERING GEAR 2 RETAINER STRG COUPLING SHIELD 3 BEARING ASSY NEEDLE STUB SH...

Page 312: ...etaining ring A RETAINING RING aDusT SEAL STUB SHAFT I HOUSING ASSEMBLY 3 REMOVE AND INSTALL PITMAN SHAFT AND SlDE COVER REMOVE 1 If pitman shaft and side cover are to be separated remove preload adju...

Page 313: ...of stub shaft and rack piston a Screw worm and valve into rack piston until valve face and rack piston face are STUB SHAFT flush d b With rack piston in position shown flats on stub shaft and piston a...

Page 314: ...eck the stub retaining ring shaft needle bearing for smoothness If O K do A not remove HOUSING ASSEMBLY DUST SEAL7 SEAL III A Remove bearings 1 J 8524 2 STUB SHAFT NEEDLE BEARING UPPER THRUST BEARING...

Page 315: ...050017 or equivalent Capacity Complete System 1 1 4 Qts Capacity Pump Only 1 2 Qts ADJUSTMENTS Valve Assembly and Seal Drag 1 to 4 in lbs Thrust Bearing Preload 3 to 4 in Ibs in excess of valve assemb...

Page 316: ...80 High Pressure Line Fitting At Gear 40 Oil Return Line Fitting At Gear 40 Pitman Shaft Adjusting Screw Locknut 35 Side Cover Bolts 35 Adjuster Plug Locknut 80 Coupling Flange Nuts 25 Return Guide Cl...

Page 317: ...1 The column is energy absorbing designed to compress in a front end collision to minimize the possibility of injury to the driver of the car 2 The ignition switch and lock are mounted conveniently o...

Page 318: ...shifting either standard or automatic is performed on the column This feature eliminates the shift tube and back drive systems The key release energy absorbing steering column assembly is used on floo...

Page 319: ...f this Section 1 If intermediate shaft was removed install on steering gear shaft install bolt and nut and torque nut to 35 ft lbs 2 Carefully position steering column from inside of car through cowl...

Page 320: ...ly installed 9 If equipped with column shift automatic connect shift indicator cable 10 Install cover over upper and lower toe pan covers 11 Install trim cap on lower portion of instrument panel 12 Co...

Page 321: ...power steering columns be sure flange on toe plate aligns with opening in dash panel Fig 3B4 5 Column Bracket X Series 5 Visually check flex coupling alignment and intermediate shaft coupling for bott...

Page 322: ...ring shaft and tighten nut until tool slightly depresses lock plate Pry wire snap ring from shaft and discard Fig 3B4 10 Remove Tool J 24653 5 Remove lock plate and cancelling cam Fig 3B4 11 NOTE Appl...

Page 323: ...SHAFT SCREW 2 n...

Page 324: ...switch wires at connector keeping wires flat and parallel then carefully pull turn signal switch and wiring from top end of column Installation NOTE Apply thin coat of lithium grease to all friction...

Page 325: ...T AWAY Removal 1 Disconnect negative cable from battery 2 Refer to STEERING WHEEL Removal 3 Lock plate cover may be removed for replacement at this time by releasing as shown Fig 3B4 9 4 Position Tool...

Page 326: ...ith drive shaft Push in until snap ring pops into groove and lock cylinder is secured in cover Check freedom of rotation 2 While pulling slightly on turn signal wiring at connector guide turn signal s...

Page 327: ...T AWAY Removal 1 Refer to TURN SIGNAL SWITCH Tilt Away Removal Steps 1 14 2 Position lock assembly in RUN position Insert a thin tool small screwdriver or knife blade into the slot next to the switch...

Page 328: ...ering shaft lock bolt Remove spring Fig 3B4 26 Installation NOTE Apply thin coat of lithium grease to all friction parts 1 Install lock bolt spring so that hook of spring engages lock bolt in slot at...

Page 329: ...essary to tap lock drive shaft into sector NOTE Flange of sector must engage lock bolt as shown in Fig 3B4 27 Fig 384 2 1 Installing Ignition Lock Fig 384 22 Remove Key Warning Buzzer Switch Fig 384 2...

Page 330: ...ng attaching screw Fig 3B4 25 the move rack assembly upward 4 Turn spring clockwise until disconnected from steering shaft lock bolt Remove spring Fig 3B4 26 5 Using snap ring pliers remove snap ring...

Page 331: ...nto slot of retainer Press in and turn approximately 1 8 turn counterclockwise Fig 3B4 31 Remove tilt spring retainer spring and guide 5 Install Tool J 21854 1and remove pivot pins as shown in Fig 3B4...

Page 332: ...ching screw Fig 3B4 25 5 Remove rack from lower end of housing 6 Remove rack spring from guide to housing Installation NOTE Apply thin coat of lithium grease to all friction parts 1 Install rack sprin...

Page 333: ...way Installation Steps1 8 6 H Series Torque flange bolt to 30 ft Ibs Except H Series Torque clamp to steering shaft nut to 55 ft Ibs SUPPORT AND OR SHIFT GATE TILT AWAY Removal 1 Refer to HOUSING Tilt...

Page 334: ...oud ribs with slots in jacket and push into position Install shroud retaining screws if removed Fig 3B4 41 3 Position shift gate retainer plate on H Series on support and install attaching screws Fig...

Page 335: ...e column with two screws Lightly push switch down the column away from the steering wheel to take out lash in the acutator rod and torque mounting screws to 35 in lbs Fig 384 45 Positioning Switch for...

Page 336: ...rom battery 2 Remove instrument panel lower trim cap or lower trim panel 3 Remove toe pan cover bolts Fig 3B4 2 4 Remove the two nuts A and B from bracket assembly Fig 3B4 2 and lower column until col...

Page 337: ...nd wiring from top end of column 12 Position lock assembly in Run position Insert a thin tool small screwdriver or knife blade into the slot next to the switch mounting screw boss right hand slot and...

Page 338: ...from support Fig 384 59 Installation 1 Slip dimmer switch actuator rod through hole in support Install rod between bowl and jacket Fig 384 59 2 Refer to SUPPORT AND OR SHIFT GATE Tilt Away Installati...

Page 339: ...od Actuator 13 Install lock hold lock cylinder sleeve and rotate knob clockwise against stop Insert cylinder into cover bore with key on cylinder sleeve aligned to keyway in sector Rotate knob counter...

Page 340: ...ten ignition switch screw Depress dimmer switch slightly to feed 3 32 drill to lock switch to body Fig 3B4 62 Force switch up to remove lash between switch and pivot Tighten screw to 35 in Ibs Remove...

Page 341: ...and hazard warning knob 8 Lift up on tilt lever and position column in center position then remove the three turn signal switch attaching screws Fig 3B4 13 9 Tape turn signal switch wires at connector...

Page 342: ...ig 384 67 Removing Shift Tube SHIFT TUBE Fig 384 68 Align Shift Tube in Jacket Installation See CAUTION on Page 3B4 1 of this Section NOTE Apply thin coat of lithium grease to all friction parts 1 Ins...

Page 343: ...tion in housing for proper installation of housing 12 Install pivot pins using a brass drift to fully seat pins 13 Lift up on tilt lever and position housing in the full UP position 14 Install guide a...

Page 344: ...must not be substituted 4 Refer to STEERING WHEEL Installation 5 Connect negative battery cable TURN SIGNAL SWITCH REGULAR Removal 1 Disconnect negative cable from battery 2 Refer to STEERING WHEEL Re...

Page 345: ...STEERING WHEELS AND COLUMNS 3B4 29 Fig 384 72 Regular Column Except H Series...

Page 346: ......

Page 347: ...g 3B4 76 9 Position new wire snap ring over steering shaft then install Tool J 23131 over shaft and tighten steering wheel attaching nut until wire snap ring can be installed in groove in steering sha...

Page 348: ...intaining a light push inward on cylinder until drive section of cylinder mates with drive shaft Push in until snap ring snaps into groove and lock cylinder is secured in cover Check freedom of rotati...

Page 349: ...STEERING WHEELS AND COLUMNS 384 33 Fig 384 80 Column Mounting Typical...

Page 350: ...Assemble buzzer switch and spring clip with formed end of clip under end of switch and spring bowed away from switch on side opposite contact Push switch and spring into hole in cover to the stop wit...

Page 351: ...automatic install shift indicator needle or link on shift bowl and adjust as shown TO EXTREME LEFT ACC 2 1 POSITION THEN MOVE SLIDER TWO DETENTS TO THE RIGHT OF 9 OFF UNLOCK POSI TlON Fig 384 87 Posit...

Page 352: ...Series ONLY 1 Position lever return spring over tapped post as shown in Fig 3B4 91 Slip lever finger into rack slot and over tapped post Make sure inner end of spring contacts lever as shown 2 Raise l...

Page 353: ...ation 7 Install lock hold lock cylinder sleeve and rotate knob clockwise against stop Insert cylinder into cover bore with key on cylinder sleeve aligned to keyway in housing Fig 3B4 84 push into abut...

Page 354: ...ck bolt assembly into housing rack teeth toward sector Slowly lower rack assembly and position sector so that the first tooth of rack assembly engages between first and second tooth of sector Fig 3B4...

Page 355: ...ck 4 Refer to HOUSING Regular Installation Steps 1 23 BOWL EXC H SERIES Removal 1 Refer to HOUSING Regular Removal Steps 1 12 2 Position bowl in Reverse and pull bowl up and rearward to remove 3 If re...

Page 356: ...olumn rests on protected front seat cushion 5 If adjusting loosen dimmer switch screw if replacing dimmer switch remove screw Fig 3B4 105 then dimmer switch Tape rod to column and separatedimmer switc...

Page 357: ...ing wires flat and parallel then carefully pull signal switch and wiring from top end of column Fig 384 108 Removing Actuator Arm COYER TURN SIGNAL SWITCH AllACHlN SCREWS Fig 384 109 Turn Signal Switc...

Page 358: ...lever retaining pin into place Position shift lever in any position except PARK automatic I LOCKING ASSEMBLY Fig 384 1 12 Removing Housing Bolts Fig 384 1 1 3 Removing Cover and Screw 7 Install lock...

Page 359: ...switch actuator arm and mounting screw and torque to 20 in Ibs Fig 3B4 118 14 Install turn signal lever by pushing straight in 15 Install hazard warning knob and screw NOTE If the signal switch is no...

Page 360: ...ring B Series into adapter on the bench then install assembly over steering shaft into position in jacket On H Series push adapter into jacket with projection aligned with slot It may be necessary to...

Page 361: ...d 5 Remove steering shaft from lower end of column 6 Remove lock plate and cancelling cam from upper end of column Installation See CAUTION on Page 3B4 1 of this Section 1 Install steering shaft into...

Page 362: ...of jacket and rotate bowl until shift tube key slides into bowl keyway 2 Loosely install the three screws into bearing at lower end of column Fig 3B4 127 3 Install first and reverse lever Fig 3B4 126...

Page 363: ...ove preload spring 8 If slip shaft seal housing must be replaced remove slip shaft seal housing and 0 ring by lightly tappingto remove from outer shaft Fig 3B4 131 Installation 1 If replacing install...

Page 364: ...removed from steering shaft Fig 384 13 0 Separating lntermediate Shaft Fig 384 13 1 Intermediate Slip Shaft Seal Housing and 0 Ring Disassembly Except F and X Series NOTE The F and X Series intermedi...

Page 365: ...flex coupling lock washers and Fig 384 135 Intermediate Shaft Assembly X Series I CLAMP COU ING RING ASSY 4 15 1 Fig 384 136 Coupling Assembly Fig 384 137 Coupling Assembly Exploded nuts Torque to 20...

Page 366: ...ar cylinder sleeve Cylinder cannot be removed until this cam is inboard Fig 3B4 140 4 Remove lock cylinder anchor washer and wave washer from sleeve 5 To determine correct tumbler usage key coding mus...

Page 367: ...Formula See CAUTION on Page 3B4 1 of this Section 1 With the alignment marks on the steering wheel hub and the steering shaft aligned install the steering wheel and nut Torque nut to 35 ft lbs and in...

Page 368: ...RK ON STEERING SHAFT WITHIN ONE FEMALE SERRATION HORN BUTTON AND ORNAMENT ASM SHAFTNUT WHEEL STEERING COLUMN INSULATOR SHAFT PUSH INSULATOR INTO CAM TOWER AND ROTATE CLOCKWISE TO LOCK IN POSITION CAUT...

Page 369: ...ft Repair Package ALL COLUMNS EXCEPT TlLT 5 116 5 1 I TlLT 5 la 5 116 L SWITCH I j4 UPPER I I JACKET t MEASURE DISTANCE BETWEEN TOP OF NEUTRAL START SWITCH WINDOW OPENING AND THE BOTTOM OF THE UPPER J...

Page 370: ...taching Screws 35 In Lbs Bracket to Steering Column Support Nuts 25 Ft Lbs Toe Pan to Dash Screws 45 In Lbs Toe Pan Clamp Screws 60 In Lbs Bracket to Steering Column Bolt 30 Ft Lbs Cover Tilt to Housi...

Page 371: ...nds through the spring housing and is secured with two grommets two grommet retainers and a nut Side roll of the front suspension is controlled by a spring steel stabilier shaft It is mounted in rubbe...

Page 372: ...SULATOR Shock absorbers mount to the lower control arm and run through the center of the coil spring to the shock absorber tower where the upper stem mounts The steering knuckle is nodular iron with a...

Page 373: ...than 1 2 flat 7 Install new cotter pin Bend the ends of the cotter pin against nut cut off extra length to ensure ends will not interfere with the dust cap 8 Measure the looseness in the hub assembly...

Page 374: ...3C 4 1977 PONTIAC SERVICE MANUAL FIG 3C 3 WHEEL BEARING ADJUSTMENT...

Page 375: ...d Installation CAUTION See CAUTION on page I of this section regarding the fastenersrefereedto in steps 6 7 and 9 1 Apply a light coat of lubricant to spindle and instide surface of hub 2 Place inner...

Page 376: ...stabilizer bar on frame 3 Torque bracket bolts and link bolt nuts as shown in the Specifications 4 Lower vehicle to floor Fig 3C 7Removing Spring with Adapter J 23028 1 Raise vehicle on hoist 2 Remove...

Page 377: ...arm This visual observation is necessary to avoid confusion with other conditions such as loose wheel bearings Replace any upper ball joint found to be loose Replacement Remove the rivets from the upp...

Page 378: ...bottom of the tire and at the same time push the tire and wheel assembly upward to free the knuckle from the ball stud 7 Remove the wheel and tire 8 Lift up on the upper control arm with the knuckle...

Page 379: ...and install Tools J 9519 10 and J 9519 9 as shown in Fig 3C 12 NOTE Position bleed vent in rubber boot of the new ball joint facing inward 2 Turn down on hex head bolt until the new ball joint is sea...

Page 380: ...teering knuckle 5 Remove the two nuts securing the upper control arm shaft to the frame bracket NOTE Tape the shims together and mark them for position from which they were removed It is necessary in...

Page 381: ...bolt that were removed and taped together J 24770 1 4166 FIg 3C 17 Installing Upper Control Arm Front Bushing First I I 4167 Fig 3C 18 Installing Upper Control Arm Rear Bushing First 5 24770 1 4168 Fi...

Page 382: ...tools as shown in Fig 3C 21 NOTE Spacer 5 21474 12 should still be in position 11 Turn hex bolt and nut until new bushing is properly seated Fig 3C 2 1 Installing L C A Bushing 12 Remove tools 13 Posi...

Page 383: ...caliper from the disc See Section 5 4 Remove hub grease cup cotter pin spindle nut and washer and remove hub and bearing Do not allow bearing to fall out of hub when removing hub from spindle Replace...

Page 384: ...l the stem through the spring tower 2 Install the lower bolts Torque to 20 ft lbs 3 Lower the vehicle to the floor 4 Install the upper rubber grommet retainer and nut to the shock absorber stem 5 Hold...

Page 385: ...OCK LOWER CONT ARM 20 LB FT VIEW A Fig 3C 26 Shock Absorber Attachment OBTAIN TORQUE BY RUNNING NUT IN UNTHREADED PORTION OF BOLT INSTALL STABILIZER BAR BUSHING WITH SLIT TOWARD FRONT OF VEHICLE AS 1...

Page 386: ...ntil ball stud is free of steering knuckle 7 Remove Tool J 23742 and remove nut from ball stud Replacement CAUTION See CAUTION on page 1 of this section regarding the fastener referred to in step 2 1...

Page 387: ...up end over the upper ball stud nut 6 Turn the threaded end of 5 23742 until ball stud is free of steering knuckle 7 Remove Tool 5 12742 and remove nut from ball stud Replacement 1 Install Tools 3 951...

Page 388: ...per to the suspension using wire Do not allow the calipertohang by the brake hose Insert a piece of wood between the shoes to hold the piston in the caliper bore The block of wood should be about the...

Page 389: ...control arm from the vehicle NOTE Inspect the tapered hole in the steering knuckle Remove any dirt and if any out of roundness deformation or damage is noted the knuckle MUST be replaced The Upper bal...

Page 390: ...l the bushing is pushed free of control arm 3 Separate the tools and discard the bushing 4 Start a new bushing in position and install Tools J 21474 3 5 2474 4 521474 5 5 21474 13 and 5 22323 1 as sho...

Page 391: ...B F and G Series lb in 90 X and H Series lb in 90 Screw Shock Absorber to Control Arm All Series 20 Nut Stabilizer Link to Shaft All Series lb in 150 Screw Stabilizer Shaft Bracket to Frame Except H...

Page 392: ...arms with rubber pivot bushings at each end of the control arm The control arms maintain the geometrical relationships of the rear axle with the frame oppose torque reaction on acceleration and braki...

Page 393: ...tagger mounted to the spring lower 3D 3 A single torque arm is used in place of upper control seats The right hand shock absorber is mounted forward of arms and is rigidly mounted to the differential...

Page 394: ...k absorber lower mounting bolt from shock absorber eye 3 Remove shock absorber upper mounting bracket bolts and withdraw shock absorber Installation A B and G Series See CAUTION on Page 3D 1 of this S...

Page 395: ...de and select a replacement arm as follows CODE PART NO A 526771 B 526773 C or No Letter Code 526773 D 526773 F 526775 H 526771 J 526775 It is not necessary to replace both upper control arms to match...

Page 396: ...REAR SUSPENSION 3D 5 I TRANSMISSION SlON VlEW A MAN SPEED DAMPER IPER VlEW B MAN BSPEED SUPPORT TRANSMISSION 4 SPRING NUT Fig 3D 6 Torque Arm H Series 151 Engine...

Page 397: ...3D 6 1977 PONTIAC SERVICE MANUAL BODY VlEW C BODY BODY 85 LB FT VlEW A d 25 LB FT L W BRACE 25 LB FT I 25 LB FT EXC H M SERIES VIEW B HM SERIES 3342 Fig 3D 7 H Series Track Rod...

Page 398: ...der Torque Arm Removal 2 Place receiver J 25317 2 under the bushing 3 Use an arbor press to force the bushing out of the arm using large O D of a driver such as J 21465 8contacting O D of bushing oute...

Page 399: ...er control arm or track rod bolts at differential housing and toruqe to 85 ft Ibs A and G Series 80 ft Ibs B Series or 85 ft Ibs H Series 5 Install brake line connector block at differential housing T...

Page 400: ...ll spring to underbody bracket 6 Position spring upper cushion between spring and axle bracket so that spring cushion ribs align with axle bracket location ribs 7 Place lower spring cushion on spring...

Page 401: ...rd this note 6 If a tram is used for checking toe out it will still be necessary to perform Steps 1 and 2 in order to check camber The necessary straightening operations may be performed using frame s...

Page 402: ...en carrying abnormal loads by merely increasing air pressure in the system When load is removed the car can be lowered to its normal riding height by decreasing air pressure Air pressure is adjusted b...

Page 403: ...CAR BOTH SIDES FRONT OF CAR ANCHOR PLATE F SERIES BODY UPPER END OF SUPPORT TO BE TORQUED AT ERTICAL 1 5 REARWARD 30 LB FT U SHAPED SECT1 OF STABILIZER BAR MUST BE REARWARD 81DOWN WHEN IN THE INSTALL...

Page 404: ...boot defective internal 0 ring 0 Diaphragm between first and second stage housings tightening through bolts may correct the leak 0 Service valve 0 Test gage connections 5 Remove hose from vacuum port...

Page 405: ...70 LB IN INSERT TUBING INTO FITTING UNTIL IT BOTTOMS BEFORE TIGHTENING NUT f INSERT TUBING INTO LB IN VIEW A VIEW B INSERT TUBING INTO FITTING REAR END VALVE AND 7 6 IN FILLER PANEL FITTING ASM REAR...

Page 406: ...PRESSOR CYCLES CONTINUOUSLY I 5 I EXTREMELY SLOW LEAK OVER NIGHT LEAK DOWN DURING COLD WEATHER I STEP 1 Check compressor tank pressure refer to figure 1 for location of service valve on compressor HIG...

Page 407: ...PLY TO COMPRESSOR I I I Compressor Cycles Compressor Inoperative I Replace Filter Proceed to Step 5 1 IProceed to Step 4 1 STEP 4 With engine running remove vacuum hose from compressor vacuum port Fig...

Page 408: ...FIGURE 3 ATTACHING GAGE TO COMPRESSOR HIGH PRESSURE FITTING 8 Perform compressor output test 1 Fill compressor reservoir to 70 PSI through service fill valve Refer to Figure 3 Observe test gauge for e...

Page 409: ...f gas C Add approximately 250 3OO to passenger car trunk Two people or equivalent weight 3 people for station wagon EXTERNAL AIR SUPPLY 7 FIGURE 4 CHECKING SYSTEM OPERATION WITHOUT COMPRESSOR 0 With e...

Page 410: ...height control valve high pressure fitting C Using external air supply charge high pressure line to 100psi thru the gauge fitting and observe if pressure holds steady or drops off I Pressure holds ste...

Page 411: ...Tubing and fittings okay TUBING TO SHOCK ABSORBERS 1 HIGH PRESSURE TUBING FROM COMPRESSOR FIGURE 7 INSPECTING HEIGHT CONTROL VALVE STEP 9 Insmct each shock visuallv a s follows I I I Tubing damaged b...

Page 412: ...to 100psi Observe if pressureholds steady or drops off I I 1 Pressure holds steady Pressuredrops off I I Recheck tubing and fittings per Step 8 Replace shock s as required and IMPORTANT recheck syste...

Page 413: ...on for approximately 30 seconds I Vehicle raises Vehicle does not raise I I To check if vehicle lowers properly Replace height control valve and move height control valve over travel repeat step 13 Ad...

Page 414: ...is secure B Check that height control valve over travel arm adjusting nut is tight r I r Height control valve and Link missing loose or worn etc attaching parts appear correct I I Proceedto Step 13 M...

Page 415: ...s 6 Connect test gage to Superlift port and open air pressure 7 With overtravel lever in neutral position no air should escape If bubbles escape from exhaust port replace control valve 8 If air escape...

Page 416: ...ride motions During changes due to loading the time delay mechanism will allow the over travel shaft to open either the intake or exhaust valve as required since this is not a rapid movement SUPERLIF...

Page 417: ...3D 26 1977 PONTIAC SERVICE MANUAL Fig 3D 34 Automatic Level Control Valve and Shocks...

Page 418: ...ters and flexible mounts on compressor end of assembly 3 Remove nuts from three reservoir retaining long bolts The bolts enter from reservoir flange side of unit 4 Remove nuts from three compressor re...

Page 419: ...AL O RING EXPANSION PLUG RETAINER SPRING CHECKVALVE PISTON O RING SEAL INTAKE VALVE WASHER ROCKER ARM RETAlNlNG PIN ROCKER ARM BUSHING FIRST STAGE HOUSING RESERVOIR THROUGH BOLT NUT COMPRESSOR RETAINI...

Page 420: ...REAR SUSPENSION 30 29 Fig 3D 36 Automatic Level Control Compressor Installation...

Page 421: ...pocket 6 If necessary remove rocker and swivel arms Grip pin with pliers and remove pin Fig 3D 40 Fig 3D 39 Installing Valve Tension Spring in Boss Fig 3D 40 Removing Rocker Arm Pin SECOND STAGE HOUSI...

Page 422: ...age housing and install rocker arm and swivel arm Align holes in rocker and swivel arms and install retaining pin small end first CA UTI0N If distributor mechanism failed to operateproperly or one or...

Page 423: ...ted hole in diaphragm with vent port in housing 5 Install second stage housing by sliding straight onto second stage piston 6 Install three compressor retaining short bolts from the first stage housin...

Page 424: ...at Axle B Series 95 A and G Series 75 Nut Shock Absorber to Upper Mount 140 Ib in Bolt Shock Absorber to Upper Mount 20 Nut Shock Absorber to Lower Mount 65 Nut Pinion Nose Bumper 15 Screw Stabilizer...

Page 425: ...Engine 25 lb in Nut or Bolt Torque Arm Outer Insulator Support Attaching Automatic Transmission 20 Manual Transmission 30 Bolt Torque Arm Inner Insulator Support Attaching Automatic Transmission 35 4...

Page 426: ...ED TIRES EXCEPT IN EMERGENCIES BECAUSE CAR HANDLING MAY BE SERIOUSLY AFFECTED AND MAY RESULT IN LOSS OF CONTROL 1 It is recommended that new tires be installed in pairs on the same axle 2 If necessary...

Page 427: ...the tread 0 Tire rim bruises and rupture 0 Tire cord breakage 0 High tire temperatures 0 Reduced handling 0 High fuel consumption Unequal pressure on same axle can cause 0 Uneven braking Steering lead...

Page 428: ...hout damage as follows 1 Retighten all lug nuts on the affected wheel then loosen each nut two turns 2 Lower vehicle onto floor 3 Rock the car from drive to reverse allowing car to move several feet i...

Page 429: ...move from side to side Wheels that are dynamically unbalanced may cause shimmy General Balance Precautions Deposits of mud etc must be cleaned from the inside of the rim Stones should be removed from...

Page 430: ...the opposing wheel and let vehicle down so opposing wheel sits on block and the wheel to be balanced is at least two inches off the ground Fig 3E 8 This is to allow only one wheel to spin Proceed wit...

Page 431: ...ting known good tire and wheel assemblies on the problem vehicle can be used Correction Non Uniform Tires If a replacement tire cannot be obtained there are several ways to correct tires which cause a...

Page 432: ...EEL MOUNTING SURFACE AND BRAKE DRUM OR DISC MOUNTING SURFACE SHOULD BE REMOVED BY SCRAPING AND WIRE BRUSHING INSTALLATION OF ALUMINUM WHEELS WITHOUT GOOD METAL TO METAL CONTACT AT THE MOUNTING SURFACE...

Page 433: ...ace of scale to zero 3 Attach empty C 0 2 canister to inflator tool being careful not to damage 0 ring on tool Tighten knurled nut finger tight 4 Press knob for approximately 15 seconds to charge cani...

Page 434: ...bricated for life and cannot be lubricated while on the car A service kit which consists of a spider with bearing assemblies and snap rings must be installed on the car if a universal joint becomes wo...

Page 435: ...quired 1 Tighten bolts to specified torque 2 Replace Straighten slinger to remove interference Objectional vibration roughness rumble or boom can If the problem is still present at the same engine spe...

Page 436: ...BALANCE TIRES 2545 M P H k TIGHT JOINTS INCORRECT FRONT OR I REAR JOINT ANGLE I IMPACT YOKE WITH SET TO HAMMER OR REPLACE SPECIFICATIONS I VISUAL EXAMINATION 1 DAMAGE SHAFT UNDER OATING MISSING ALANC...

Page 437: ...arm bolts on all other cars and repositioning the pinion nose up or down This takes advantage of all the bolt hole tolerances in the brackets All complaints of propeller vibration should be accompani...

Page 438: ...Be sure sufficient clearance is maintained so that clamp heads do not contact floor pan of car when axle is in contact with rebound bumper in frame In order to gain sufficient clearance it may be nec...

Page 439: ...E PIN FRONT 2 19 2 52 2 54 3 5 2 36 0 25 0 53 0 17 0 53 LM1 CHEVROLET BUILT CODED L L34 OLDSMOBILE BUILT CODED R L76 PONTIAC BUILT CODED P REAR 3 14 2 59 2 42 2 10 2 36 3 45 3 49 3 41 3 49 1 Angles ma...

Page 440: ...ve shaft at 4 points 90 degrees apart at rear of shaft just forward of balance weights as shown in Fig 4A 10 3 Place strobe light wheel balancer pick up under the nose of the differential Fig 4A 11 Fi...

Page 441: ...ith Step 5 If the shaft still needs more than three hose clamps at the same clock position replace the shaft However if the clamps are also 180degrees from the original position after the shaft was ro...

Page 442: ...joints to bend to extreme angle as this might fracture injected joints internally Support propeller shaft during removal INSTALLATION OF PROPELLER SHAFT ASSEMBLY The propeller shaft must be supported...

Page 443: ...eals 1 Remove bearing cap snap ring from yoke 2 Support rear yoke on a piece of 1 1 4 I D pipe on an arbor press 3 Using a suitable socket or rod press on spider until bearing cap is almost out Grasp...

Page 444: ...ring groove is exposed enough to install the snap ring When the bearing is correctly positioned in the yoke turn the assembly over remove the guide J 9522 7 and again place bearing over the bore in th...

Page 445: ...the yoke Turn the spider to make certain that it is free Fig 4A 20 Assemble of Universal Joint H and X Series When reassembling a propeller shaft use complete universal joint repair kit Fig 4A 21 Pla...

Page 446: ...lange Use a reliable torque wrench to tighten the parts listed H Series 15 to insure proper tightening without straining or distorting parts These specifications are for clean and lightly lubricated S...

Page 447: ...aft position of the pinion is obtained by placing shims between the head of the drive pinion and the rear pinion bearing The differential case is of one piece construction and is supported in the car...

Page 448: ...connection Since the rear of the propeller shaft is connected to the differential drive pinion through the pinion flange the transmission output shaft propeller shaft and differential drive pinion al...

Page 449: ...DIFFERENTIAL 4B 3 Fig 46 1 Exploded View Typical Standard Differential...

Page 450: ...s produced with car standing and driving 5 Vibration 6 A knock or click approximately every two revolutions of rear wheel 7 Noise most pronounced on turns 2 a Road noise b Tire noise 3 Tire noise 4 a...

Page 451: ...setting GEAR TOOTH NOMENCLATURE The side of the ring gear tooth which curves outward or is convex is referred to as the drive side The concave side is the coast side The end of the tooth nearest cente...

Page 452: ...nion closer to centerline of the ring gear by increasing shim thickness will cause the high heel contact on drive side to lower and move toward the toe the high toe contact on coast side will lower an...

Page 453: ...rough engine speeds corresponding to car speed at which the noise was most pronounced If a similar noise is produced with car standing it is caused by the engine or transmission and not the rear axle...

Page 454: ...alignment at reinstallation Disconnect propshaft from companion flange and support shaft out of the way If U joint bearing cups are not held by a retainer strap use a piece of wire or tape to retain b...

Page 455: ...replacementpart oflesser qualityorsubstitute design Torque valuesmust be used as specified during reassembly to assure proper retention of these parts 1 Connect lower control arms to housing Control...

Page 456: ...r J 21579 with a slide hammer Fig 4B 11 Fig 4B 11 Removing Non C Lock Type Axle Shaft REMOVE AND INSTALL AXLE SHAFT BEARING AND OR SEAL NON C LOCK TYPE AXLES The rear wheel bearing and bearing retaine...

Page 457: ...6704 1and Installer J 23469 Then position new service retainer ring over shaft and press it against inner race of bearing i i 4B 15 b On B Series vehicles press bearing against shoulder of axle shaft...

Page 458: ...bearing grease on the seal surface of the shaft Install axle shaft 3 For C Lock type axles proceed as follows a Insert axle shaft through the seal and bearing and as far as possible through the side...

Page 459: ...load setting which will help in determining cause of axle noise Backlash should be recorded so that if same gears are reused they may be reinstalled at original lash to avoid changing gear tooth conta...

Page 460: ...wo 5 16 24x2 bolts with flat washers Holding companion flange stationary remove pinion nut and washer Fig 4B 27 Fig 48 26 Removing Preload Thrust Blocks and Springs 3 Pull companion flange from pinion...

Page 461: ...rear pinion bearing race is to be replaced use Installer J 8611 01on 6 1 2 ring gear axles J 7818on 7 1 2 ring gear axles or J 8608 on 8 1 2 or 8 3 4 ring gear axles with Driver Handle J 8092 Fig 4B...

Page 462: ...to make sure that both pinion bearings are properly seated c Hold end of stud with wrench on its flats and tighten hex nut until 20 lb in torque is required to keep gage plate in rotation REAR PINION...

Page 463: ...he amount specified on pinion 3 If using production or service pinion which has no marking the correct shim will have a thickness equal to the gage reading 9 Remove pinion gage assembly and both pinio...

Page 464: ...a pound inch torque wrench Fig 4B 38 Fig 46 39 Installing Ring Gear on Differential Case Fig 46 38 Checking Pinion Preload After pre load has been checked final tightening should be done veiy cautious...

Page 465: ...by changing the thickness of both the right and left shims by an equal amount By changing the thickness of both shims equally the Fig 4B 41 Checking Side Gear to Pinion Gear Backlash Fig 4B 42 Compre...

Page 466: ...differential bearing pre load will be maintained Shift 002 in shim thickness for each 001 change in backlash desired If backlash is 002 too much decrease thickness of right shim 004 and increase thick...

Page 467: ...inion flange is required see procedure for adjusting pinion bearing pre load DO NOT exceed the additional tightening of the nut by a distance of more than 1 16 from its original position as tightening...

Page 468: ...urer and build date information is stam ed on the right rear axle tube on AXLE SHAFT END PLAY the forward side Refer t i Fig 4B 45 i n y reports made on rear axle assemblies must include the full code...

Page 469: ...8 3 23 2 92 2 56 2 73 2 93 3 42 2 41 2 56 3 08 3 23 3 42 LETTERS Fig 48 45 Axle Usage Chart RING GEAR vs PINION TEETH 41 17 41 16 41 15 40 13 41 13 41 16 41 15 41 13 41 17 41 17 41 16 41 15 40 13 41 1...

Page 470: ...taller J 8609 Installer J 8611 01 Remover J 8612 Puller J 8614 2 Puller J 8614 3 Holder J 8614 10 Djscs J 8619 10 Pilot J 8619 12 Stud J 8619 13 Installer J 21022 02 Installer J 21491 Puller J 21579 A...

Page 471: ...7 Brake Pipes 5 8 Brake Hoses 5 9 Parking Brake Cables 5 11 Parking Brake Adjustment 5 14 Combination Valve 5 17 Master Cylinder 5 18 Master Cylinder Overhaul 5 18 Disc Brakes 5 21 Lining Inspection...

Page 472: ...raked but turning wheels will stop car in less distance than locked wheels More tire to road friction is present with a heavily braked turning tire than with a sliding tire External Conditions that Af...

Page 473: ...for stuck or sluggish pistons proper lubrication 6 Install new shoe and lining in complete axle sets 7 Check for inoperative auto adjusting mechanism defective lining grease or brake fluid on lining...

Page 474: ...m for a failure and repair Also check warning light It should have indicated a failure 2 Fill reservoirs with approved brake fluid Check for leaks Check warning light 3 Bleed system 4 Adjust rear brak...

Page 475: ...rotors to obtain a thickness variation no greater than 0005 and a lateral runout no greater than 004 b Check caliper freeness With rotor removed install caliper and mounting bolts pins Check for 005...

Page 476: ...5 6 1977 PONTIAC SERVICE MANUAL Fig 5 1 Brake Diagnosis...

Page 477: ...e fully depressed against the pedal shank Adjust switch by moving in or out as necessary H AND X SERIES The stop light switch is mounted on a flange protruding from the brake pedal support 1 Release t...

Page 478: ...er valve and release brake pedal 5 Repeat steps 3 and 4 until all air is evacuated Check and refill master cylinder reservoir as required to prevent air from being drawn through master cylinder 6 Repe...

Page 479: ...T MUST BE FREE OF SEALANTOR ANY FOREIGNMATERIAL FRONT OF DAS ARM ASSEMBLY BRAKE PE OVER BRAKE PEDAL PAD 4645 Fig 5 4 Brake Pedal Mounting A G Series NUT I A BRACKET BRAKE PEDAL MOUNTINQ POWER HEAD SCR...

Page 480: ...me bracket or crossmember Fitting fits the bracket in only one position With least amount of twist in hose install fitting in this position There should be no kinks in hose 3 Install U clip to female...

Page 481: ...AKES 5 10 HOSE RIGHT REAR FRONT BRAKE CALIPER ASSEMBLY WASHER SPL VIEW A TYPICAL 4637 Fig 5 7 Front Brake Pipes H Series PIPE ASSEMBLY REAR BRAKE FRONT TE HANGER 4638 Fig 5 8 Center Brake Pipes H Seri...

Page 482: ...Remove adjusting nut from equalizer See Figures 5 19 and 5 20 3 Remove retainer clip from rear portion of front cable at frame and from lever arm 4 Disconnect front brake cable from parking brake ped...

Page 483: ...SEMBLY FRONT PIPE ASSEMBLY FRONT BRAKE RIGHT HAND HOSE ASSEMBLY VIEW A FLANGE ON BRAKE HOSE ASSEMBLY MUST BE POSITIONEDTO NOTCH ON CALIPER ASSEMBLY PRIOR TO TORQUING SCREW PlPE MUST LIE ON SURFACE OF...

Page 484: ...5 13 1977 PONTIAC SERVICE MANUAL I PIPE FRONT 7 RIGHT REAR BRAKE FRONT IAR BRAKE FRONT PlPE Fig 5 1 1 Center Brake Pipes X Series Fig 5 12 Rear Brake Pipes X Series...

Page 485: ...re than 16 ratchet clicks under heavy foot pressures all series 1 Depressparking brake pedal exactlytwo ratchet clicks on the X Series three ratchet clicks on the A Series and six ratchet clicks on th...

Page 486: ...ECURE BRAKE PIPESTO TEE FIRST NEXT TOTHE WHEEL CYLINDER AND FINALLY TO THE AXLE J FRAME CROSSMEMBER HOUSINGBY CLOSING THE RETAINER CLIPS BOLT SPECIAL 1 150 LB IN nlunI rlrt TUBE NUTS CENTERLINE OF HOS...

Page 487: ...nt Brake Pipes B Series AME CROSSMEMBER PlPE ASSEMBLY BRAKE CENTER POSITIONS20 THRU 23 70 LB IN MIN BRAKE PIPE FULLY DRIVE AND NOT STR POSITIONS 21 22 HOSE ASSEMBLY 70 LB IN MINIMUM FULLY DRIVEN SEATE...

Page 488: ...rical Circuit of Combination Valve 1 Disconnect wire from switch terminal and use a jumper to connect wire to a good ground 2 Turn ignition key to On warning lamp should light If lamp does not light b...

Page 489: ...voir cover before removal to avoid getting dirt into reservoir Remove cover and diaphragm Add fluid as required to bring level to 1 4 plus or minus 1 8 from the lowest portion of the top of each reser...

Page 490: ...parts on clean paper or lint free clean cloth Do not use anti freezealcohol gasoline kerosene or any other cleaningfluid that might contain even a trace of mineral oil Inspect cylinder bore for scori...

Page 491: ...ABLE FRONT CONNECTOR 2 RETAINER 2 GUIDE b EQUALIZER MUST BE OPEN SIDE DOWN RETAINER PARKING BRAKE CABLE FRONT CONNECTOR 2 PARKING BRAKE TRANSMISSION CABLE CENTER EQUALIZER MUST BE OPEN SlDE DOWN PARKI...

Page 492: ...unng reassembly to assure proper retention of this part 3 Connect brake pipes to master cylinder 4 Bleed hydraulic system 5 Road test car for proper brake performance DISC BRAKES MAINTENANCE AND ADJUS...

Page 493: ......

Page 494: ......

Page 495: ...tion CAUTION It is essentialthat thenewsleevesand rubber bushings be used in order to insure the proper functioning of the sliding caliper design 2 Use Tool J 22835 to install the sleeves SeeFig 5 44...

Page 496: ...assure proper retention of this part 7 Add fresh approved brake fluid to the master cylinder reservoirs to bring the level up to within 1 8 inch of the top 8 Pump brake pedal to seal linings against...

Page 497: ...PIPE ASSEMBLY CLUTCH CABLE VIEW A MANUAL RIGHT REAR BRAKE 4646 Fig 5 26 Distributor Switch to Master Cylinder Mounting H Series MANUAL BRAKES POWER BRAKES Fig 5 27 Combination Valve to Master Cylinder...

Page 498: ...T BE REPLACED NO REPAIRSARE PERMISSIBLE Fig 5 28Brake Lines Master Cylinder to Combination Valve A G Series PlPE ASSEMBLY 26 00 MM MINIMUM CLEARANCEBETWEEN FRONT AND REAR PlPE COILS 26 00 MM MINIMUM C...

Page 499: ...IR TUBE SEAT INSERTS BAIL BODY AsL PRIMARY SEAL SECONDARY PISTON 4 iH O N D A R y SPRING PISTON 3283 ig 5 3 1 Explided View Master Cylinder H Series Manua Brakes rig 5 30 Exploded View Power Brake Mas...

Page 500: ...PONTIAC SERVICE MANUAL BODY SECONDARY SEAL VIIMARY LOCK v SECONDARY PISTON RING SPRING 3282 I ig 5 33 Exploded View Manual Brake Master Cylinder A Series Fig 5 32 Power Brake Master Cylinder Exploded...

Page 501: ...BRAKES 5 29 SECONDARY PISTON Fig 5 34 Secondary Piston Exploded View VACUUM POWER BRAKE HEAD ASH PEDAL PUSH MANUAL BRAKE 4649 Fig 5 35 Master Cylinder Mounting Typical...

Page 502: ...FLUID BOOT SEAL PISTON INLET ROTOR WARNING SENSOR SPRING INBOARD SHOE OUTBOARD SHOE 4339 Fig 5 36 Single Piston Disc Brake N E W S H O E 8 LINING READY F O R REPLACEMENT 4219 Fig 5 38 New and Worn Li...

Page 503: ...nting Bolts lBooT PISTON Fig 5 43 Boot Installation Fig 5 44 Sleeve Installation Fig 5 4 1 Remove Sleeves THE DIMENSION BETWEEN EACH CALIPER STOP AND THE CALIPER SHOULD BE 005 012 FILE TO OBTAIN Fig 5...

Page 504: ...SERVICE MANUAL Fig 5 45 Inserting Shoe Support Spring 3 Fig 5 48 Installing Mounting Bolts Fig 5 46 Installing Inboard Shoe Fig 5 47 Installing Outboard Shoe I CLINCHING LOOP EARED SHOE Fig 5 49 Clinc...

Page 505: ...t Check the boot for cuts cracks or other damage CAUTI0N Do not use compressed air to clean the caliper This could cause the dust boot to become unseated 3 Clean caliper sliding surfaces with a wire b...

Page 506: ...ON Cleaning and Inspection 1 The boot piston seal rubber bushings and sleeves are to be replaced each time the caliper is overhauled Discard do not bother to clean and inspect these parts I Fig 5 53 R...

Page 507: ...mference of the rotor All measurements must be made at the same distance in from the edge of the rotor 2 A rotorthat varies over 0005 causes pedal vibration as well as front end vibration during brake...

Page 508: ...ew linings 1 Remove old linings by drilling out rivets Punching rivets out will distort shoe rim Thoroughly clean surface of shoe rim and file off any burrs or high spots 2 Use Pontiac brake lining or...

Page 509: ...ition if required 6 Clean all dirt from brake assemblies then inspect brake linings for uneven wear oil soaking loose rivets or imbedded foreign particles If linings are oil soaked replacement is requ...

Page 510: ...s are balanced within three ounce inches These weights must not be removed After drums are turned or if difficulty is experienced in maintaining proper wheel balance it is recommended that brake drums...

Page 511: ...ousing of the power head Plug vacuum hose to prevent dust and dirt from entering hose 3 Disconnect the power brake push rod from the brake pedal 4 Remove the four nuts from the mounting studs which ho...

Page 512: ...the secondary diaphragm from the secondary support plate 7 Remove the reaction piston and reaction disc from the center of the secondary power piston by pushing down on the end of the reaction piston...

Page 513: ...ACHINE SLOT IN BOTH TANGS ON TOOL q MACHINE SLOT IN BOTH TANGS ON TOOL TOOLREWORKTOACCOMMODATE OPTIONAL POWER PISTONDESIGN 1782 Fig 5 62 Tool Rework J 23 1 01 Fig 5 63 Positioning Secondary Power Pist...

Page 514: ...half housing assemblies polish clean with crocus cloth or fine emery paper washing clean afterwards Dirt is the major cause of trouble and wear in service Be sure to keep parts clean until re assembl...

Page 515: ...y since the floating control valve is a component part of this assembly and cannot be disassembled from the push rod ig 5 70 Installing Floating Control Valve Retainer With Installer J 23 175 4 Place...

Page 516: ...on See Fig 5 63 25 Fold the secondary diaphragm away from the O D of the secondary support plate 26 Holding the edges of the support plate with the locking tangs down place the secondary diaphragm and...

Page 517: ...in the depression in the face of the secondary power piston Check that the bead on the O D of the secondary diaphragm is positioned between the edges of the housing 7 Continue to press down on the rea...

Page 518: ...se the screw of the tool to permit the two 2 shells to separate WARNING THE DIAPHRAGM RETURN SPRING IS COMPRESSED IN THE POWER SECTION AND EXPANDS AS THE PRESSURE ON THE SHELLS IS REMOVED IF THE SHELL...

Page 519: ...BRAKES 5 47 VALVE POPPET SILENCER RETAINER 4595 Fig 5 75 Removing Air Valve Rod...

Page 520: ...ate assembly in rear housing by carefully guiding rear plate hub through seal in rear housing Bosses on center plate must be aligned between lances in rear housing for reassembly Work outer rim of fro...

Page 521: ...adjusting the self locking screw to meet the gaging specifications 8 Wipe a thin film of silicone lubricant on the I D of the front housing seal and position seal in the depression in the housing DIS...

Page 522: ...ck nut from push rod Disassembly of Power Brake Unit All Except X Car 1 Scribe a mark on bottom center of front and rear housings to facilitate reassembly Fig 5 84 Installing Rear Diaphragm Retainer 2...

Page 523: ...d limiter washer and air filter 13 Remove floating control valve assembly from push rod as it must be replaced by a new floating control valve assembly at rebuild 14 The master cylinder push rod can n...

Page 524: ...ration of rubber or warped value face 1 Air valve scratches dents distortion I D or O D All seats to be smooth and free of nicks and dents 2 Push rod must move freely in air valve but must not pull ou...

Page 525: ...BRAKES 5 53 FRONT HOUSl ASM 3280 Fig 5 86 Power Brake Unit Exploded View Fig 5 87 Separating Power Brake Unit...

Page 526: ...ROD REACTION RETAIN AIR VALVE SPRING AIR VALVE REACTIONBUMPER POWER PISTON SUPPORT PLATE PUSHROD ASSEMBLY FILTER Fig 5 88 Power Piston Assembly Exploded View Fig 5 89 Removing Lock Ring From Power pis...

Page 527: ...KES 5 55 Fig 5 91 Positioning Support Plate Retainer in Vise Fig 5 94 Removing Power Piston Snap Ring DIAPHRAGM Fig 5 92 Positioning Power Piston on Support Plate Remover Fig 5 93 Removing Support Pla...

Page 528: ...staller on top of retainer and pushing down by hand See Fig 5 96 11 After floating control valve is seated position push rod limiter washer over push rod and down onto floating control valve Air filte...

Page 529: ...be on stud side of housing 2 Coat inside of power piston bearing with Power Brake Lube Final Assembly of Power Brake Unit X Car 1 Wipe power piston hub with power brake lube 2 Push hub of power piston...

Page 530: ...to Dash Nut 8 Parking Brake Front Cable to Equalizer Nut 6 Parking Brake Lever to Side Bracket Bolt 12 Screw Front Brake Hose Bracket To Frame A G 12 Screw Front Brake Hose Bracket to Frame F 8 Screw...

Page 531: ...E 1 Exhaust System 6F 1 ENGINE IDENTIFICATION CODES Engine build code locations are as follows Throughout this section engines will be identified by the vehicle identification code letter as well as t...

Page 532: ...the oil fill tube 305 350 V8 Codes U L Machined surface on the front of the block below right cylinder head NOTE Engine codes may also be obtained from the scanner labels located on the covers of mos...

Page 533: ...n define them If the definition is not understood and the exact Symptom is not used the Diagnostic procedure will not work It is important to keep two facts in mind 1 The procedures are written to dia...

Page 534: ...t idle or low speed Momentary lack of response as the accelerator is depressed Can occur at all car speeds Usually most severe when first trying to make the car move as from a stop sign May cause the...

Page 535: ...ollow instructions on can If condition still exists suggest that owner try different gasoline B Detonation 1 Check for obvious overheating problems a Low coolant b Loose fan belt c Restricted air flow...

Page 536: ...lowing for sticking a Carburetor choke and throttle linkage b Fast idle cam c Carburetor flooding See cleaning inspection and adjustment of carburetor Section 6C 4 With engine running visually check v...

Page 537: ...ming and idle speed See emission control information label 4 Check P C V valve for proper operation by placing finger over inlet hole in valve end several times Valve should snap back If not replace v...

Page 538: ...o rough idle hot diagnosis charts 4 If there is no rpm drop on one or more cylinders remove spark plug and check for A Cracks B Wear C Improper gap D Burned Electrodes E Heavy Deposits Repair or repla...

Page 539: ...pump squirt check and adjust the following Pump rod adjust ment see Carburetor Adjustment Section 6C 4 If no pump squirt remove carburetor air horn and repair pump system as necessary See air horn re...

Page 540: ...advance unit 5 Check carburetor fuel inlet filter Replace if dirty or plugged 6 Test fuel pump by connectning hose from carburetor fuel feed line to a suitable container Start engine and let idle for...

Page 541: ...heck for full throttle valve opening in carburetor by depressing accelerator pedal to floor also check for full choke valve opening and free operating air valve if equipped Repair as necessary See car...

Page 542: ...n label Disconnect and plug vacuum advance hose NOTE To check mechanical advance observe timing mark It should advance as throttle is opened and return to mark as throttle is closed 4 Check carburetor...

Page 543: ...nlet filter Replace if dirty or plugged 5 Test fuel pump by connecting hose from carburetor fuel feed line to a suitable container Start engine and let idle for 15 seconds a Mechanical pump should sup...

Page 544: ...h spark plug wire removed Output voltage should read 25 KV or above If any reading is below speicifcations or arcing occurs stop engine remove distributor cap and visually inspect for moisture dust cr...

Page 545: ...ngine to see if timing mark moves If not check for stuck mechanical advance Refer to Section 6D Repair as necessary and recheck timing 3 Check the following a Choke throttle linkage and fast idle cam...

Page 546: ...ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY AS IT IS IMPORTANT IN PREVENTING DAMAGE AND IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE When raising or supporting the engine for any reason do not use a...

Page 547: ...nd install valve stem seals worn oversize service valves and or new valve stem seals g Piston rings not 1 Allow adequate time for seated broken or worn rings to seat 2 Replace broken or worn rings as...

Page 548: ...wheel contacting 2 Reposition splash Knock increases with splash shield shield torque 3 Loose or broken 3 Tighten or replace balancer or drive as necessary pulleys 4 Excessive piston to 4 Replace pist...

Page 549: ...nce 7 Connecting rod alignment 8 Insufficient piston to bore clearance 1 Tension and or replace as necessary 2 Replace as necessary 3 Replace pump 4 Replace parts as necessary 5 Install proper viscosi...

Page 550: ...The block is a high silicon content aluminum alloy throughout for exceptional wear characteristics Five main bearings support the crankshaft which is retained by recessed bearing caps that are machin...

Page 551: ...g a check ball and a check ball retainer When the lifter is riding on the low point of the cam the plunger spring and oil pressure keeps the plunger in contact with the valve stem When the lifter body...

Page 552: ...me the carburetor or air cleaner is removed the intake opening should be covered This will protect against accidental entrance of foreign material which could follow the intake passage into the cylind...

Page 553: ...sely against cover 3 Install the cover upper screw and nut torque upper and lower screws to 50 lbs in 4 Install accessory drive belts and tighten to specification 5 Install fan spacer and fan torque b...

Page 554: ...elts to specifications and install engine front cover Checking Timing Belt Tension Check timing belt for correct tension using timing belt tension gage Tool J 26486 as follows 1 Loosen but do not remo...

Page 555: ...he three screws securing the camshaft seal and retainer assembly and timing cover to the cylinder head 3 Examine seal to determine if it is good If new seal is needed pry it from retainer and install...

Page 556: ...ol J 23624 into end of crankshaft Pull sprocket onto crankshaft until flush with end by tightening nut against large washer and thrust bearing Fig 6A1 13 3 Install timing belt adjust tension timing be...

Page 557: ...t bolts Remove support from baffle 10 Remove bolt securing oil drain back tube to baffle then rotate baffle 90 towards left side of car and remove baffle from pick up screen Fig 6A1 15 Installation 1...

Page 558: ...clean cut and leaving no raveled edges 10 Install seal in bearing cap using Tool J 23625 cut ends of seal flush with cap Fig 6Al 17 11 Place a piece of gaging plastic the full width of crankpin and pa...

Page 559: ...22 7 Check gear end clearance clearance should be 001 002 Fig 6A1 23 NOTE The pump gears and body are not serviced separately If pump gears or body are worn replacement of the entire oil pump is nece...

Page 560: ...ds front of engine and torque cover bolts to 35 lbs in 3 Connect positivecrankcaseventilation valve and hose to cover grommet 4 Install ventilation tube to air cleaner and cam cover while positioning...

Page 561: ...is removed from the cylinder head so that the tool seats properly b Align valve lifter depressing levers on Tool J 23591 so that each lever will depress both the intake and exhaust valve for their res...

Page 562: ...ft Torque retainer screws to 18 lbs ft 4 Attach a dial indicator to cylinder head so that indicator plunger can follow camshaft movement Move camshaft forward and rearward and record movement Fig Fig...

Page 563: ...10 Remove the seal by pulling straight up on the removal tool Fig 6A1 35 Installation Fig 6Al 36 Installing New Seal Fig 6Al 37 Seating Valve Stem Seal Replace all eight valve stem seals 1 Place the...

Page 564: ...from the old unit a Carburetor with linkage mounting plate b EGR valve with new gasket c Vacuum fitting d Heater hose fitting 1 Clean gasket surfaces on cylinder head and manifold 2 Sosition new gask...

Page 565: ...g Cleaning 1 Cleanall carbon from combustionchambers and valve ports using Tool J 8089 Fig 6A1 41 2 Thoroughly clean the valve guides using Tool J 8101 Fig 6A1 42 3 Clean valve stems and heads on a bu...

Page 566: ...icator reading the camshaft should be replaced 7 Inspect the camshaft gear for wear or damage Repairs Fig 6A1 46 Reaming Valve Guide Valve Guide Bores Valves with oversize stems are available in three...

Page 567: ...e springs using a narrow thin scale Fig 6A1 50 Measure from spring seat to the top of the valve spring If this measurement is found to exceed the specified height install a valve spring seat shim appr...

Page 568: ...replaced immediately because of the added strain placed on other mounts and drive line Fig 6A1 53 Engine Mounts Typical CHECKING ENGINE MOUNTS Front Mount Raise the engine to remove weight from the m...

Page 569: ...ignment of front mounts and tighten all mounting bolts to specified torque CONNECTING ROD AND PISTON ASSEMBLIES Removal 1 Use a ridge reamer to remove any ridge and or deposits from the upper end of t...

Page 570: ...er with a telescope gage 2 1 2 from top of cylinder bore Fig 6A1 56 b Measurethe piston diameter at skirt acrosscenterline of piston pin Fig 6A1 57 c Subtract piston diameter to determine piston to bo...

Page 571: ...ds of the ring is below specifications remove the ring and try another for fit 5 Fit each compression ring to the cylinder in which it is going to be used 6 If the pistons have not been cleaned and in...

Page 572: ...s removed install Tool J 23627 on connecting rod bolts CAUTION Be sure nng gaps are properly positioned as previously outlined 4 Install each connecting rod and piston assembly in its respective bore...

Page 573: ...r with a micrometer If not within specifications replace or recondition the crankshaft If within specificationsand a new Fig 6A1 66 Installing Connecting Rod Fig 6A1 67 Installing Piston Assembly bear...

Page 574: ...undersizeinsert which will decrease the clearance 0005 from using a full standard bearing NOTE If for any reason main bearing caps are replaced shimming may be necessary Laminated shims for each cap a...

Page 575: ...regrind the crankshaft journal for use with the next undersize bearing 8 Proceed to the next bearing After all bearings have been checked rotate the crankshaft to see that there is no excessive drag...

Page 576: ...it out with a screwdriver Install and seat a new valve by tapping it in place using a 9 16 thin wall deep socket REPAIRS Cylinder Conditioning In the event that bores are excessively scored or worn t...

Page 577: ...pe piston can be distorted through careless handling Thoroughly clean the bores with hot water and detergent Scrub well with a stiff bristle brush and rinse thoroughly with hot water It is extremely e...

Page 578: ...to Head Manifold Bolts Clutch Housing to Case Clutch Pressure Plate to Flywheel 13 8 18 1 Inlet Manlold to Head Stud p Engine Mount Stud To Block Main Bearing Caps Cylinder Head Torque 7 16 20 1 2 13...

Page 579: ...barrel face No 1 chrome plated No 2 chrome plated inside bevel c NO 1 015 025 NO 2 009 019 Compression Compression Oil material coating etc Width Oil a 0775 0780 Description spacer expander Rails mat...

Page 580: ...MAIN OIL SEAL INSTALLER 15 J 23654 BELT TENSION ADAPTER 7 J 9510 PISTON PIN ASSEMBLY TOOL 16 J 8101 VALVE GUIDE CLEANER 8 J 23600 BELT TENSION GAUGE 17 J 23627 CONNECTING ROD INSERTER 9 J 5830 1 VALV...

Page 581: ...2 18 Piston Rings 6 2 1 8 Piston Pins 6A2 20 Cylinder Bores 6A 2 20 Engine Assembly 6A2 22 Crankshaft 6A2 23 Bolt Torque Specifications 6A2 24 Engine Specifications 6A2 24 Special Tools 6A2 26 GENERAL...

Page 582: ...hrough oil holes which intersect the main gallery PISTONS AND CONNECTING RODS The pistons are of a light weight cast all aluminum slipper skirt type and cam ground so that the diameter across the thru...

Page 583: ...Valve Train HYDRAULIC VALVE LIFTERS Hydraulic valve lifters are used to keep all parts of the valve train in constant contact Each letter is an automatic adjuster maintaining zero lash under all cond...

Page 584: ...ocker The oil is metered by miscs under push rod seat Three valves are incorporated into the oil system to insure proper flow of oil A bypass valve in the oil pick up screen insures adequate oil flow...

Page 585: ...151 ENGINE 6A2 5 OIL P R E S S U R E SENDING UNIT DISTRIBUTOR SHAFT TIMING GEAR OIL NOZZLE F U L L FILTER BY PASS SYSTEM Fig 6A2 8 Engine Lubrication L4...

Page 586: ...n be used to lift engine on X Series SERVICE REAR INSULATOR REMOVE AND REPLACE 1 Remove crossmember to rear insulator bolts 2 Raise rear of engine and transmission with suitable lifting equipment 3 Re...

Page 587: ...loosely Place the manifolds on a straight flat surface and hold securely during tightening and final torque This will assure the proper mating of surfaces when installing the manifold assembly on the...

Page 588: ...air hose adapter 5 22794 into spark plug hole and apply air pressure to hold valves in place 5 After removing rocker arm thread rocker arm nut on rocker arm stud Insert slotted end of tool 5 5892 1 un...

Page 589: ...lifter plunger remover 5 4160 A with push rod end of lifter downward Hold tool firmly in hand with thumb over lifter body and sharply strike tool against a block of wood Fig 6A2 15 until plunger fall...

Page 590: ...submerged at all times Continue pumping for several strokes after definite resistance is detected 5 Raise weight arm to allow plunger spring to expand fully lower arm onto ram and commence turning cr...

Page 591: ...ocker arms 4 Clean valve stems and heads on a bufing wheel Fig 6A2 21 Upper Valve Train Parts Fig 6A2 22 Cleaning Valve Guide Bore Typical 5 Clean carbon deposits from head gasket mating surfaces 6 Wa...

Page 592: ...f the valve face to its seat the grinding stones should be carefully refaced before any grinding is done Valve seat angles should be 46 and valve face angles 45 for proper seating Assemble 1 Starting...

Page 593: ...sure a clean cut 3 Install seal to front cover pressing tips into holes provided in cover 4 Coat the gasket with gasket sealer and place in position on cover 5 Apply a 1 8 inch bead of silicone rubber...

Page 594: ...If less than 0015 the spacer ring should be replaced If more than 0050 the thrust plate should be replaced Replace 1 Install the camshaft assembly in the engine block being careful not to damage beari...

Page 595: ...Disconnect exhaust pipe at manifold and loosen hanger bracket 6 Remove starter and set to one side 7 Remove flywheel housing inspection cover On H series proceed to step 10 8 Remove hub bolt and inst...

Page 596: ...rances become excessive the next undersize bearing insert should be used Remove 1 Remove oil pan 2 Rotate crankshaft as necessary to bring crankpin carrying bearing to be replaced straight toward bott...

Page 597: ...lly push with a hammer handle until seal is rolled into place 5 To remove the upper half of the seal use a small hammer and a soft blunt punch to tap one end of oil seal Fig 6A2 39 until it protrudes...

Page 598: ...ith the next undersize bearing and recheck clearance Bearings are available in standard size 001 and 002 undersize 5 Install a new rear main bearing oil seal in the cylinder block and main bearing cap...

Page 599: ...oles in oil ring groove using suitable cleaning tools and solvent 2 Clean piston pin rod cap bolts and nuts in suitable solvent Reinstall cap on connecting rod to prevent subsequent mixing of caps and...

Page 600: ...cylinder gage 5 8087 or comparable at top middle and bottom of bore Fig 6A2 47 Measure cylinder bore parallel and at right angles to the centerline of the engine to determine out of round Variation in...

Page 601: ...emove all traces of abrasive If all traces of abrasive are not removed rapid wear of new rings and piston will result Intermixing different size pistons has no effect on engine balance as all pistons...

Page 602: ...ntake and exhaust manifold 7 Connect fuel line and vacuum lines to carburetor 8 Install push rods move rocker arms into position and tighten rocker arm nuts 9 Install rocker arm cover ENGINE Remove 1...

Page 603: ...each for reinstallation 10 Push connecting rod and piston assemblies away from crankshaft 11 Remove main bearing caps with bearings and identify for reinstallation 12 Remove crankshaft Replace 1 With...

Page 604: ...ng Order 1 3 4 2 Production Engine Number Pad at Right Side by Distributor Shaft Hole Cylinder Numbers Front to Rear 1 2 3 4 CAMSHAFT Material Camshaft Hardened Alloy Cast Iron Material Cam Bearings B...

Page 605: ...damper 1 66 Installed Height 1 69 VALVE TRAIN Lifter Leak Down Rate 12 90 seconds with 50 lbs load Plunger Travel 125 Gage Pushrod Material Ball End Steel Tubing Length 9 70 Rocker Arm Material Stamp...

Page 606: ...LT GUIDE SET HANDLE CAMSHAFT BUSHING REMOVER INSTALLER USE WITH J 21473 1 TOOL NO NAME TIME COVER SEAL ALIGNER INSTALLER AIR LINE ADAPTER HYDRAULIC VALVE LIFTER PLUNGER REMOVER VALVE CLUTCH SPRING TES...

Page 607: ...e Specifications 61 3 24 General Specifications 61 3 24 ENGINE CONSTRUCTION The left bank of cylinders as viewed from rear is set slightly forward of the right bank so that connecting rods of opposite...

Page 608: ...engine is started forces out all air and completelyfills the plunger and lower chamber of each lifter with oil LUBRICATION SYSTEM The engine lubrication system is of the force feed type in which oil...

Page 609: ...rm and valve is supplied with oil through the tubular push rod This oil comes from the inside of the lifter passing around the metering valve and through a hole in the lifter push rod seat Oil from th...

Page 610: ...the engine block dowel pin 3 Install manifold to cylinder head bolts New intake manifold gasket and seals must be used whenever a manifold is removed When installing manifold start with the No 1 and...

Page 611: ...ay with hoses attached 4 Disconnect wires from spark plugs and remove the spark plug wire clips from the rocker arm cover studs 5 Remove exhaust manifold bolts from head being removed 6 With air hose...

Page 612: ...orque to 80 Ib ft Fig 6A3 12 Cylinder Head Bolt Tightening Sequence 231 Engine 6 Assemble exhaust manifolds to heads Torque bolts to specifications 7 Wipe rocker arm shaft and bosses on cylinder head...

Page 613: ...y surface on the intakes or the 0004 to 0015 nickel plated surface on the exhausts will be removed 10 Test valves for concentricity with seats and for tight seating The usual test is to coat the valve...

Page 614: ...er the pump pump cover or timing chain cover is disturbed If the pump is not packed it may not begin to pump oil as soon as the engine is started 2 The gasket surface of the block and timing chain cov...

Page 615: ...Remove camshaft and crankshaft 2 Assemble puller screw to required length 3 Select proper size expanding collet and back up nut Fig 6A3 19 Oil Slinger Installation 4 Install expanding collet on expand...

Page 616: ...l occur when the new bearing is pulled into the engine block 6 Slide mandrel assembly and bearing into bearing bore as far as it will go without force 7 Thread end of puller screw onto the end of the...

Page 617: ...ver on primer attachment while at the same time holding valve on tester base down to assure that oil will be lifted instead of air being drawn from bearings etc Hold these positions until a light spra...

Page 618: ...A3 26 c Check oil pump cover flatness by placing a straight edge across the cover face using a feeler gage between straight edge and pump cover If clearance is 001 or more the pump cover must be repla...

Page 619: ...gage is soluble in oil 2 Place a piece of plastic type gage lengthwisealong the bottom center of the lower bearing shell Fig 6A3 27 View A then install cap with shell and torque bolt nuts to specific...

Page 620: ...h affects the crankshaft bearings may also affect the connecting rod bearings it is advisable to inspect connecting rod bearings first If crankpins are worn to the extent that crankshaft should be rep...

Page 621: ...ings have been installed and tested tighten all bearing cap bolts to specified torque 17 Replace rear main bearing oil seals 18 Install oil pan bame pipe and screen assembly and oil pan Installation o...

Page 622: ...ng cap Repeat the procedure for the other side Use the rear main bearing cap as a holding fixture when cutting the seal 5 Install Guide Tool J 21526 1 onto cylinder block See Fig 6A3 33 Fig 6A3 33 Gui...

Page 623: ...down fully to hold the upper bearing shell in place while removing the piston and rod assembly See Fig 6A3 36 5 Use the long guide to push the piston and rod assembly out of the cylinder then removeg...

Page 624: ...der to maintain engine balance since all oversize service pistons are held to the same weights as standard size pistons Standard size servicepistons are high limit or maximum diameter therefore they c...

Page 625: ...n fell free during this check with the 0025 feeler gage 002 feeler gage for new pistons then that particular piston is too samall for the bore and a larger diameter piston will be required NOTE When c...

Page 626: ...d Rod Assembly 5 Install piston pin on installer and pilot springand pilot in support See Fig 6A3 46 6 Install piston and rod on support indexing pilot through piston and rod 7 Place support on press...

Page 627: ...liesin the same manner When piston and rod assemblies are properly installed the notches on al1 the pistons will point towards the front of the engine The boss on the connecting rods in the right bank...

Page 628: ...2 Lower the car and support the transmission automatic transmission only 23 Attach a lifting device to the engine and raise the engine enough so mounting through bolts can be removed Make certain wiri...

Page 629: ...ure to the flywheel SeeFig 6A3 49for clip installation locations If a flywheel is found to be out of balance it can be corrected in the following manner 1 Remove lower flywheel housing Mark the flywhe...

Page 630: ...Intake Manifold to Cylinder Head 45 Exhaust Manifold to Cylinder Head 25 Carburetor to Intake Manifold 15 Fuel Pump to Cylinder Block 20 Motor Mount to Cylinder Block 55 Fuel Pump Eccentric and Timing...

Page 631: ...Ring 015 035 Piston Pin Length 3 060 Diameter of Pin 9391 9394 Clearance In Piston Selected 0004 0007 Press Fit In Rod 0007 0017 Direction and Amount Offset in Piston 040 Major Thrust Side All measur...

Page 632: ...SION RATIO 8 0 1 FUEL REQUIREMENTS UNLEADED OCTANE REQUIREMENTS MOTOR 82 OCTANE REQUIREMENTS RESEARCH 91 CYLINDER NUMBERS FRONT TO REAR RIGHT BANK 2 4 6 CYLINDER NUMBERS FRONT TO REAR LEFT BANK 1 3 5...

Page 633: ...n Bearings Rear Main Bearing Upper Oil Seal Rod Assembly Checking Cylinder Bore Piston Rings Piston Pins Engine Assembly Crankshaft Flywheel Torque Specifications Engine Specifications Special Tools D...

Page 634: ...tion will open at 5 3 to 6 3 psi Oil then enters the right oil galley where it is distributed to the five main bearings The right bank valve lifters receive oil from this galley from eight feed holes...

Page 635: ...urnals A groove around each main bearing furnishes oil to the drilled crankshaft passages Oil returns to the oil pan reservoir from the rocker arms through passages at each end of the cylinder heads O...

Page 636: ...ded end of the bolt into the oil dipstick guide and clamp with a vise type pliers 3 Use slide hammer to tap out tube POSITION GUIDE TO 4 FRONT OF ENGINE REAR OF OPENING I N EXHAUST MANIFOLD DIPSTICK G...

Page 637: ...6A4 5 CYLINDER BLOCK ENGINE BLOCK BOSSES ENGINE MOUNT BRACKET d 2R CROSSMEMBER SHOWN rnuN I r FRONT 3689 Fig 6A4 7 Front Engine Mounts Typical L 3 FRONT e FRONT VERTER BRACKET 3685 Fig 6A4 8 Rear Eng...

Page 638: ...ir cleaner 2 Remove hot air shroud Fig 6A4 12 3 Remove lower generator bracket 4 Hoist car 5 Remove crossover pipe 6 Lower car 7 Remove exhaust manifold from above To install reverse removal procedure...

Page 639: ......

Page 640: ...e installed 2 Install spark plugs Torque to 25 lbs ft 3 Install rocker arm assemblies VALVE LIFTERS Operation Oil is supplied to the lifter through a hole in the side of the lifter body which indexes...

Page 641: ...parts If either the body or plunger isdefective replace with APPLY A Y1Z BEAD OF R T V IROOM TEMRRATURE VULCANIZ INCl SEALER ON THE VALVE COVER AS SHOWN I 3669 Fig 6A4 14 Applying Sealer on Valve Cov...

Page 642: ...ALL LIFTER ONLY ROD ROCKER FEED M E T E R I G VALVE I RETAINER SPRING 268 Fig 6A4 18 Valve Lifter Cutaway View Fig 6A4 16 Removing Valve Springs Fig 6A4 19 Removing Valve Lifter 6 Hold plunger with sp...

Page 643: ...ould be damaged when starting engine if dry 1 Install lifters and push rods into original position in cylinder block See note under Removal 2 Install manifold gaskets and manifold 3 Position rocker ar...

Page 644: ...composition gasket that must be used WITHOUT a sealer These gasketsare to be installed with the contrasting color stripe facing up Fig 6A4 25 1 Clean and dip cylinder head bolts in engine oil torque b...

Page 645: ...een installed on valves tap each valve stem end with a hammer to seat valve rotators and keys Using Gauge BT 6428 as shown in Figs 6A4 28 and 6A4 29 re gauge all valves between valve stem and gauge 01...

Page 646: ...quire an oversize valve If the oversize marking is present only that particular bore would be oversize not all bores in that cylinder head Service valves are available in five differenct stem diameter...

Page 647: ...is 00lW tight to 0007 loose 3 Install washer and bolt Torque 200 310 ft lbs 4 Install pulley and belt Adjust belts using belt adjusting gauge BT 7002 3 FRONT COVER Removal 1 Drain cooling system Disc...

Page 648: ...r bolt Torque to 200 300 ft lbs 14 Connect bypass hose and radiator hoses 15 Install crankshaft pulley and four attaching bolts Torque to 10 ft lbs Fig 6 44 38 Rework Pan Seal Fig 6A4 39 Sealer On Pan...

Page 649: ...keyway is machined only part way in crankshafl gear and breakage would occur Installation 1 Install camshaft gear crankshaft gear and timing chain together and align timing marks Fig 6A4 45 NOTE When...

Page 650: ...d disconnect throttle cable 11 Loosen generator belt adjusting bolt remove belt 12 Remove generator bracket attaching bolts move generator to one side for access 13 Remove power steering pump bracket...

Page 651: ...ngine in car proceed as follows Removal 3 Remove No 3 and 4 bearings in the same manner using BT 6409 3 and BT 6409 4 removers 4 To remove No 5 bearing with engine in chassis use Puller BT 6409 8 Inst...

Page 652: ...ed Place a straight edge across the machined surface of the rear of the block and measure from the straight edge to the lip of the plug Dimension should be 250 maximum to l6O minimim OIL PAN Removal 1...

Page 653: ...r end clearance should be gauged Proper end clearance is 0015 to 0085 Also check the pressure regulator valve valve spring and bore for damage Proper valve to bore clearance is 0025 to 0050 The checki...

Page 654: ...provide access to rear connecting rod bearings 2 With connecting rod journal at the bottom stamp cylinder number on machined surfacesof connecting rod and cap for identification when reinstalling then...

Page 655: ...g cap and wipe oil from crankshaft journal and outer and inner surfaces of bearing shell 2 Place a piece of plastic gauging material in the center of bearing 3 Use a floor jack or other means to hold...

Page 656: ...earing Install new asbestosoil seal in the rear main bearing cap REAR MAIN BEARING OIL SEAL Fig 6A4 64 Install 1050805 or equivalent sealer on cap as shown Fig 6A4 64 Installing Rear Main Oil Seal 10...

Page 657: ...age to tool 4 Clean bearing insert and install in bearing cap 5 Clean crankshaft bearing journal and seal contact Install sealer on cap as shown 6 Install bearing caps lubricate bolt threads with engi...

Page 658: ...ing Piston Clearance Reconditioned cylinder bores should be held to not more han OOln out of round and OOlmtaper If the cylinder bores are smooth the cylinder walls should not be deglazed If the cylin...

Page 659: ...k oil ring side clearance the oil rings must be installed on the piston ALLOWABLE SIDE CLEARANCE Compression Rings 002 to 004 Oil Rings 001 to 005 Fig 6A4 74 Piston Ring Identification ROD AND PISTON...

Page 660: ...cess Remove Threaded Plug Springand Piston Pin Guide assembly prior to using the tool Piston Pin should fall through center of Guide Tube after it is pushed through connecting rod CAUTION Always be su...

Page 661: ...l 5 Disconnect radiator hoses automatic transmission cooler lines heater hoses vacuum hoses power steering hose bracket from engine air conditioning compressor with brackets and hoses attached fuel ho...

Page 662: ...Fig 6A4 80 Crankshaft Removal 2 Position crankshaft keyway in the same position as removed and lower into block The connecting rods will follow the crank pins into the correct position as the cranksh...

Page 663: ...4 82 Installing Rear Main Oil Seal Upper Half 6 Torque Nos 1 2 3 and 4 main bearing cap bolts to 80 ft lbs and No 5 bolt to 120 ft Ibs 7 Reassemble engine and install in chassis FLYWHEEL One bolt hole...

Page 664: ...er to Crankshaft Bolt 200 310 Oil Filter Element to Base 20 Oil Filter Assembly to Cylinder Block Bolts 35 Support Front Cover to Cylinder Block Bolts 3 8 35 Fan Driven Pulley to Hub Bolts 20 Fan Driv...

Page 665: ...No of Teeth on Starter Pinion 9 LUBRICATION SYSTEM Crankcase Capacity Drain and Refill 4 Qts Drain Refill with Filter Change 5 Qts Oil Pump Clearance Pressure Relief Valve in Bore 0025 0050 End Clear...

Page 666: ...1 156 1 166 NO 3 1 1985 2 0015 No 5 1 882 Diameter Connecting Rod Bearing Journal 2 1248 2 1238 Width Connecting Rod Bearing with fillets 1 877 1 887 Length Overall Crankshaft 26 470 Diameter Oil Hole...

Page 667: ...5 Pin to Rod Fit 0008 0018 Press PISTON RINGS No of Compression Rings per piston 2 Width of Compression Rings top bottom 0780 0770 Gap Clearance Compression Rings 010 023 Clearance in Groove Compressi...

Page 668: ...le Valve 30 Angle Valve Seat 31 Width Valve Seat Cylinder Head 050 090 Overall Length 4 675 Clearance In Guide 0015 0032 Lash Hydraulic VALVE SPRINGS Length 1 96 Diameter Wire 192 Inside Diameter 1 06...

Page 669: ...APTER CLUTCH PILOT BEARING REMOVER VALVE SEAL INSTALLER VALVE GUIDE CLEANER BT 6812 1 PULLINGJAW ENGINE SUPPORT BAR BT 6812 2 PILOT VALVE STEM HEIGHT GAUGE BT 6812 3 PULLING BOLTS REAR MAIN BRG OlL SE...

Page 670: ...ain Bearings 6A5 17 Main Bearing Rear Oil Seal 6A5 18 Connecting Rod and Piston 6A5 19 Piston Pin 6A5 21 Cylinder Bores 6A5 2 1 Piston Fit and Replace 6A5 22 Piston Rings 6A5 22 Engine Assy Remove 6A5...

Page 671: ...mmended material M400 A located in the proper position on the crankshaft upper lower The rear main bearing is sealed by a packing seated in a groove in the block and bearing cap A slinger on the crank...

Page 672: ...ISTON PIN R1GH T BANK LEFT BANK 1904 Fig 6A5 05 Connecting Rod and Piston Assembly Typical VALVE TRAIN A very simple ball pivot type valve train is used Fig FUEL DISTRIBUTION SYSTEM 6A5 06 Motion is t...

Page 673: ...filter mounting to insure oil circulation even if the filter becomes plugged Fig 6A5 08 Intake Manifold 350 400 LUBRICATION SYSTEM OIL PUMP Oil is circulated under pressure by a spur gear type pump T...

Page 674: ...nge bolts on opposite side manifold to gain clearance for removal Replace 1 Thoroughly clean gasket surfacesof cylinder head and exhaust manifold 2 Install exhaust manifold and new gasket 3 Place mani...

Page 675: ...Disconnect crankcase vent hose 10 Disconnect throttle cable from carburetor and manifold 11 Remove attaching bolts and manifold Replace When a new manifold is to be installed transfer carburetor adapt...

Page 676: ...entilation hoses if disconnected 3 Connect electrical wire s at rocker arm cover clips 4 Install air cleaner VALVE SPRINGS SHIELD OR SEAL Remove 1 Remove rocker arm cover spark plug and distributor ca...

Page 677: ...grinders or other sources of dust and foreign material Lifters should at all times be stored in a covered box which will aid in keeping them clean The lifter box should be kept dry and as free of oil...

Page 678: ...with previous service operations concerned with lifters cleanliness is paramount The tester cup and ram should be thoroughly cleaned and testing should be done in an area free of dust and dirt The tes...

Page 679: ...or engine ground strap and automatic transmission oil level indicator tube bracket Also install the engine oil level indicator 9 Install intake manifold using new gaskets and 0 ring seal 10 Install ex...

Page 680: ...intain that height See Specifications Weak springs affect power and economy and should be replaced if below specified pressure VALVE GUIDE BORE Recondition Valves with 003 oversize stems are available...

Page 681: ...CAUTI0N Do not pry on 0 D of harmonic balancer The harmonic balancer is a rubber mounted inertia member and balance could be affected 6 Install new harmonic balancer by reversing above steps lining up...

Page 682: ...screws and tighten to 12 lb ft 6 Install harmonic balancer retainer bolt with retainer and tighten to 160 Ib ft 7 Connect lower radiator hose to pump inlet 8 Position pulley and fan on water pump hub...

Page 683: ...o be replaced insert installeradapter in center bearing to act as support for shafi If rear bearing is to be removed it will be necessary to remove camshaft rear plug 2 Insert replacer adapter J 6173...

Page 684: ...so Front center and rear center journals should not be polished except to remove slight roughness or scratches Slight warpage of the camshafiis not harmful provided the journals are polished down unti...

Page 685: ...here crossbar is now positioned Make sure crossbar is parallel to ground Fig 6A5 11 13 Place loose ends of chain across top of support to prevent chain from slipping out of hooks 14 Remove both frame...

Page 686: ...crews to 105 Ib in and check to see that shaft turns freely 4 Install regulator valve plunger spring retainer and pin CONNECTING ROD BEARING CLEARANCE 1 After removing oil pan remove the cap of the be...

Page 687: ...shown in Fig 6A5 38 made from brass bar stock to pack upper seal as follows a Insert tool against one end of the oil seal in the cylinder block and drive the seal gently into the groove until the tool...

Page 688: ...see Fig 6A5 42 Rods are assembled on the crank with the dimvles facing rear on the both banks 301 engine and forward on the rigit bank and rearward on the left bank of the 350 and 400 engine 3 From be...

Page 689: ...ven wear and proper fit 5 5 Inspect bearing shells to see that they are not damaged Fit of bearings should be checked when engine is being assembled Assemble There is a notch cast in the top of all pi...

Page 690: ...r with the gage at the same zero setting when removed from the cylinder Fig 6A5 46 Fine vertical scratches made by ring ends will not by themselves cause excessive oil consumption therefore honing to...

Page 691: ...rd size pistons and for 01OW 020 and 030 oversize pistons When selecting rings be sure they match the size of the piston on which they are to be installed i e standard rings for standard pistons 010 o...

Page 692: ...g equipment to engine and lower engine into chassis guiding engine to align with bell housing 2 With engine supported by lifting equipment install two upper bell housing bolts CAUTION Do not lower eng...

Page 693: ...o Block Bolt Oil Pump to Block Bolt Harmonic Balancer to Crankshaft Bolt Exhaust Manifold to Head Bolt Intake Manifold to Head Bolt Camshaft to Sprocket Nut Rocker Arm to Stud Stud Rocker Arm Spark Pl...

Page 694: ...ne SAE 1541 Steel Intake 350 400 Engine 1541 Steel Exhaust 21 2N Steel Diameter of Head Intake 301 Engine 1 72 Intake 350 400 2 10 Exhaust 301 1 50 Exhaust 350 400 1 65 Overall Length Intake 301 5 07...

Page 695: ...1 Eng 1 66 Installed Height 350 400 Eng 1 54 LUBRICATION SYSTEM Type of Lubrication Main Bearings Pressure Connecting Rods Pressure Piston Pins Splash Camshaft Bearings Pressure Lifters and Rocker Arm...

Page 696: ...OIL SEAL INSTALLER PISTON RING COMPRESSOR 4 VALVE SEAL INSTALLER TESTER VALVE GUIDE CLEANING TOOL TIMING CHAIN COVER OIL SEAL INSTALLER TOOL NO J 22794 J 8929 02 J 23515 02 J 8056 J 4160 J 6173 01 J 5...

Page 697: ...Head 6A6 8 Rocker Arm Studs 6A6 11 Valve Guide Bores 6A6 11 Valve Seats 6A6 11 Valves 6A6 12 Torsional Damper 6A6 12 Crankcase Front Cover 6A6 13 Oil Seal Front Cover 6A6 13 Camshaft 6A6 13 Camshaft...

Page 698: ...he connecting rod journals are located so that oil is supplied to give maximum lubrication just prior to full bearing load VALVE TRAIN A very simple ball pivot type train is used Motion is transmitted...

Page 699: ...vehicle on a hoist Push up and pull down on the transmission tailshaft while observing the transmission mount If the rubber separates from the metal plate of the mount or if the tailshaft moves up but...

Page 700: ...6A6 4 1977 PONTIAC SERVICE MANUAL DISTRIBUTOR SHAFT OILING TIMING CHAIN 7 OILING F U E L PUMP PUSH ROD OILING OIL FILTER AND BY PASS VALVE FIG 6A6 1 ENGINE LUBRICATION...

Page 701: ...nifold Installation NOTE If installing a new right side manifold the carburetor heat stove must be transferred from the old unit Fig 6A6 4 Fig 6A6 4 Choke Stove Installation 1 Clean mating surfaces on...

Page 702: ...time to reach the number 1 position b With the engine in the number 1 firing position as determined above the following valves may be adjusted Exhaust 1 3 4 8 Intake 1 2 5 7 c Back out adjusting nut u...

Page 703: ...nd inspect them carefully If any parts are damaged or worn the entire lifter assembly should be replaced If the lifter body I Lifter Body 6 Push Rod Seat 2 Push Rod Seat Rete ner 3 Metering Valve 7 Pl...

Page 704: ...be removed from the exhaust manifold Fig 6A6 10 Assembling Hydraulic Lifter 5 Remove valve mechanism as previously outlined 6 Drain cylinder block of coolant 7 Remove cylinder head bolts cylinder head...

Page 705: ...laced if not within 10 Ibs of the specified load without dampers 5 Inspect rocker arm studs for wear or damage Assembly 1 Insert a valve in the proper port Fig 6A6 14 Measuring Valve Stem Clearance Ty...

Page 706: ...n engines using a STEEL gasket coat both sides of a new gasket with a good sealer Spread the sealer thin and even One method of applying the sealer that will assure the proper coat is with the use of...

Page 707: ...ing Rocker Arm Stud 2 Ream hole for oversize stud using Tool J 5715 for 003 oversize or Tool J 6036 for 013 oiersize Fig 6A6 22 CAUTI0N Do not attempt to instaffan oversize stud without reaming stud h...

Page 708: ...be necessary 3 Remove accessory drive pulley then remove damper retaining bolt 4 Install Tool J 23523 on damper then turning puller screw remove damper Fig 6A6 25 Installation CAUTI0N The inertial wei...

Page 709: ...to specifications 9 Install torsional damper and water pump as previoulsy outlined OIL SEAL FRONT COVER REPLACEMENT WlTH COVER REMOVED 1 With cover removed pry oil seal out of cover from the front wit...

Page 710: ...aring journals should be measured with a micrometer for an out of round condition If the journals exceed 001 out of round the camshaft should be replaced The camshaft should also be checked for alignm...

Page 711: ...st washer installed to end of threads index pilot in camshaft front bearing and install puller screw through pilot 3 Install remover and install tool with shoulder toward bearing making sure a suffici...

Page 712: ...installed flush to 1 32 deep and be parallel with rear surface of cylinder block OIL PAN Removal 1 Drain engine oil 2 Remove oil dip stick and tube 3 Remove exhaust crossover pipe 4 On vehicles equipp...

Page 713: ...could result in an air leak and loss of oil pressure Mount the pump in a soft jawed vise apply sealer to end of pipe and using Tool J 8369 Fig 6A6 38 tap the pipe in place with a plastic hammer CAUTI...

Page 714: ...o specifications 8 When all connecting rod bearings have been installed tap each rod lightly parallel to the crankpin to make sure they have clearance 9 Measure all connecting rod side clearances see...

Page 715: ...nly torque the retaining bolts to specifications 4 Remove bearing cap The flattened gaging plastic will be found adhering to either the bearing shell or journal 5 On the edge of gaging plastic envelop...

Page 716: ...SEAL REAR MAIN Replacement NOTE Always replace the upper and lower seal s a unit Install seal with lip facing front of engine The rear main bearing oil seal can be replaced both halves without removal...

Page 717: ...ed to the cap to case interface being careful to keep sealant off the seal split line Fig 6A6 49 I DUST SEAL I I Fig 6A6 49 Sealing Bearing Cap CONNECTING ROD AND PISTON ASSEMBLIES Removal Fig 6A6 48...

Page 718: ...cleaning solvent DO NOT WIRE BRUSH ANY PART O F THE PISTON Clean the ring grooves with a groove cleaner and make sure oil ring holes and slots are clean PISTON PIN REMOVER J 24086 8 FIXTURE Fig 6A6 5...

Page 719: ...g with a feeler gage Fig 6A6 53 Fig 6 A 6 5 3 Measuring Ring Gap 4 If the gap between the ends of the ring is below specifications remove the ring and try another for fit 5 Fit each compression ring t...

Page 720: ...when installed in the cylinder bore If a connecting rod is ever moved from one block or cylinder to another new bearings should be fitted and the connecting rod should be numbered to correspond with t...

Page 721: ...A6 25 ENGINE LEFT 4 ENGINE FRONT ENGINE RIGHT 1 3 5 7cyl A OIL RlNG SPACER GAP Tong in Hole or Slot within Arc B OIL RlNG RAIL GAPS C 2ND COMPRESSION RlNG GAP 1 D TOP COMPRESSION RlNG GAP Fig 6A6 55 R...

Page 722: ...aner 20 Install hood 21 Connect battery cables NOTE To avoid possible arcing of battery connect positive battery cable first 22 Start engine check for leaks and check timing CRANKSHAFT The crankshaft...

Page 723: ...il 4 Install crankshaft being careful not to damagebearing surfaces 5 Apply a thin coat of brush on type oil sealing compound to block mating surface and corresponding surface of cap only Fig 6A6 60 D...

Page 724: ...6A6 28 1977 PONTIAC SERVICE MANUAL Fig 6A6 61 Engine Torques...

Page 725: ...EAT RUNOUT VALVE SEAT WIDTH INTAKE VALVE SEAT WIDTH EXHAUST VALVE STEM CLEARANCE INTAKE VALVE STEM CLEARANCE EXHAUST VALVE SPRING TENSION CLOSED VALVE SPRING TENSION OPEN INSTALLED HEIGHT INTAKE INSTA...

Page 726: ...BUSHING INSTALLER OIL PICK UP SCREEN INSTALLER OIL PICK UPSCREEN INSTALLER CAM BEARING TOOL CAMSHAFT GEAR SUPPORT TORSIONAL DAMPER PULLER TORSIONAL DAMPER INSTALLER CRANKSHAFT SPROCKET PULLER 9 J 5239...

Page 727: ...e RADIATOR A cross flow radiator is used on all models Tanks in this type radiator are located to the right and left of the core instead of above and below Fig 6B 1 Radiators used with automatic trans...

Page 728: ...1977 PONTIAC SERVICE MANUAL COLD RADIATOR Fig 66 1 Cross Flow Radiator...

Page 729: ...hroughWplasticreservoir similar to the familiar windshield washer jar is connected to the radiator by a hose As the car is driven the coolant is heated and expands The portion of the fluid displaced b...

Page 730: ...l filled with silicone oil which is located above the pump inlet from the radiator hermetically sealed The finned rear housing contains a hub assembly secured to the housing bearing which attaches to...

Page 731: ...y closed until the control temperatures are reached as does a lower temperature thermostat NOTE All thermostats are not alike Check parts catalog for proper application Improper thermostat application...

Page 732: ...otion will cause the clutch to free wheel which is a normal condition when operated in this manner This should not be considered a test by which replacement is determined NOTE pointer movement for eac...

Page 733: ...D BY HOT LlGHT OR TEMP GAGE FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REOUIRED 4 ISOVERHEATING OCCURRING AFTER PROLONGEDDRIVING IN SLOW CITY TRAFFIC TRAFFIC JAMS PARADES ETC IF ANSWER IS YES INSTRUCT OW...

Page 734: ...em is out of the ordinary or of a major nature Listed on Sheet 3 are two groups of problem areas that should be checked i n the order listed I LEAKS Check Hoses Radiator Clamps Water Pump Thermostat H...

Page 735: ...OLING SYSTEM 1 INCORRECT OR DAMAGED FAN CHECK PART NO AGAINST PARTS LlST 2 FAULTY EMISSION SYSTEM COMPONENTS COULD CAUSE OVERHEATING AT IDLE a PCV VALVE 1SEE CHASSIS SERVICE MANUAL b TVS OR TCS 3 PRES...

Page 736: ...n created by coolant contraction The cooling system has been filled at the factory with a high quality inhibited year around coolant that meets the standards of General Motors Specification 1899 M Thi...

Page 737: ...s which may occur in the area of vehicle operation Maintain cooling system freeze protection at 20 F 29 C or below to ensure protection against corrosion and loss of coolant from boiling even though f...

Page 738: ...emperature of 192 F 89 C to 1 98 F 92 C and should be fully open 5 16 or more at a temperature not in excess of 222 F 106 C A used thermostat can be about 10 F 7 C above or below this setting 185 205...

Page 739: ...ess with impeller facing upward 3 Press bearing out of pump body and impeller with one pressing operation 4 Pry seal from pump body and discard all parts except pump body 5 Clean gasket material and o...

Page 740: ...cal I I Fig 68 16 Radiator Mountings G and A Series Typical Remove Install 1 Remove cap and tube from coolant reservoir 1 Place coolant reservoir in position and install retaining 2 Remove retaining s...

Page 741: ...ENGINE COOLING 68 15 Fig 68 17 Radiator Mountings F Series Typical SUPPORT 81BAFFLE ASM I Fig 68 18 Radiator Mountings X Series Typical...

Page 742: ...6B 16 1977 PONTIAC SERVICE MANUAL Fig 68 19 Radiator Mountings H Series Typical RADIATOR UPPER Fig 68 20 Radiator Mountings H M Series Typical...

Page 743: ...ENGINE COOLING 68 17 COOLANT RECOVERY TANK MOUNTING TO FENDER SKIRT Fig 68 2 1 Coolant Reservoir Tank Mounting 8 Series Typical Fig 68 22 Coolant Reservoir Tank Mounting G and A Series Typical...

Page 744: ...ervoir Tank Mounting F Series Typical ALL BELTS 110 TO 140 LBS NEW 70 LBS USED AIC ALTERNATOR CRANK STEERING CRANK STEERING CRANK STEERING CRANK STEERING SHAFT SHAFT SHAFT SHAFT POWER STEERING POWER S...

Page 745: ...XCEPT SUPER COOLING POWER STEERING WISUPER COOLING WlTH AIR CONDITIONING RADIATOR OR AIR CONDITIONING RADIATOR EXCEPT AIR CONDITIONING 3310 Figb 68 25 Belt and Pulley Diagrams 350 403 Engines VI Codes...

Page 746: ...ING AND POWER STEERING 4727 Fig 68 27 Belt and Pulley Diagrams 350 Engine VI Code L Cal Only ALTERNATOR ALTERNATOR POWER STEERING POWER STEERING POWER STEERING POWER STEERING WITH POWER STEERING WITH...

Page 747: ...TEERING A N D A I R AlC A N D A I R 4729 Fig 66 29 Belt and Pulley Diagrams 2 3 1 Engine VI Code C ALTERNATOR ALTERNATOR c ALLBELTS 110 140 LBS 70 LBS USED GENERATOR ONLY AIR CONDITIONING POWER STEERI...

Page 748: ...P P Z Z Z Z Z Z K K K V C Y Y Y Y Y Y U R RADIATOR STD HD STD HD STD HD STD HD STD STD HD STD HD STD HD STD HD STD HD STD HD STD STD HD STD STD HD STD HD X x X X X X X X X X X X X X X X X X X X X X X...

Page 749: ...p 5 16 20 Bolt Water Pump 3 8 30 COOLING SYSTEM Type Pressure with vent Operating Pressure 14 17 PSI Pump Type Centrifugal Pump and Fan Drive Except 140 Eng V Belt Pump and Fan Drive 140 Eng Ground Si...

Page 750: ...SERIES 231 EXCEPT WAGON 231 301 350 350 400 403 A SERIES 301 WAGON 350 400 403 G SERIES 301 350 350 400 403 F SERIES 231 231 301 350 350 400 403 X SERIES 151 231 231 301 305 350 H SERIES EXCEPT HM HM...

Page 751: ...fmtivenessof the Emission Control Systems CARBURETOR All enginesare equipped with either a 2 barrel or 4 barrel carburetor attached to the intake manifold FUEL FILTER All engines have a pleated paper...

Page 752: ...uel pump are made with synthetic rubber hose attached with spring clamps FUEL CAP The fuel cap is a screw on type for all series except H Series and incorporates a ratchet action which prevents over t...

Page 753: ...NEAR CARBURETOR INSERT FUEL HOSE INTO A SUITABLE CONTAINER WlTH ENGINE IDLING A PINT MEASURE I FUEL FLOW 1 FUEL FLOW 0K LOW PROBLEM IS OTHER THAN FUEL PUMP CHECK ELECTRICAL OR CARBURETOR SECTION FOR D...

Page 754: ......

Page 755: ...SWITCH CONNECTOR IN TRUNK LEFT SIDE CONNECTOR IGNITION I N RUN NEAR WHEELHOUSE IN TRUNK TO TANK POSITION I 2 AND PROBE BOTH TERMINALS OF ELECTRIC FUEL FUSE IGNITION I I I I TEST LAMP ON TEST LAMP OFF...

Page 756: ...ON ENGINE STOPPED TEMPERATURE PRESSURE LAMP SHOULD BE ON TEMPERATURE PRESSURE TEMPERATURE PRESSURE LAMP OFF LAMP ON TO 12 VOLTS AND PROBE PURPLE SECTION FOR DlAGNOlS OF REPLACE OIL PRESSURE REPAIR OPE...

Page 757: ...E TEMPERATURE TEMPERATURE PRESSURE LAMP I GOES OUT STAYS ON I 1 F EhClhE IS NOT OVERHEATED REPLACE TEMPFRATURE SWITCH IF ENGINE OVER DIAGNOSIS I TEMPERATURE PRESSURE LAMP GOES OUT STAYS ON I I TEMPERA...

Page 758: ...ed by a mechanically operated accelerating system Fig 6C 12 to the primary stage of the carburetor The power enrichment system Figs 6C 13 and 14 consists of 1 a vacuum operated fuel enrichment valve 2...

Page 759: ...ions a small center section for gradual heating of the thermostatic coil and a large outer section for additional rapid heating of the thermostatic coil The ceramic resistor functions as follows AIR T...

Page 760: ...with a secondary vacuum break designed to pull the choke blade to a wider position after the engine has reached 105 F coolant temperature There are two modes of operation dependent upon initial engine...

Page 761: ...and High Altitude certified engines are equipped with a secondary vacuum break The secondary vacuum break diaphragm shaft will retract when the engine coolant temperature is above 115 F If the shaft...

Page 762: ...to vacuum hose schematic on vehicle emission control information label On Car Check 1 Allow engine to cool long enough for the engine coolant temperature to be below 105 F In warmer climates this may...

Page 763: ...CHOKE VALVE AND INSIDE AIR HORN WALL a REMOVE THREE SCREWS NOTE HOLD GAUGE VERTICAL A N D REMOVE CHOKE COlL ASSEMBLY M E PLACE CAM FOLLOWER BEND ROD COIL LEVER CLOCKWISE ON HIGHEST STEP TO ADJUST TO...

Page 764: ...TO SPECI FICATION sh cxF 1 WITH CURB IDLE SPEED CORRECT PLACE TRANSMISSION I N PARK OR NEUTRAL AND SET FAST IDLE 2 DISCONNECT AND PLUG OEGR PORT SCREW ON HIGH STEP OF FAST IDLE CAM FAST IDLE ADJUSTME...

Page 765: ...FROM BOTTOM OF AIR HORN TO TOP OF FLOAT SHOULD BE 1 k118 IFLOAT DROP SETTING TURN SCREW IN UNTIL I T TOUCHES SECONDARY THROTTLE LEVER 81THEN TURN SCREW A N ADDITIONAL 114 TURN TOUCH THROTTLE LEVER SE...

Page 766: ...n carburetor and tighten securely 6 Install fuel line and tighten connector to 300 inch pounds SOLENOID OR SOLENOID DASHPOT The solenoid or solenoid dashpot should be checked to assure that the soleno...

Page 767: ...horn is necessary Choke Bi Metal Coil L4 140 1 Remove choke water housing retaining screw washer housing and gasket 2 Remove three choke bi metal retaining screws retainer ring thermostat housing and...

Page 768: ...charge check and weight balls Throttle Lever Solenoid or Dashpot and Hot Idle Compensator Fig 6C 34 1 Remove two screws and remove solenoid or dashpot and bracket 2 Straighten lock washer and remove n...

Page 769: ...age for excessive wear binds or distortion 2 Inspect choke vacuum diaphragms for leaks 3 Clean or replace carburetor filter 4 Inspect inlet needle and seat assembly for sticking dirt etc 5 Examine fas...

Page 770: ...SPEED BLEED PRIMARY MAlN METERING JET SECONDARY Fig 6C 33 Carburetor Body ASSEMBLY When float has been assembled to air horn adjust float Refer to disassembly illustrations and reverse for float leve...

Page 771: ...he other in the bottom of the fuelbowl The 2GE carburetor for altitude option engineswill not use the power valve in the bottom of the float bowl A blank valve body will be used instead An electricall...

Page 772: ...roll over should occur Fuel for the pump system is obtained through a hole located in a raised cast in boss on the floor of the float bowl which prevents the entry of dirt into the accelerator pump p...

Page 773: ...resistor causes the section to heat up and warm the thermostatic coil which allows gradual opening of the choke valve for good cold engine warm up performance As the small section of the ceramic resi...

Page 774: ...cuum break assembly Electric Choke If the electric choke fails to open the following checks should be made 1 Check voltage at the choke heater connection with the engine running If voltage is between...

Page 775: ...assembled Check filter 1 Remove air cleaner and gasket 2 Disconnect fuel and vacuum lines from carburetor 3 Disconnect accelerator linkage and electrical connectors 4 Remove carburetor attaching bolts...

Page 776: ...ENT MAlN NOZZLE PART THROTTLE ADJUSTMENT SCREW THROlTLE MAIN WELL VALVE Fig 6C 44 Main Metering System 2GC MANIFOLD PIS CHI POWER RESTRICTIONS I RETURN SPRING y 1 INLET M A l N FUEL WELL VACUUM POWER...

Page 777: ...ly 6 Install fuel line and tighten connector Idle Stop Solenoid Assembly If Used CAUTI0N The electrically operated idle stop solenoidshould be removed from thefloat bowl for complete carburetor disass...

Page 778: ...rmostatic coil housing 9 Remove fast idle cam attaching screw from side of float bowl Fig 6C 58 Remove fast idle cam from end of choke rod by rotating rod out of hole in fast idle cam Remove choke rod...

Page 779: ...ree screws holding venturi cluster to float bowl and remove cluster and gasket Then remove the plastic main well inserts in the main well cavity 5 Using a pair of long nosed pliers remove pump dischar...

Page 780: ...being loaded compressed air Make sure all fuel passages and metering heavier than normal VISUALLY CHECK FOR FLOAT ALIGNMENT AIR HORN GASKET I FLOAT LEVEL ADJUSTMENT AIR HORN RIGHT SIDE UP TO ALLOW FLO...

Page 781: ...OT I N LEVER SEE INSET LOOSEN THREE RETAINING SCREWS NOTE TIGHTEN ON HIGHEST ST CHOKE COlL L INSET AUTOMATIC CHOKE COlL ADJUSTMENT BEND TANG TO ADJUST SEE INSET 2 or 3 CHOKE ROD FAST IDLE CAM ADJUSTME...

Page 782: ...REMOVE TAPE AFTER USE OUTSIDE VACUUM O U R C E ADJUSTMENT VACUUM BREAK ADJUSTMENT CHOKE SIDE 19 a G A u G E BETWEEN UPPER EDGE OF CHOKE VALVE AND WALL OF AIR H O R N u TO ADJUST HOLD THROTTLE VALVE WI...

Page 783: ...TO FULLY EXTEND TURN IDLE SPEED SCREW TO SET CURB IDLE SPEED TO SPECIFICATIONS AIC OFF THROTTLE SEE EMISSION LABEL OSOLENOID ENERGIZED AIC COMPRESSOR LEAD n COMPRESSOR AIT TRANSMI ELECTRICAL CONNECTI...

Page 784: ...ts improper seating of inlet or discharge balls and scores in pump well 4 Check pump linkage for excessive wear repair or replace as necessary 5 Check power valve in pump well for leakage and proper i...

Page 785: ...mostatic coil and cover assembly with new gasket where used and end of coil below plastic tang on the inner choke housing lever Refer to adjustment chart choke coil setting Install three choke thermos...

Page 786: ...justment chart 10 Install choke rod in upper choke lever and collar assembly rotating rod until tang on end of rod aligns with slot in lever Completion of Carburetor Assembly 1 Place the air horn asse...

Page 787: ...mechanical and vacuum enrichment more accurately controls fuel metering during light and heavy power requirements Carburetor Replacement 6C 40 Fuel Filter Replacement 6C 40 Carburetor Overhaul 6C 44...

Page 788: ...NLOADER TAN0 ADJUSTING FOLLOWER SCREW 3042 MAIN WELL AIR BtEEDS INTERNAL VENT FACTORY METER1 ADJUSTMENT SCR MAlN VENTURI R ENRICHMENT POWER PISTON M I N b THROTTLE VALVE ING VACUUM MAlN METERING METER...

Page 789: ...perating temperature choke full open and air conditioning OFF connect a tachometer to engine 2 Set parking brake and block drive wheels 3 Disconnect and plug hoses from vapor canister and EGR valve 4...

Page 790: ...ine without draining fuel from bowl Contents of fuel bowl may then be examined for contamination as carburetor is disassembled Check filter 1 Remove air cleaner and gasket 2 Disconnect fuel and vacuum...

Page 791: ...HOKE HOUSING CHOKE l A l I C A CLO 1 LOOSEN THREE RETAINING SCREWS AND 3 oREMOVE THE THERMOSTAT IC COVER AND COIL ASSEMBLY FROM CHOKE HOUSING CHOKE VALVE TO ADJUST PUSH UP ON THERMOSTATIC COIL TANG CO...

Page 792: ...ACE MAGNET SQUARELY ON TOP OF CHOKE VALVE 4 ROTATE BUBBLE UNTIL IT IS CENTERED FIGURE 2 5 ROTATE SCALE SO THAT DEGREE SPECIFIED FOR ADJUSTMENT IS OPPOSITE POINTER 6 SEAT CHOKE VACUUM DIAPHRAGM USING V...

Page 793: ...nut in carburetor and tighten securely 6 Install fuel line and tighten connector Solenoid Replacement The solenoid should be checked to assure that the solenoid plunger extends when the solenoid is e...

Page 794: ...iver and twisting rod counterclockwise 3 Remove vacuum hose from front vacuum break unit 4 With Tool 5 25322 drive roll pin pump lever pivot pin inward just until pump lever can be removed from air ho...

Page 795: ...from the well CAUTION TheA P 7 meteringrodadjustment screw is pre set at the factory and no attempt should be made to change this adjustment in service If float bowl replacement is required during se...

Page 796: ...5 To disassemble intermediate choke shaft from choke housing remove coil lever retaining screw at end of shaft inside the choke housing Then remove thermostatic coil lever from flats on intermediate c...

Page 797: ...all lower end of pump rod in throttle lever by aligning tang on rod with slot in lever End of rod should point outwards towards throttle lever Float Bowl NOTE If a new float bowl assembly is used stam...

Page 798: ...ment after adjustment 6 Install plastic filler block over float needle pressing downward until properly seated 7 Install power piston spring in power piston well If metering rods were removed from han...

Page 799: ...ump lever casting bosses 6 Connect choke rod into lower choke lever inside bowl cavity then install choke rod into slot in upper choke lever and retain the choke lever to the end of the choke shaft wi...

Page 800: ...t off fuel flow to the carburetor float bowl to prevent fuel leaks if a car roll over should occur Fig 6C 92 An electrical idle speed solenoid is used on air conditioned cars except 400 V8 with Manual...

Page 801: ...nnected and there are no signs of damage 2 If choke or linkage binds sticks or works sluggishly clean with United Delco Choke Cleaner X 20 A or equivalent Use cleaner as directed on can If cleaning do...

Page 802: ...Unplug and reconnect hose from vapor canister and EGR valve 11 Shut off engine and remove tachometer Carburetor Adjustments Refer to Figs 6C 102thru 106for carburetor adjustment procedures and specifi...

Page 803: ...resh air hose Removal 1 Remove air cleaner 2 Detach hose at modulator 3 Pry up tabs on modulator retaining clip remove clip and modulator from air cleaner Replace 1 Install modulator and gasket assemb...

Page 804: ...5 Install vacuum lines and loosely connect fuel line 6 Tighten four attaching bolts to 145 in lbs 7 Tighten fuel inlet nut to 300 inch pounds 8 Connect accelerator linkage and downshift controls if s...

Page 805: ...CHOKE VALVE BEND CHOKE ROD AT THIS POINT TO ADJUST ON THERMOSTATIC NG COUNTERCLOCKWISE HOKE VALVE IS CLOSED LOWER EDGE O F LEVER SHOULD JUST CONTACT SIDE OF PLUG INSERT SPEC1FlED GAUGE PLUG GAUGE CHO...

Page 806: ...COND STEPOF iTMENT CAM NEXT TO w HIGHSTEP CHOKE ROD FAST IDLE CAM ADJUSTMENT USE OUTSIDE AND END OF SLOT I N LEVER BLEED HOLE REMOVE ACTER ADJUSTMENT 1 AIR VALVE ROD ADJUSTMENT I CARB NO CARB NO 17057...

Page 807: ...HEST STEP OF CAM AUTOMATIC CHOKE COlL ADJUSTMENT IED CARB NO l7O5725O 253 255 256 258 262 263 266 274 502 504 550 653 582 584 CARB NO 17057250 253 255 256 258 262 263 266 274 502 504 550 553 582 584 C...

Page 808: ...1 SECONDARY LOCKOUT ADJUSTMENT SECONDARY LOCKOUT LEVER SECONDARY LOCKOUT SIDE CLEARANCE 110 2 OPENING CLEARANCE I WlDE O P E M A M FOLLOWER O F F STEPS O F FAST IDLE CAM CLEARANCE w I SECONDARY CLOSIN...

Page 809: ...ON Thesolenoid should not be immersed in any type of carburetor cleaner and should always be removed before complete carburetor overhaul Air Horn Removal See Figure CARB NO 17057250 253 255 256 258 26...

Page 810: ...use care to prevent bending the small tubes protruding from the air horn These tubes are permentntly pressed into the airhorn casting DO NOT REMOVE Fig 6C 110 Air Horn Screws Air Horn Disassembly Remo...

Page 811: ...rocedure may have to be repeated several times CAUTI 0N Do not removepo werpiston by using pliers on metering rod hanger 5 Remove the power piston spring from the well CAUTI0N TheA P 7 metering rod ad...

Page 812: ...coil assembly Then pull straight outward and remove cover and choke assembly from choke housing Remove choke cover gasket Do not remove baffle plate from beneath the thermostatic coil Distortion of t...

Page 813: ...TILE BC GASKCT WELLS Fig 6C 119 Throttle Body Gasket 1 Inspect pump plunger for cracks scores or excessive cup wear A used pump cup will shrink when dry Soak in fuel for 8 hrs before testing if dried...

Page 814: ...cavity on choke housing before assembling choke housing to bowl Install choke housing to bowl sliding intermediate choke shaft into lower choke lever Fig 6C 120 NOTE The intermediate choke shaft leve...

Page 815: ...the bleed tubes accelerating well tubes pull over enrichment tubes if used and pump plunger stem are positioned properly through the holes in the air horn gasket CAUTION Do not force the air horn ass...

Page 816: ...ever become plugged the engine will stop An engine stoppage caused by a plugged filter element will be preceeded by a hesitation or sluggish operation Fuel Pump Electric The pump operates under the f...

Page 817: ...using a dome type fuel tank on Sedans and Coupes 3 To protect the tank from mechanical damage in the event of excessive internal or external pressures resulting from the operation of this closed syste...

Page 818: ...l and lnstallation of Mechanical Fuel Pump Removal All Series 1 Disconnect negative battery cable 2 Disconnect fuel inlet hose from pump Disconnect vapor return hose if so equipped 3 Disconnect fuel o...

Page 819: ...ket into tank and install tank Connect tank unit wires and all fuel lines except pump to carburetor line see Removal of Tank for proper procedure 11 Connect a hose to fuel line at carburetor insert ot...

Page 820: ...eral and or California or other state or Provincial Fig 6C 126 Accelerator Controls F Series IOTE SLIP ACCELERATOR CONTROL CABLE THRU IOLE IN ROD INSTALL RETAINER BEING URE IT ISSEATED DASH TOE PANEL...

Page 821: ...spark timing follow instructions on Emission Control Information Label very carefully NOTE ROUTE CABLE OVER SPARK PLUG WIRES CAUTION FLEXIBLE COMPONENTS HOSES WIRES CONDUITS ETC MUST NOT BE ROUTED WI...

Page 822: ...le speed to specification shown on Emission Control Information Label Fig 6C 135 Accelerator Control Cable 151 Engine V I BOTH LOCKING LUGS MUST BE EXPANDED AND LOCKED IN HOLE CARB LEVER FIGURE I 468...

Page 823: ...LOW ALT 400 4 BBL LOW ALT 403 4 BBL LOW ALT 403 4 BBL HIGH ALT 403 4 BBL CALIF 8 EXCEPT F SERIES WITH W 72 F SERIES WlTH W 72 ENGINE CODE Y6 TRANS AUTO MAN AUTO MAN AUTO MAN AUTO MAN MAN AUTO AUTO MA...

Page 824: ...H Series Electric Fuel Tank Engine Code C 231 A X F B Series Mechanical Left Front of Engine Engine Code Y 301 All Mechanical Left Front of Engine Engine Code P Z 350 400 All Mechanical Left Front of...

Page 825: ...systems Figure 6D 2 and 6D 3 show the engine electrical diagnostic connector diagnostic procedures and the connector circuitry DIAGNOSIS All of the tests listed below in coniunction with the diagnost...

Page 826: ...6D 2 1977 PONTIAC SERVICE MANUAL...

Page 827: ...int Liquid Level Below Plates Fill battery to proper level charge the battery and recheck complaint POOR CRANKING OR SOLENOID CLICKS OR CHATTERS lgnition Switch in Start 2 Bat to Bat at battery 3 Bat...

Page 828: ...place generator belt if necessary Charge battery Run engine at 1 500 to 2 000 RPM for one minute with lights on high beam heater on high radio and defogger blower on 1 to G Under 12 5 volts Faulty gen...

Page 829: ...VOLTAGE FROM IF OK REPAIR ENGINE BLOCK TO BATT NEG POST KEY IN START POSITION POS LEAD ON L BLOCK I LIGHTS STAY BRIGHT I r TURN ON RADIO HE TER AND TURN SIGNALS I NEU ST SW NEU ST SW LESS THAN 5 VOLT...

Page 830: ...NKING VOLTAGE AT BATTERY TERMINAL POSTS I 9 6 VOLTS OR MORE w MEASURE VOLTAGE FROM BATTERY NEGATIVE TERMINAL TO ENGINE BLOCK POS LEAD ON BLOCK 5 VOLT OR MORE a REPAIR GROUND CABLE AND CONNECTIONS LESS...

Page 831: ...6D 7 Sealed Battery case partitions between cells The battery top is a one piece cover The cell connectors passing through the cell partitions connect the elements along the shortest practical path Th...

Page 832: ...el should never be allowed to drop below the level of the plates as permanent damage to the battery may result VALUE OF GRAVITY 80 F CARRIER AND HOLD DOWN FREEZING TEM The battery carrier and hold dow...

Page 833: ...racked or broken case or cover that could permit loss of electrolyte If obvious physical damage is noted replace the battery If not proceed to step 2 2 CHECK CHARGE OF BATTERY Sealed Battery a DARK GR...

Page 834: ...6D 10 may be needed When the maximum time in Figure 6D 13 is reached for charging the sealed battery charging should be stopped even if the green dot is not visible It should be noted that these time...

Page 835: ...h each other as this could cause a ground connection and counteract the benefits of this procedure 5 Attach one end of the remaining negative cable to the negative terminal of the booster battery and...

Page 836: ...TIAC SERVICE M A N U A L I A B G I F SERIES V 8 I RIGHT FRONT FENDER RIGHT FRONT FENDER 1 A SERIES V 6 RIGHT FRONT FENDER 6 SERIES V 6 RIGHT FRONT FENDER I X SERIES ALL ENGINES Id Fig 6D 15 Remove and...

Page 837: ...ator rotor bearings contain a supply of lubricant sufficiently adequate to eliminate the need for periodic lubrication Two brushes carry current through the two slip rings to the field coil mounted on...

Page 838: ...therwise proceed to one of the following three abnormal conditions 1 Switch Off Lamp On In this case disconnect the two leads from the generator No 1 and No 2 terminals If the lamp stays on there is a...

Page 839: ...beam a blower on hi speed Zero Voltage 6 Run engine as required to obtain maximum current output and record ammeter reading Check 10 amp Output NOT within 10 ampa of rated Check battery connections an...

Page 840: ...s 1 through 5 check satisfactorily check generator as follows a Disconnect battery ground cable b Connect an ammeter in the circuit at the BAT terminal of the generator c Reconnect battery ground cabl...

Page 841: ...ither end frame see Engine Cooling Section Remove From Car 1 Disconnect negative battery terminal at battery CAUTION Failure to observe this step may result in an injury from hot battery lead at gener...

Page 842: ...ntry of dirt and other foreign material and also place a piece of tape over the shaft on the slip ring end If brushes are to be reused clean with a soft dry cloth CAUTI0N Use pressure sensitive tape a...

Page 843: ...ew and removing the stator assembly Note that the insulating washer on the screw is assembled over the top of the diode trio connector Connect an ohmmeter having a 1 1 2 volt cell and using the lowest...

Page 844: ...nerator fails to supply rated output shorted stator windings or an open delta winding on 27 SI Series are indicated Also a shorted stator can cause the indicator lamp to be on with the engine at low s...

Page 845: ...ory cable into the accessory socket on the Tester front panel Fig 6D 22R H Series With 140 L 4 Power Steering 4 Disconnect the regulator connector from the generator Then plug the on car testing acces...

Page 846: ...lishing cloth against the slip rings until they are clean CAUTION The rotor must be rotated in order that the sf rings will be cleaned evenly Cleaning the slip rings by hand without spinning the rotor...

Page 847: ...cessively worn Fill the cavity between the retainer plate and bearing with 1948791 lubricant 1 CHECK FOR OPEMI OHMMETER OHMMETER CHECK FOR OPENS CHECK FOR GROUNDS 1444 Fig 60 28Checking Stator Fig 6F2...

Page 848: ...bly Remember when assembling the pulley to secure the rotor in a vise only light enough to permit tightening the shaft nut to 50 lb ft If excessive pressure is applied against the rotor the assembly m...

Page 849: ...the distributor contains a permanent magnet a pole piece with internal teeth and a pick up coil When the teeth of the timer core rotating inside the pole piece line up with the teeth of the pole piece...

Page 850: ...signed for this purpose SPARK PLUGS R44TSX R45TSX and R46TSX resistor type tapered seat plugs with long reach are used in V8 engines except VI Code R and K and in the 151L 4 see Fig 6D 35 The R43TS an...

Page 851: ...ctuator rod assembly to close the ignition primary circuit and to energize the starting motor solenoid for cranking The ignition switch used on all cars has five positions Two O F F positions OFF and...

Page 852: ...1 ACC IGN 1 RUN GRD 2 0 0 GRD 1 ION KEY AND LOCK IGN 1 ACC OFF 1 w 0GRD 2 BAT 1 0GRD 1 h I me ACC ACCESSORY GRD 2 I U GRD 1 Fig 6D 36 Ignition Switch I SOL I I I NOTE ALL ABOVE IGNITION SWITCH AND KEY...

Page 853: ...are equipped with a spark retard delay orifice to maintain vacuum advance during quick throttle openings when the engine coolant temperature is below approximately 120 F This feature improves engine...

Page 854: ...8 350 403 VIN CODES R K DS TVS 220 F MANIFOLD VACUUM SOURCE PORT OUTPUT PORT TO DS VDV CLOSED BELOW CALIBR OUTPUT PORT TO SVB CLOSED BELOW CA USAGE AND CALIBRATION VALUE L4 140 SVBIDS TVS 105 F VACUUM...

Page 855: ...ntrifugsl advance on engine B 6 Check secondary wiring 8 7 Twist boots to loosen remove all spark plug and check for proper gap fouling cracked insulators etc I B 8 If no defects are found follow proc...

Page 856: ...e is usually just below the crimped part of shell and may not be visible OHMMETER OHMMETER I Fig 6D 4 1 Checking Pick Up Coil VACUUM UNIT ATTACHING SCREWS A THIN C rHER PICKUP SCREW MODULE CONNECTOR d...

Page 857: ...If the engine was accidentally cranked after the distributor was removed the following procedure can be used for installing a Remove No 1 spark plug b Place finger over No 1 spark plug hole and crank...

Page 858: ...e isabove 115 F Turn ignition off and observevacuum reading Vacuum should drop immediately If vacuum does not drop immediately either the vacuum hoses between the DS TVS and VDV are plugged or the DS...

Page 859: ...on switch 9 If Steps 6 and 7 above check out correctly and there is still no vacuum present as required in Step 4 above replace TCS solenoid V8 301 Engine With Automatic Transmission And Air Condition...

Page 860: ...vacuum Observe vacuum reading for 20 seconds If vacuum drops more than one inch replace vacuum unit 2 Start engine and note idle RPM Re connect vacuum hose at distributor and note increase in idle RP...

Page 861: ...Heat TVS to a temperature above the calibration temperature Never apply a torch or open flame directly to the TVS 5 Compare vacuum gage reading to the correct reading indicated in Fig 6D 37 IGNITION S...

Page 862: ...6D 38 1977 PONTIAC SERVICE MANUAL I CABLE 3 CALLE EXISTING BRACKET 3637 Fig 6D 43 Spark Plug Wire Routing...

Page 863: ...ENGINE ELECTRICAL 6D 39 DISTRIBUTOR DISTRIBUTOR Fig 6D 44 Spark Plug Wire Routing Fig 6D 45 Spark Plug Wire Routing VIN Code U and L V8 s...

Page 864: ...itions and splash A typical motor is shown in Figure 6D 47 In the basic circuit shown in Figure 6D 46 the solenoid windings are energized when the switch is closed The resulting plunger and shift leve...

Page 865: ...e cranking motor A general diagnosis is covered in Figure 6D 3 and 6D 4 Once a problem has been traced to the starter proceed to the test procedure below Test Procedure With the cranking motor removed...

Page 866: ...ature coils Inspect the commutator for badly burned bars after disassembly c Broken brush springs worn brushes high insulation between the commutator bars or other causes which would prevent good cont...

Page 867: ...ore removing the armature assembly 5 Remove the thrust collar from the armature shaft 6 Remove the pinion from the armature by sliding a metal cylinder onto the shaft with a hammer striking the metal...

Page 868: ...ns A high reading indicates a shorted or grounded hold in winding and a low reading excessive resistance To check the pull in winding connect from the solenoid switch terminal and to the solenoid moto...

Page 869: ...ng down into the groove V O L T M E T E R BATTERY u Fig 6D 54 Connections For Checking Solenoid d Remove the washer e Assemble collar over shaft 2 Refer to the disassembly procedure and follow in reve...

Page 870: ...or field coil connector from the solenoid motor terminal and INSULATE IT CAREFULLY BATTERY SOLENOID Fig 6D 57 Circuit For Checking Pinion Clearance 4 Push the in ion back towards the commutator end to...

Page 871: ...LL STD STD H D A F G X SERIES 301 305 350 400 403 ALL V 8 COLD CRANK BATTERY IINDICATED 1 BY Xu STD STD H D B SERIES 301 350 400 403 ALL V 8 STD STD H D FIG 6D 59 BATTERY APPLICATIONS AND SPECIFICATIO...

Page 872: ...Y 305 V 8 U X u ONLY 61 61 55 55 350 V 8 P 400 V 8 2 1 FIG 6D 60 GENERATOR APPLICATIONS 63 63 63 55 CAL 63 OTHER ENGINE ICAR LINE STARTER 1108771 MANUAL 1108772 AUTO FIG 6D 6 1 STARTER MOTOR APPLICATI...

Page 873: ...ol EEC The emission control system for some engines may use an additional emission control device called Air Injection Reaction AIR GENERAL DESCRIPTION EMISSION CONTROL COMPONENTS CARBURETOR CALIBRATI...

Page 874: ...f crankcase vapors See Figure 6E 2 To maintain idle quality a PCV valve is used which restricts the ventilation system flow whenever intake manifold vacuum is high See Figure 6E 3 Diagnosis and servic...

Page 875: ...um differential valve as described above The differential vacuum delay and separator valve delays the air bypassing function during heavy accelerations This delay allows air to be injected during acce...

Page 876: ...ffectiveness while minimizing any negative effect on driveability The types of vacuum control valves used are Thermal Vacuum Switches W S Vacuum Delay Valves VDV Check Valves CV Vacuum Modulator Valve...

Page 877: ...I EMISSION CONTROL SYSTEMS 6E 5 Fig 6E 6 L 140 C I D Nationwide Fig 6E 7 L4 151 C I D California Automatic Transmission Without Air Conditioning...

Page 878: ...ISSION CANISTER Fig 6E 8 L4 15 1 C I D California Automatic Transmission With Air Conditioning 2 BBL CARBURETOR 0 IL c Z E N k s 0 VACUUM CODE 7 MANIFOLD m PORTED SPARK RETARD DELAY VIOLET 1 EVAPORATI...

Page 879: ...DE DISTRIBUTOR M MONIFOLD P PORTED EFE VALVE Fig 6E 10 L4 15 1 C I D Low Altitude Automatic Transmission With Air Conditioning TO AIR CLEANER PCV VALVE I BP EGR VALVE MANIFOLD VACUUM PORTED VACUUM 340...

Page 880: ...R CLEANER PCV VALVE BP EGR VALVE VALVE MANIFOLD VACUUM PORTED VACUUM Fig 6E 12 V6 23 1 C I D High Altitude DVDV PCV VALVE BP EGR VAL DlSTRlBUTO EFE VALVE MANIFOLD VACUUM PORTED VACUUM 3403 Fig 6E 13 V...

Page 881: ...LVE BP EGR VALVE EFE CV ISTRIBUTOR EFEIEGR MANIFOLD VACUUM TO FUEL TANK PORTED VACUUM CH RCOAL CANISTER Fig 6E 14 V6 23 1 C I D California Automatic Transmission VIOLET EFE TVS VACUUM CODE MANIFOLD T...

Page 882: ...ANIFOLD VACUUM PORTED VACUUM Fig 6E 16 V8 301 C I D Low Altitude Automatic Transmission Without Air Conditioning OPT VALVE DESIGN 2 EEL CARE M MANIFOLD VACUUM EFE VALVE SEZZ P PORTED VACUUM 3185 Fig 6...

Page 883: ...PTIONAL DELAY OR1FICE VACUUM CODE MAN1FOLD 5 PORTED Fig 6E 18 V8 350 and 400 C I D VIN Codes P and 2 Low Altitude Automatic Transmission EGR fVIOLET BACKPRESSURE iFE EGR TVS GREEN l II VACUUM CODE M A...

Page 884: ...ICE MANUAL MANIFOLD VACUUM PORTED VACUUM Fig 6E 20 V8 350 and 403 C I D VIN Codes R and K Low Altitude PVC FILTER 7 BP EGR TO TRANS NOT USED PORTED VACUUM 3265 Fig 6E 21 V8 350 and 403 C I D VIN Codes...

Page 885: ...EMISSION CONTROL SYSTEMS 6E 13 MANIFOLD VACUUM m m m s m PORTED VACUUM Fig 6E 22 V8 350 and 403 C I D VIN Codes R and K California...

Page 886: ...e a If valve does not close the valve could be seized Lubricate with manifold heat valve lubricant part number 1050422 or equivalent or replace as required b If valve closes the problem is not the EFE...

Page 887: ...pintle movement Valve is satisfactory if it takes over 20 seconds for the pintle to seat or for the diaphragm to achieve full travel Valve unsatisfactory and must be replaced if it takes less than 20...

Page 888: ...leaning POSITIVE CRANKCASE VENTILATION SYSTEM FUNCTIONAL TEST OF PCV SYSTEM 1 Remove PCV valve from intake manifold or rocker arm cover 2 Run the engine at idle 3 Place your thumb over end of valve to...

Page 889: ...rmometer as close as possible to the sensor Let air cleaner cool until thermometer reads below 79 F 26 C about 5 to 10minutes Reinstall air cleaner on engine and continue to step 2 below 2 Start and i...

Page 890: ...C check the position of the snorkel valve The cold air intake should be completely closed off 2 Start the engine and allow to warm up At approximately 50 F 10 C the thermostatic coil will begin to ope...

Page 891: ...nd adjust if below 70 lbs using a belt tension gage Adjustment Loosen pump mounting bolt and pump adjustment bracket bolt Move pump until belt is properly tensioned then tighten adjustment bracket bol...

Page 892: ...which does not function this way Replace Disconnect pump outlet hose at check valve Remove check valve from pipe assembly being careful not to bend or twist the assembly DIVERTER VALVE AND SILENCER A...

Page 893: ...I R injection pump for proper mounting and bolt torque 7 Repair irregularities in these components asnecessary 8 If no irregularities exist and the air injection pump noise is still excessive replace...

Page 894: ...N A 7 M X 2 U 527203121 CVB VDV DS VDV F N I l I 4NR EFE EGR TVS FPl2l DS TVS TAC PCV EEC 5272Wl11 EFE EGR OC 7044379 N A 720X2U 527202121 CVB VDV DS VDV F L I l l 4NR EFEIEGR TVS FMiZI ZJ ZH ENG FRI...

Page 895: ...EMISSION CONTROL SYSTEMS 6E 23...

Page 896: ...Some muffler installations have a slot in the inlet and or outlet pipe which indexes to a key tab welded on the exhaust and or tail pipe to help maintain alignment RESONATOR A resonator is used on so...

Page 897: ...in each hose If the car has dual tailpipes attach the aspirator to one pipe and place a plug in the other pipe 1 Install aspirator Fig 6F 2 Fig 6F 4 Chisel Pressed Plug NOTE Do not pry fill plug from...

Page 898: ...ft Ibs If built with a pressed plug install service fill plug Fig 6F 9 as follows Install the bolt into the bridge and position the bridge into the converter opening Move bolt and bridge back and for...

Page 899: ...bottom outside edge Fig 6F 13 Do not remove the fill plug The depth of the cut must be very shallow to prevent damage to the inner shell of the converter Fig 6F 10 Bridge Positioning Fig 6F 1 1 Servic...

Page 900: ...ach 2 clamps over retaining channels at each end of the converter Fig 6F 16 Fig 6F 13 Bottom Cover Removal cover after the insulation is in position Apply extra sealer at the front and rear opening fo...

Page 901: ...equired The compound planetary gear set produces three forward speeds and reverse The 3 element torque converter consists of a pump or driving member a turbine or driven member and a stator assembly T...

Page 902: ...run without driving the vehicle D DRIVE range is used for all normal driving conditions and maximum economy Drive range has three gear ratios from the starting ratio to direct drive Detent downshifts...

Page 903: ...R W E INTERMEDIATE FORWARD LO AND REVERSE DIRECT ROLLER CONTROL VALVE COMPOUND PLANETARY ASSEMBLY GEAR SET...

Page 904: ...lever through each range 3 Immediately check fluid with the selector lever in PARK engine running at SLOW IDLE and the car on a LEVEL surface The fluid level on the dip stick should be at the FULL HO...

Page 905: ...cluding converter proceed as follows 1 Add 4 2 litres 4 5 quarts of transmission fluid through filler tube 2 With manual control lever in park P position start engine and place on cold idle cam DO NOT...

Page 906: ...nstructions of the manufacturer mix a sufficient amount of epoxy No 1360016 or equivalent to make repair Observe cautions of manufacturer in handling 5 While the transmission case is still HOT apply t...

Page 907: ...3 firmly against the converter hub the reading obtained on the dian indicator will be the converter end clearance End should be less than 0 1 27 mm 0 050M If the end clearance is greater the converter...

Page 908: ...es can be checked by viewing them when looking into the converter neck or feeling through the opening to make sure they are not cracked broken or mispositioned The stator roller clutch can be checked...

Page 909: ...TURBO HYDRA MATIC 200 7A1 9 Fig 7A1 7 Retaining Converter With Tool J 2 1366...

Page 910: ...OMETER TO ENGINE I 1 CHECK OIL PRESSURES IN THE FOLLOWING MANNER I I 1 CAUTION TOTAL RUNNING I TIME FOR THIS COMBINATION I NOT TO EXCEED 2 MINUTES I I WARNING BRAKES MUST BE APPLIED AT ALL TIMES 1 RAN...

Page 911: ...TURBO HYDRA MATIC 200 7A1 11 Fig 7A1 8A Oil Flow Chart...

Page 912: ...bore D Control Valve Asm 1 Manual valve disconnected from inside detent lever pin 2 Control valve assembly gasket mis positioned E Forward Clutch 1 Forward clutch does not apply piston cracked seals m...

Page 913: ...ng 1 Valve binding 2 Wrong spring Check pres sure regulator bore plug leaking F Control Valve Asm 1 Throttle valve or throttle valve plunger binding 2 Shift T V valve binding 3 Intermediate boost valv...

Page 914: ...tle valve and throttle valve plunger binding E Case Assembly 1 Porosity FIRST SPEED ONLY NO 1 2 UPSHIFT A Throttle valve cable 1 Misadjusted 2 Binding disconnected or broken 3 Wrong T V cable B Govern...

Page 915: ...lugged Drive to Governor orifice in spacer plate G Case 1 Porosity in case channels or undrilled 2nd speed feed holes 2 Excessive leakage between case bore and intermediate band apply pin 3 Intermedia...

Page 916: ...or leaking 2 Check ball missing or mislocated 3 Pump to case gasket off location 4 Rear oil seal ring on pump cover leaking or missing 5 Cup plug missing H Direct Clutch 1 Oil seals missing or damage...

Page 917: ...Lo overrun clutch valve binding Line presure readings will be normal E Valve body spacer plate and gaskets 1 Orifices plugged 2 Control valve assembly gaskets in reverse order F Case Assembly 1 Lo and...

Page 918: ...or missing and spring 2 Leak between piston and pin in control valve assembly 3 Spring broken or missing F Case 1 Porosity in 2nd clutch passages G Pump Assembly 1 Forward clutch feed hole in the pum...

Page 919: ...om case in the intermediate servo bore area G Pump Assembly 1 Pump to case gasket mis positioned or damaged 2 Pump channels cross feeding leaking or restricted 3 Pump cover oil seal rings damaged or m...

Page 920: ...RES B Lo and reverse Clutch NOTE No reverse should also Assembly be a complaint with any of the 3 following conditions 1 Piston seals broken or missing 2 Porosity in piston or housing 3 Clutch housing...

Page 921: ...mp Assembly 1 Pressure regulator valve binding or stuck F Control Valve Asm 1 T V exhaust valve lifter binding unhooked or missing 2 1 2 or 2 3 valves sticky 3 Throttle valve plunger binding 4 Throttl...

Page 922: ...ston damaged stuck or missing b Check ball in clutch housing damaged stuck or missing c Clutch piston damaged seals damaged missing or rolled over d Low line pressure e Pump cover oil seal rings cut m...

Page 923: ...negative battery cable and remove the air cleaner 2 Raise car on hoist and remove the exhaust to converter bolts Let the catalytic converter and exhaust pipe hang down 3 Place jack stand under transmi...

Page 924: ...l result Refer to Refilling of Transmission portion of this section for correct fluid level REAR HOUSING OIL SEAL Removal 1 Remove propeller shaft 2 Pry out lip oil seal with screwdriver or small chis...

Page 925: ...nsmission tailshaft while observing transmission mount If rubber separates from metal plate of mount or if tailshaft moves up but not down mount bottomed out replace mount If there is relative movemen...

Page 926: ...g the threads 5 If tapped threads in aluminum parts are stripped or damaged the part can be made serviceableby the use of Heli Coils or equivalent 6 Seal protecting tools must be used when assembling...

Page 927: ...CAR FROM ROLLING 2 Bearing and thrust surfaces of all parts should be checked for excessive wear and scoring 3 Check for broken seal rings damaged ring lands and damaged threads 4 Inspect seals and 0...

Page 928: ...7Al 28 1977 PONTIAC SERVICE MANUAL SWIVEL CLAMP SLEEVE STEERING COLUMN CONTROL ROD 1 27 N m 20 LB FT 27 N m 20 LB FT L 6 1 A CHASSIS LUBRICANT J Fig 7A1 15 Column Shift Controls B Series Shown...

Page 929: ...TURBO HYDRA MATIC 2 0 0 7A1 29 TRANS CO LEVER SHIFTER ASSEMBLY MUST BE INSERTED INTO SLOT OF SELECTOR LEVER PRIOR TO TORQUING NUT Fig 7A1 16 Console Shift Controls H Series Shown...

Page 930: ...taining filler tube to engine Fig 7A1 14 and remove tube from transmission case 3 Hoist car 4 Remove retaining bolt for T V cable Figs 7A1 12 or 14 Remove T V cable from link Plug hole 5 Disconnect tr...

Page 931: ...onverter assembly by pulling straight out 2 Installing Holding Fixture J 8763 02 on transmission and place into Holding Fixture J 3289 20 with manual shaft facing bench and oil pan side up Fig 7A1 18...

Page 932: ...anual valve d Holding manual valve with finger remove control valve assembly spacer plate and gaskets together to prevent the dropping of 4 check balls located in the control valve assembly Fig 7A1 23...

Page 933: ...7 Removing Governor Cover Fig 7A1 28 Removing Intermediate Servo Retaining Ring Fig 7A1 25 Removing 5th Check Ball c Remove intermediate servo is ton and band amlv Fig 7A1 30 NOTE If intermediate serv...

Page 934: ...dial indicator J 8001 and position dial indicator point on top of J 25014 2 zero post and set dial indicator to zero NOTE Seat J 25014 2 squarely against the servo retaining snap ring d Align stepped...

Page 935: ...n pump side up c Remove pump to case bolt and washer and install 278mm 1 1 long bolt and locking nut as shown Fig 7A1 37 d Push turbine shaft downward e Install J 25022 on J 24773 tool and secure on e...

Page 936: ...hor pin Fig 7A1 42 I Fig 7Al 38 Removing Pump Seal b Remove remaining pump to case bolts and washers discard washers c Using J 24773 tool remove pump assembly pump to case gasket Fig 7A1 39 3 Forward...

Page 937: ...g lntermediate Band Anchor Pin d Move output shaft upward by turning adiustinn screw on J 25013 5 until the whit or scribed line on sieeve i25013 begins to disappear then read end play should be 0 10...

Page 938: ...gear rear selective washer and tanged thrust washer b Remove rear selective washer and thrust washer from front internal gear 5 Remove front carrier assembly and the front internal gear to front carri...

Page 939: ...1 NOTE The flat side of the ring should have been against the low and reverse clutch housing with beveled side up c Using J 25013 remove low and reverse clutch housing assembly by moving J 25012 back...

Page 940: ...n to vertical position with rear end up 7 If necessary remove real oil seal Fig 7A1 57 OUTPUT WAFT 1502 Fig 7A1 56 Removing Rear internal Gear 1 REAR 01L SEAL Fig 7A1 57 Removing Rear Oil Seal MANUAL...

Page 941: ...h a hex head plug or a pressure switch in it near the intermediate servo bore Do remove the switch or plug unless replacement is required IOENTlFlCATlON PIN GROOVE Fig 7A1 60 Removing Manual Shaft Fro...

Page 942: ...ion to vertical position rear end up 9 Inspect cooler line connectors for damage Do not remove unless replacing 10 Inspect case bushing for damage or scoring 11 If removed install a new oil seal using...

Page 943: ...g 7A 1 72 7 Install parking pawl shaft retaining pin 8 While holding the parking pawl toward center of transmission install parking brake bracket Torque bolts to 20 0 27 0 N m 15 20 lb ft 9 Install pa...

Page 944: ...dometer drive gear roceed as follows a Depress speedometer drive gear clip b Remove gear and clip tapping gear lightly with plastic hammer NOTE Make sure speedometer drive gear is located so speedomet...

Page 945: ...ar Carrier Assembly NOTE Models CN CU and CZ use a rear carrier with 2 pinions All other models use 4 pinions SPEEDOMETER DRIVE GEAR CLIP SPEEDOMETER I SNAP RING DRIVE GEAR I Fig 7 A l 7 5 Output Shaf...

Page 946: ...he energizing spring with forefinger and inserting roller from outer edge Fig 7A1 82 3 Install roller clutch assembly into roller clutch cam Fig 7A1 83 4 Install roller clutch race spline side out and...

Page 947: ...If drive gear is not visible it may be located on wrong journal of shaft Fig 7A1 87 lnstalling Tools On Rear End of Case p p Fig 7A1 88 Installing Rear Unit Parts LOW AND REVERSE CLUTCH Inspection CAU...

Page 948: ...Snap Ring Fig 7A1 91 Removing Wave Release Spring CLUTCH PISTON CLUTCH OUTER SEAL LIP UP 1538 Fig 7A1 92 Removing or Installing Clutch Outer Seal LIP up 1537 Fig 7A1 93 Removing or Installing Clutch...

Page 949: ...waved release spring Fig 7A 1 95 7 Install retainer cupped faced down Fig 7A1 96 8 Comress retainer and install snap ring 9 Check low and reverse clutch piston travel as follows a Center the low and...

Page 950: ...and rear sun gear NOTE It may be necessary to loosen adjusting screw on J 25013 5 on output shaft to install snap ring e Repeat the above steps if low and reverse clutch housing is not fully seated pa...

Page 951: ...844 16 99mm 669 1 3 Check pinion end play Pinion end play should be 0 24mm 0 69mm 0 009 0 027 Fig 7A1 108 NO NO WIDTH 1 1 12 50mm 492 4 Thoroughly clean air dry and inspect closely front carrier to f...

Page 952: ...e thrust washermust be installed with the identificationnumber toward the fiont of the transmission 2 Install rear selective washer Fig 7A1 105 Front Sun Gear Identification Fig 7A1 106 Installing Fro...

Page 953: ...sition extension against end of output shaft Set dial indicator to zero 4 Move output shaft upward by turning the adjusting screw on J 25013 5 until the white or scribed line on sleeve J 25013 1 begin...

Page 954: ...7A1 115 1 Remove snap ring Fig 7A1 7 116 2 Remove the clutch backing plate from the direct clutch housing 3 Remove the clutch plates from the direct clutch housing and keep them separated from the fo...

Page 955: ...s 7A1 118 and 119 CLUTCH CLUTCH OUTER SEAL PISTON LIP UP 1552 g 7A1 1 18 Removing or Installing Direct Clutch Piston Outer Seal 14 Do not remove the clutch apply ring from the piston unless the piston...

Page 956: ...prings All other models use a retainer and spring assembly with 10 release springs 9 Using J 23327 tool compress retainer and spring assembly past the snap ring groove Install the snap ring Fig 7Al 12...

Page 957: ...ntified by number 0 Models BH BL BU BZ CD CE CK CO CR CY OS OW OZ and PZ identified by number 8 18 Inspect forward clutch housing for cracks opened oil passeges or other damage Fig 7A1 133 19 Check fo...

Page 958: ...in their groove see Fig 7A1 139 for correct way to position cut ends Retain rings in place with petrolatum Forward and Direct Clutch Installation 1 Position direct clutch assembly clutch plate end up...

Page 959: ...128 Removing Forward Clutch to Direct Clutch Thrust Washer Fig 7A1 130 Removing Forward Clutch Release Spring Snap Ring SNAP RING CLUTCH BACKING PLATE Fig 7A1 129 Removing Snap Ring From Forward Clut...

Page 960: ...for nicks or damage 5 Inspect spring and guide for damage or distortion 6 Inspect pressure regulator valve for free operation in bore Fig 7A 1 135 lnstalling Forward Clutch Release Spring Snap Ring Fi...

Page 961: ...The drive gear has 1 identification mark on each drive tang Fig 7A1 148 This side should be facing away from the pump body gear pocket 4 Inspect drive and driven gear pocket and crescent for scoring...

Page 962: ...of pump body Fig 7A1 152 See Fig 7A 1 149 for identification Fig 7A 1 147 Removing Pressure Regulator Valve Retaining Ring Fig 7A1 144 Installing Intermediate Band PUMP PUMP COVER CHEC BALL W PRESSUR...

Page 963: ...using a 7 14mm 9 32 below top of hole using a 7 14mm 9 32 diameter rod on the tow smaller plugs and a 7 92mm 5 16 diameter rod on the four larger plugs Stake top hole two places directly opposite each...

Page 964: ...driver and install retaining ring Fig 7A1 158 8 If removed install 3 new oil seal rings make sure cut ends are assembled in the same relationship as cut Fig 7A1 159 Also make sure rings are seated in...

Page 965: ...7 0 N m 15 20 lb ft NOTE Make sure turbine shaft rotates freely Fig 7A1 161 Guide Pins Installed Thru Pump to Case Check Front Unit End Play Fig 7A1 162 Fig 7A1 162 Checking Front Unit End Play 1 Inst...

Page 966: ...ONT UNIT END PLAY WASHER THICKNESS CHART THICKNESS IDENTIFICATION Number and or Color 1 2 3 Black 4 Light Green 5 Scarlet 6 Purple 7 Cocoa Brown 8 Orange 9 Yellow 10 Light Blue 11 12 13 Pink 14 Green...

Page 967: ...ainst the band apply lug Also make sure the band anchorpin isproperly located in the case and band anchor lug c Install dial indicator J 8001 and position dial indicator point on top of J 25014 2 zero...

Page 968: ...rmediate servo piston 8630083 at start of production will be identified by the part number 8628111 cast on the piston with the letter A stamped on it OS and PZ models prior to transmission serial numb...

Page 969: ...rmediate servo piston s 1585 Fig 7A1 169 Compressing Intermediate Servo Piston Reassembly 1 Install washer on snap ring end of band apply pin Fig 7A1 166 2 Install servo spring on washer 3 Install ban...

Page 970: ...valve train in the order that it is removed and in a separate location relative to its position in the valve body None of the valves bushings or springs are interchangeable some coiled pins are interc...

Page 971: ...NG DlRECT CLUTCH EXHAUST VALVE REVERSE BOOST VALVE REVERSE BOOST SPRING REVERSE BOOST BORE PLUG RETAINING COILED PIN RETAINING COILED PIN 1 2ACCUMULATOR BORE PLUG 1 2 ACCUMULATOR VALVE 1 2ACCUMULATOR...

Page 972: ...coiled pin Fig 7A1 177 Remove the throttle valve NOTE The detent pin is used only on BR CN CU CX and CZ models All other models do not use a detent pin 10 From upper left bore remove coiled pin inter...

Page 973: ...TION I Fig 7A1 178 Installing 1 2 Throttle Valve B ishing 10 In next bore up install 2 3 shift valve longer stem end out making sure valve isseated at the bottom of the bore Install 2 3 throttle valve...

Page 974: ...ing for damage or cuts 3 If damaged remove and discard 0 ring Reassembly 1 If removed install new 0 ring on housing 2 Install speedometer driven gear into housing 3 Install speedometer driven gear ass...

Page 975: ...er 8628925 or equivalent into place until tool bottoms Fig 7A1 202 Rear Sun Gear a Using tool J 25019 14 with Slide Hammer J 7004 1 remove bushing Fig 7A 1 203 b Place rear sun gear with gear side dow...

Page 976: ...ng tool J 25019 7 with Driver Handle J 8092 driver or pfess new bushing part number 8628947 or equivalent into place until tool bottoms Fig 7Al 208 Case Bushing a Using tool J 21424 9 with driver Hand...

Page 977: ...y rig 7A1 188 Install Throttle Lever and r c k e t ssembly TV EXHAUST VALVE LIFTER SPRING TO CABLE I VALVE LIFTER LINK Fig 7A1 187 Throttle Lever and Bracket Assembly OIL SCREEN I Fig 7A1 189 Installi...

Page 978: ...SERVICE MANUAL PUMP COVER Fig 7A1 19 1 Removing Pump Cover Bushing Front Fig 7A1 193 Removing Pump Cover Bushing Rear Fig 7A1 192 Installing Pump Cover Bushing Front Fig 7A1 194 Installing Pump Cover...

Page 979: ...Fig 7A1 197 Removing Direct Clutch Housing Bushing Front Fig 7A1 200 Installing Direct Clutch Housing Bushing Rear Fig 7A1 196 Installing Pump Body Bushing 3608 Fig 7A1 198 Installing Direct Clutch Ho...

Page 980: ...ing REAR SUN GEAR Fig 7A1 204 Installing Rear Sun Gear Bushing ERSE 3616 Fig 7A1 202 Installing Front Internal Gear Bushing Fig 7A1 203 Removing Rear Sun Gear Bushing LO REVERSE Fig 7A1 205 Removing L...

Page 981: ...ach code is BH 231 cu in 2 bbl engine except California HM Series BL 231 cu in 2 bbl engine California only X Series BU 231 cu in 2 bbl engine California only HM Series BZ 231 cu in 2 bbl engine excep...

Page 982: ...m 20 25 flb ft 20 0 27 0 N m 15 20 Ib ft 7 0 14 0 N m 5 10 Ib ft 13 0 17 0N m 9 12 lb ft 13 0 17 0N m 9 12 Ib ft 13 0 17 0N m 9 12 Ib ft 8 0 14 0 N m 6 10 lb ft NOTE All critical torque specification...

Page 983: ...83 Rear Seal Installer 1 Dial Indicator Set 1 Plunger Extension 1 Transmission Holding Fixture 1 Transmission Holding Fixture Base 1 Converter Holding Tool 1 Servo Piston Spring Compressor 1 Forward C...

Page 984: ...and impede its pumping action So at low turbine speeds fluid is redirected by stator to converter pump in such a manner that it actually assists converter pump to deliver power or multiply engine tor...

Page 985: ...FLUID LEAK DIAGNOSIS Determining Source of Fluid Leak Before attempting to correct a fluid leak the acutal source of leak must be determined In many cases source of leak can be deceiving due to wind...

Page 986: ...ncheshg absolute mainfold pressure transmission oil pressure gage attached and vacuum modulator tube connected the transmission line should read 55 psi Drive 82 psi L1 L2 88 psi Rev Fig 7A2 3 CASE POR...

Page 987: ...color smear is indicated plate should be reused If severe heat spot discoloration or surface scuffing is indicated plate must be replaced 3 Clutch Release Springs Evidence of extreme heat or burning...

Page 988: ...tion The 2 1 downshift at closed throttle will be accompanied by increased engine RPM and an engine braking effect should be noticed Line pressure should be approximately 80 PSI Stop vehicle Reverse R...

Page 989: ...7A2 6 1977 PONTIAC SERVICE MANUAL Fig 7A2 5 Diagnosis Chart...

Page 990: ...hub direct clutch oil seal rings broken or missing b Clutch piston seals missing improperly assembled or cut c Clutch plates burned see BURNED CLUTCH PLATES above No First Speed Starts in Second Spee...

Page 991: ...tor pipe b Check vacuum line connections at engine and transmission c Vacuum modulator assembly and valve and pressure regulator valve train Governor a Valve sticking b Feed holes restricted or leakin...

Page 992: ...ion Pump Assembly a Gears damaged b Driving gear assembled backwards c Crescent interference d Oil seal rings damaged or worn Converter a Loose flexplate to converter bolts b Converter damage c Water...

Page 993: ...7A2 10 1977 PONTIAC SERVICE MANUAL Fig 7A2 6 Circuit Schematic Typical Drive Range Third Gear Shown...

Page 994: ...al fluid is required add enough fluid to bring level to 1 4 inch below ADD mark on dipstick If transmission fluid level is correctly established at 7WF it will appear at FULL mark on dipstick when tra...

Page 995: ...ount or if tailshaft moves up but not down mount bottomed out replace mount If there is relative movement between a metal plate of mount and its attaching point tighten screws or nuts attaching mount...

Page 996: ...unting screws and remove control shifter assembly Installation Reverse removal procedure steps 1 thru 4 Thoroughly coat pointer inner shaft and guide slot with lub lithium soap or equivalent When inst...

Page 997: ...AC SERVICE MANUAL CONSOLE COVER CONSOLE COVER a VlEW B GUIDE DETENT Lb COVER bo FIG 7A2 9 CONSOLE COVER ASSEMBLY DETENT COVER CONTROL SHlFTER ASSEMBLY SHIFT CONTROL VlEW A ASSEMBLED FIG 7A2 10 CONTROL...

Page 998: ...1 Disconnect speedometer cable 2 Remove reatiner bolt retainer speedometer driven gear and O ring seal Installation Installation of speedometer driven gear speed control switch assembly is the reverse...

Page 999: ...p oil seal if required and new gaskets Adjust fluid level REMOVE TRANSMISSION 1 Before raising vehicle disconnect negative battery cable detent downshift cable at carburetor and release parking brake...

Page 1000: ...tainer with a screw driver 6 Using a screwdriver and hammer gently tap along governor cover lip Fig 7A2 14 remove governor cover and 0 ring seal Fig 7A2 15 Discard seal I EXTENSION HOUSING Fig 7A2 13...

Page 1001: ...Fig 7A2 21 5 Remove upper valve gasket valve body transfer plate and lower valve gasket Fig 7A2 22 6 Remove 4 check balls from correct passages in case face Fig 7A2 23 7 Remove oil pump pressure scre...

Page 1002: ...pawl f replacement is required Fig 7 2 32 NOTE The parking pawl shaft retaining clip may be removed by using a bolt extractor REMOVAL OF OIL PUMP AND INTERNAL CASE COMPONENTS 1 Remove eight 8 pump at...

Page 1003: ...tion carrier assembly from output ring gear and shaft assembly Fig 7A2 48 Fig 7A2 25 Removing Governor Feed Screen Fig 7A2 26 Removing Manual Shaft to Case Retainer 18 Remove reaction carrier to outpu...

Page 1004: ...er seal Fig 7A2 56 25 Install tool J 23069 to compress 1 2 accumulator piston cover and remove retaining ring Fig 7A2 57 26 Remove 1 2accumulator piston cover Remove 0 ring seal from case Fig 7A2 58 2...

Page 1005: ...ICE MANUAL Fig 7A2 31 Removing Parking Pawl Disengaging Spring 4375 Fig 7A2 32 Parking Pawl Shaft Retaining Plug Park Pawl Shaft and Park Pawl Fig 7A2 33 Oil Pump Attaching Bolts Fig 7A2 34 Removing O...

Page 1006: ...IC 250 TRANSMISSION 7A2 23 Fig 7A2 35 Intermediate Band Anchor Bolt and Nut Fig 7A2 36 Intermediate Band Fig 7A2 37 Removing lntermediate Servo I CUWION PISTON t SPRING SNAP SEAT RING L Fig 7A2 38 lnt...

Page 1007: ...7A2 24 1977 PONTIAC SERVICE MANUAL Fig 7A2 4 1 Removing Output Carrier to Output Shaft Snap Ring Fig 7A2 40 Removing lnput Ring Gear Front Thrust Washer Fig 7A2 42 Removing lnput Ring Gear...

Page 1008: ...ANSMISSION 7A2 25 Fig 7A2 43 Removing Input Ring Gear Rear Thrust Washer Fig 7A2 44 Removing Output Carrier Assembly Fig 7A2 46 Removing Low and Reverse Clutch Support Retaining Ring Fig 7A2 45 Removi...

Page 1009: ...erse Clutch Pack OUTPUT RING GEAR7 I I TANGED THRUST WASHER I Fig 7A2 50 Removing Output Ring Gear Tanged Thrust Washer OUTPUT RING GEAR AND SHAFT ASSEMBLY ASSEMBLY Fig 7A2 48 Removing Reaction Carrie...

Page 1010: ...Gear to Case Needle EAR TO CASE LOW AND REVERSE CLU 1 Fig 7A2 52 Compressing Low and Reverse Clutch Piston Spring Retainer I m 7 mAPPLY AIR PRESSURE HERE TO REMOVE 1 Fig 7A2 54 Removing Low and everse...

Page 1011: ...ove retaining pin plug manual low control valve spring and manual low control valve 7 From next bore remove retaining pin detent regulator valve spring spring seat and detent regulator valve 8 From bo...

Page 1012: ...manual low control valve spring plug and retaining pin 6 In top right hand bore install detent regulator valve spring seat spring and retaining pin OIL PUMP FIG 7A2 60 Disassembly 1 Place pump cover a...

Page 1013: ...type oil seal rings Install two 2 forward clutch to pump hub hook type oil seal rings PUMP COVER AND STATOR SHAFT ASSEMBLY PUMP BODY Fig 7A2 63 Removing Pump Cover From Pump Body Fig 7A2 64 Checking...

Page 1014: ...ve direct clutch piston center seal on drum Fig 7A2 75 Inspection 1 Inspect drive and driven clutch plates for signs of burning scoring or wear 2 Inspect seventeen 17 springs for collapsed coils or si...

Page 1015: ...gs for collapsed coils or signs of distortion 3 Inspect piston for cracks 4 Inspect clutch housing for wear scoring open oil passages and free operation of ball check exhaust Fig 7A2 83 5 Inspect outp...

Page 1016: ...etaining ring Fig 7A2 89 Discard retaining ring 5 If bushing is to be replaced refer to Bushing Replacement Replacement Section lnspection Check gear and sun gear shell for damage or wear Reassembly 1...

Page 1017: ...Clutch piston Center Seal 020 MUSIC WIRE CRIMPED DIRECTC UTCH HOUSING M I 9 Fig 7A2 76 Installing Direct Clutch Piston 2 Install low and reverse clutch support 3 Install low and reverse clutch to cam...

Page 1018: ...k governor sleeve for free operation in bore of transmission case 4 Inspect governor valve for nicks burrs scoring or galling 5 Check governor valve for free operation in bore of governor sleeve PRESS...

Page 1019: ...in until it bottoms on shoulder 5 A new pin hole must be drilled through sleeve and gear Locate hole position 90 degrees from existing hole center punch and then while supporting governor in press dri...

Page 1020: ...lutch Pressure Plate BUSHING REPLACEMENT EXTENSION HOUSING BUSHING Removal Collapse bushing with a screw driver Fig 7A2 95 Installation OUTPUT SHAFT BUSHING Removal With output shaft properly supporte...

Page 1021: ...7A2 38 1977 PONTIAC SERVICE MANUAL INPUT RING GEAR S U N G E A R ASSEMBLY DRIVE SUELL REACTION SUPPORT CARRIER...

Page 1022: ...ISSION 7A2 39 Fig 7A2 87 Removing Sun Gear Drive Shell Rear Retaining Ring Fig 7A2 88 Removing Sun Gear to Drive Shell Rear Thrust Washer Fig 7A2 89 Removing Sun Gear to Drive Shell Front Retaining Ri...

Page 1023: ...U T INSTALL ROLLER FROM OUTSIDE IN AS SHOWN TO AVO 1 0 BENDING SPRWGS FIG 7A2 90 LOW AND REVERSE CLUTCH ASSEMBLY EXPLODED VIEW OVERRUN CLUTCH RACE CI 4435 LOW REVERSE R O L L E R ICLUTCH RETAINING RIN...

Page 1024: ...TURBO HYDRA MATIC 250 TRANSMISSION 7A2 41 q LOW REVERSE ROLLER CLUTCH ASSEMBLY 4437 Fig 7A2 93 Removing Roller Clutch Assembly...

Page 1025: ...7A2 42 1977 PONTIAC SERVICE MANUAL Fig 7A2 94 Governor Assembly Exploded View EXTENSION HOUSING BUSHING Fig 7A2 96 Installing Extension Housing Bushing Fig 7A2 95 Removing Extension Housing Bushing...

Page 1026: ...pported remove front bushing Fig 7A2 98 Place Tool J 21424 7 and Drive Handle J 8092 with Extension J 21465 13 through front of the stator shaft and drive out rear 2 bushings lnstallation Using Tool J...

Page 1027: ...8092 Installation Using Tool J 23062 3 and Drive Handle J 8092 install m A Fig 7A2 102 Installing Sun Gear Bushings DIRECT CLUTCH BUSHING Removal With direct clutch drum properly supported remove bus...

Page 1028: ...ow and reverse clutch support assembly with position of notch with low and reverse clutch support retainer anti clunk spring as shown on Fig 7A2 105 IMPORTANT Make certain the splines on inner race of...

Page 1029: ...l pump assembly into case Install attaching bolts with new washer type seals IMPORTANT If input shaft cannot be rotated as the pump is being pulled into place direct and forward clutch housings have n...

Page 1030: ...al Shaft MANUAL SHAFT TO CASE RETAINER Fig 7A2 1 11 Installing Manual Shaft To Case Retainer 11 Install manual shaft to case retainer Fig 7A2 111 VALVE BODY OIL PAN AND GASKET 1 Install oil pump press...

Page 1031: ...tainer with tangs pointing toward modulator 1 2 ACCUMULATOR FIG 7A2 115 1 Install 1 2 accumulator piston assembly 2 Install accumulator spring 3 Install new 0 ring seal in groove in case before instal...

Page 1032: ...mation on original cover onto the new cover All Transmission parts returned to Pontiac Motor Division and any communication concerning same must be identified by transmission identification and vehicl...

Page 1033: ...lnstaller Extendon Housing Bushing Removerand J 21427 1 Installer Umd with J8092 J 9539 Stator Shaft Front Bushing J 8105 Installer U dwith 5 21 J 5586 Input Ring Gear Bushing J 24367 Remowr and Inst...

Page 1034: ...l connections to the transmission are 1 Manual Linkage To select the desired operating range 2 Engine Vacuum To operate the vacuum modulator 3 Cable Control To operate the detent valve The following s...

Page 1035: ...car a Install oil pressure gage b Road test using all selective ranges noting when discrepanciesin operation or oil pressure occur See Fig 7A3 2 c Attempt to isolate the unit or circuit involved in th...

Page 1036: ...Manual shaft seal damaged or improperly installed f Line pressure gap plug loose 4 Leak at Front of Transmission a Oil pump seal leaks 1 Seal lip cut Check converter hub etc 2 Bushing moved and damag...

Page 1037: ...his is found WITHOUT the presenceof oil the modulator MUST NOT BE CHANGED Check solution that comes out of the modulator for evidence of lubricity If the solution does not have the feel of oiliness it...

Page 1038: ...d circuit to forward clutch oil seal rings missing or broken on pump cover leak in feed circuits pump to case gasket mispositioned or damaged c Clutch drum ball check stuck 4 Control valve assy 5 Forw...

Page 1039: ...nnels blocked c Valve body gaskets leaking damaged incorrectly installed 3a Porosity between channels b Governor feed channel blocked Governor bore scored or worn allowing cross pressure leak 4a Clutc...

Page 1040: ...cated b 2 3 valve train stuck in up shifted position This will also cause 1 3 upshift in drive range c 1 2 valve train stuck in upshifted position 5 Piston or pin stuck so intermediate overrun band is...

Page 1041: ...tions in line b Modulator valve stuck c Valve body regulator or boost valve stuck d Pump to case gasket off location or damaged 2 Porosity between channels 3a Oil rings damaged b Piston stuck c Broken...

Page 1042: ...ve and 2 Sticks or disconnected linkage or broken 3 2 3 shift valve 3 Stuck No detent downshifts 1 Control valve assy 2 Detent valve and linkage 1 2 3 valve stuck 2 Sticks or disconnected or broken Lo...

Page 1043: ...rking pawl staying in due to a burr on leading edge Cold morning reverse no drive till engine warms up 1 Pressure regulator bore or sleeve tight 1 Remove and repair Shifts cold but not warm 1 Governor...

Page 1044: ...1 Valve body 2 Shift selector lever 1 Leaking valve body support plate 2a Bent or S hook hole off location b S hook bent c Detent roller spring hole off location d Manual valve S hook hole off locatio...

Page 1045: ...01EOkTHOLES MAUKO GOVER SOR ULATOR 1FtW PETENT VAlVE r D R l V E I p D R A i N UTCH DRIVE MANUAL L O W 11 M0D S V MODULATOR THRU DETENT VALVE REVERSE DETENT 3 2 DETENT MODULATOR...

Page 1046: ...TURBO HYDRA MATIC 350 TRANSMISSION 7A3 13 TRAL W DETENT M O D U L A T O R DETENT VALVE LOW AND REVERSE 2784 Fig 7A3 6 Case Oil Channels Bottom View...

Page 1047: ...ll llCOOLER IN PUMP PRESSURE7 T O RADIATOR 9 I Fig 7A3 10 Case Oil Channels Front View MAINTENANCE AND ADJUSTMENTS ADJUST COLUMN SHIFT CONTROLS ADJUST CONSOLE SHIFT CONTROLS 1 Loosen screw on adjustin...

Page 1048: ...page and transmission failure can result Fluid level too low can cause slipping particularly when the transmission is cold or the car is on a hill Check the transmission fluid level with the engine ru...

Page 1049: ...e front wheels in a straight ahead under most conditions position However the drive shaft must be disconnected or the car towed on its front wheels if tow speeds in excess of 35 mph ROCK1NG CAR are ne...

Page 1050: ...RBO HYDRA MATIC 350 TRANSMISSION 7A3 17 FRONT 75 LB IN DETENT CABLE VIEW C TRANS L H SlDE OF ENGINE CARB LEVER RELEASED POSITION R H SlDE OF ENGINE 4887 Fig 7A3 13 Downshift Detent Control Cable Typic...

Page 1051: ...ed it must be replaced 2 Remove 0 ring seal from governor cover and replace See Fig 7A3 17 3 Withdraw governor assembly from case Fig 7A3 18 Check governor bore and governor sleeve for scoring The gov...

Page 1052: ...FILTER AND VALVE BODY Removal of Oil Pan 1 Remove 13 oil pan attaching screw and washer assemblies oil pan and gasket Removal of Oil Filter 1 Remove two 2 filter assembly to valve body attaching screw...

Page 1053: ...7A3 24 Removing Spacer Plate and Gasket Fig 7A3 25 Location of Check Balls 3 Shut engine off and thoroughly clean area to be repaired with a suitable cleaning solventand a brush air dry A clean dry s...

Page 1054: ...osition start engine DO NOT RACE ENGINE apply emergency brake and move selector lever through each range 6 With selector lever in park engine running check fluid level 7 Add additional fluid to bring...

Page 1055: ...ing Bolt I VACUUM MODULATOR 4893 Fig 7A3 30 Removing Modulator Valve and O ring Seal Removal of Extension Housing Seal 1 Remove extension housing to case oil seal Fig 7A3 32 Removal of Extension Housi...

Page 1056: ...n Fig 7A3 37 2 Remove governor screens from case and clean Fig 7A3 38 Removal of Check Balls 1 Remove four check balls from case face Fig 7A3 25 Fig 7A3 33 Removing Lip Oil Seal Fig 7A3 34 Collapsing...

Page 1057: ...ing seat and apply pin Fig 7A3 43 2 If the piston seal needs replacing the piston assembly will have to be replaced This is due to a plastic grooved piston that is not serviceable Piston and Seal are...

Page 1058: ...ing 5 Charring 6 Chips or metal particles imbedded in lining If a lined drive plate exhibits any of the aboveconditions replacement is required B Wipe steel plates dry and check for heat discoloration...

Page 1059: ...Fig 7A3 46 lntermediate Overrun Brake Band 2 Remove input ring gear Fig 7A3 48 Removal of Output Carrier Assembly 1 Remove input ring gear to output carrier needle thrust bearing 2 Remove output carr...

Page 1060: ...tch Plates 1 Remove five 5 or four 4 low and reverse clutch faced plates and five 5 or four 4 steel separator plates Fig 7A3 52 Fig 7 3 4 9 Removing Output Carrier Snap Ring Fig 7A3 50 Removing Drive...

Page 1061: ...sed air in passage shown Fig 7A3 58 Removal of Low and Reverse Clutch Piston Seals 1 Remove low and reverse clutch piston outer seal Fig 7A3 53 Removing Reaction Carrier Fig 7A3 54 Removing Output Rin...

Page 1062: ...3 61 2 Install intermediate clutch 1 2 accumulator piston spring Fig 7A3 58 Using Air to Remove Piston 3 Place 0 ring seal on intermediate clutch 1 2 accumulator piston cover and install cover into ca...

Page 1063: ...ged or the pump seal drain back hole is un drilled Assembly Fig 7A3 62 Removing Pump Cover Attaching Bolts 7 Filler cooler by pass passage with grease and insert Tool J 23071 or J 23134 and force by p...

Page 1064: ...music wire crimped into copper tubing 6 Install spring retainer and install five 5 attaching bolts finger tight Fig 7A3 63 7 Place pump aligning strap J 21368 over pump body and cover and tighten 8 Ti...

Page 1065: ...e and Driven Gears COOLER BY PASS VALVE J 23071 2743 Fig 7A3 67 Removing By Pass Valve Seat Disassembly of Direct Clutch 1 Remove intermediate overrun clutch from retainer ring and retainer Fig 7A3 72...

Page 1066: ...TURBO HYDRA MATIC 350 TRANSMISSION 7A3 33 Fig 7A3 68 Pump t o Case 0 Ring Seal Fig 7A3 69 Removing Pump Body Lip Oil Seal Fig 7A3 70 Installing By Pass Valve Seat...

Page 1067: ...ng Clutch Retainer LER OUTER RACE sl Fig 7A3 73 Removing Overrun Outer Race 3 Glazing 4 Cracking 5 Charring 6 Chips or metal particles imbedded in lining If a lined drive plate exhibits any of the abo...

Page 1068: ...ng with the aid of a piece of 020 music wire crimped into copper tubing Fig 7A3 82 SNAP RING PLIERS 4914 Fig 7A3 78 Compressing Spring Retainer 4 Install spring retainer and springs Compress spring re...

Page 1069: ...specific part number must be used 020 MUSIC WIRE CRIMPED 1 INTO COPPER TUBING I DIRECT CLUTCH HOUSING 2765 Fig 7A3 82 Installing Direct Clutch Piston Disassembly of Forward Clutch 1 Remove forward clu...

Page 1070: ...WISE ROTATIONI r RETAINER DIRECT CLUTCH DRUM AND INTERMEDIATE CLUTCH OVERRUN INNER C A M L P o s I T I o N WITH 4 HOLES TOWARD FRONT OF TRANSMISSION 2761 Fig 7A3 84 Intermediate Overrun Clutch Explode...

Page 1071: ...ng care support forward clutch housing on rear thrust washer surface and press input shaft into housing until it is properly seated c Runout at rear thrust washer surface should be no more than 005 FO...

Page 1072: ...emove front retaining ring from sun gear Fig 7A3 96 Reassembly of Sun Gear to Drive Shell 1 Install sun gear to drive shell front retaining ring and install gear into drive shell Fig 7A3 96 Use a new...

Page 1073: ...WARD CLUTCH PISTON ASSEMBLY I RETAINING 7 FORWARD CLUTCH DRUMi I STEEL SEPARATOR PLATE7 RING 1 CUSHION SPRING Fig 7A3 90 Forward Clutch Assembly Exploded View Fig 7A3 92 Checking Plate Clearance Fig 7...

Page 1074: ...TRANSMISSION 7A3 41 Fig 7A3 96 Removing or lnstalling Front Retaining Ring Fig 7A3 94 Removing or Installing Rear Retaining Ring Fig 7A3 93 Pressure Plate Identification Fig 7A3 95 Removing or Install...

Page 1075: ...HOLES O N THIS SIDE IF ROLLER FALLS OUT INSTALL ROLLER FROM OUTSIDE IN AS SHOWN TO AVOID BENDING SPRINGS 2778 Fig 7A3 97 Low and Reverse Clutch Support and Overrun Roller Clutch Assembly Fig 7A3 98 In...

Page 1076: ...AL VALVE AND LINK ASSEMbLY i 14 1 1 SHlfT VALVE I 17 DETENT VALVE I 2 PRESSURE REGULATOR VALVE I 5 1 2 SHIFTCONTROL VALVE 2 8 WASHER 3 PRESSURE REGULATOR VALVE SPRING c 16 1 2 SHIFT CONTROL VALVE SPRI...

Page 1077: ...2shift control valve control valve spring control valve sleeve and retaining pin C 7 In the next bore up install the manual low control valve spring plug and retaining pin E 8 In the top right hand b...

Page 1078: ...o use with specifictransmission model and engine combination When replacing piston assembly specific part number must be used 1 Oil and install low reverse clutch steel separator plates and faced plat...

Page 1079: ...put shaft snap ring Use new snap ring and do not overstress on installing USE PROPER SNAP RING PLIERS lnstalling Input Ring Gear 1 Install input ring gear Fig 7A3 115 J Fig 7A3 109 lnstalling eactionk...

Page 1080: ...ll intermediate clutch overrun brake band Fig 7A3 118 lnstalling lntermediate Clutch Pressure Plate Clutch Plates and Cushion Spring NOTE Refer to specifications in rear of this section to determine t...

Page 1081: ...roperly installed to index the faced plates with their respective parts This condition must be corrected before the pump is pulled into place 5 To check direct clutch to oil pump clearance attach slid...

Page 1082: ...ing to case square cut 0 ring seal Fig 7A3 126 NOTE Extension has studs for the catalytic converter support on the right side 3 Install speedometer driven gear retainer and bolt Torque bolt to 12 lb f...

Page 1083: ...ICE MANUAL Fig 7A3 122 Installing Shim and Thrust Bearing on Pump Hub DOMETER DRIVE GEAR Fig 7A3 125 ln alling speedometer Drive Gear Fig 7A3 123 Installing Pump Assembly Fig 7A3 124 Checking Direct C...

Page 1084: ...ug in case Fig 7A3 129 4 Install park lock bracket and torque bolts to 29 lb ft Fig 7A3 130 5 Install actuating rod under the park lock bracket and parking pawl Fig 7A3 131 Fig 7A3 128 Parking Pawl As...

Page 1085: ...pring Assembly and Filter 1 Install valvebody spacer plate to case gasket and valve body spacer plate Fig 7A3 138 Fig 7A3 131 Installing Actuator Rod 2 Install valve body to spacer plate gasket This g...

Page 1086: ...ctive allowing engine coolant to enter the transmission 3 A small amount of wear appears on the hub where the oil pump drive gear locates A certain amount of such wear is normal for both the hub and o...

Page 1087: ...7A3 54 1977 PONTIAC SERVICE MANUAL Fig 7A3 134 Intermediate Servo Assembly Exploded View...

Page 1088: ...Location of Check Balls 7 VALVE BODY SPACERPLATE I VALVE BODY SPACER PLATE TO CASE GASKET I OIL P U M P PRESSURE SCREEN Fig 7A3 136 Installing Pump Pressure Screen I Fig 7A3 137 Installing Governor S...

Page 1089: ...upport Plate TORQUE Fig 7A3 142 Installing Detent Spring and Roller Fig 7A3 144 Installing Gasket and Oil Pan VALVE LINK Fig 7A3 140 Connecting Detent Control Valve Wire Fig 7A3 14 1 Connecting Manual...

Page 1090: ...BO HYDRA MATIC 350 TRANSMISSION 7A3 57 Fig 7A3 145 Governor Cover and Seal Fig 7A3 146 Installing Modulator Valve and Modulator Fig 7A3 147 Air Checking Converter Fig 7A3 148 lnstalling Tool J 2 137 1...

Page 1091: ...s follows Fig A production day and shift built number transmission 7A3 153 model and model year are stamped on the governor cover Fig 7A3 152 Since the production day built number and model number fur...

Page 1092: ...7A3 153 Transmission Model and Clutch Plate Usage ALL V 6 ENGlNES ALL V 8 ENGINES TIGHTENING SPECIFICATIONS p p LOCATION THREAD SIZE TORQUE LBS FT Oil Pan to Transmission Case 5 16 18 13 Pump Assembly...

Page 1093: ...nsion 7A4 27 Front End Play Checking Procedure 7A4 28 Oil Pump 7A4 28 Disassembly of Gear Unit 7A4 30 Overhaul of Major Units Governor Assembly 7A4 37 Front Servo 7A4 38 Rear Servo 7A4 38 Control Valv...

Page 1094: ...hus always rotates at engine speed The converter pump is an integral part of the converter housing therefore the pump blades rotating at engine speed set the oil within the converter into motion and d...

Page 1095: ...detent solenoid is activated by an electric switch on the firewall When the throttle is fully opened the switch is closed activating the detent solenoid and causing the transmission to downshift at s...

Page 1096: ...M SET ENGINE IDLE TO 60 TO 85 SPEC1FICATIONS DRIVE BRAKES APPLIED ENGlNEATl00ORPM 60 TO 90 SUPER OR LO BRAKES APPLIED ENGINE AT 1000 RPM 135 TO 160 L 5 I DOWNSHIFT SWITCH ACTIVATED I 1 7 IGOVERNOR CHE...

Page 1097: ...aks Hold a finger firmly against the end of the hose and apply 20 of vacuum Vacuum must not drop any for at least 30 seconds Also make sure the hose that fits over the modulator pipe is very tight 381...

Page 1098: ...ever in LO RANGE and accelerate the vehicle form 0 MPH No upshift should occur in this range except possibly in some vehicles which have a high numerical axle ratio and or engine rpm 2nd GEAR OVERRUN...

Page 1099: ...W TRANSMISSION OIL LEVEL 2 MODULATOR ASSEMBLY PERFORM A BELLOWS COMPARISON CHECK SEE INSPECTION OF MODULATOR AND VALVE TRANSMISSION MALFUNCTION RELATED TO OIL PRESSURE I MALFUNCTION NO 1 2UPSHIFT AND...

Page 1100: ...EALS FOR DAMAGE 3 CHECK TURBINE SHAFT JOURNALS FOR DISTRESS 4 CHECK STATOR SHAFT BUSHINGS FOR DAMAGE B DIRECT CLUTCH LEAK PRESSURE NORMAL IN NEUTRAL LOW SUPER AND DRIVE PRESSURE LOW IN REVERSE 1 CHECK...

Page 1101: ...ETENT 55 70 PSI 9 I SWITCH THE PROBLEM IS NOT IN THE 60 90 PSI I 1 INOPERATIVE DETENT SOLENOID I SEE CONTROL VALVE ASSEMBLY GOVERNOR LlNE PRESSURE CHECK CHECK LINE TO DETENT ORIFICE IN SPACER PLATES F...

Page 1102: ...VACUUM LlNE AND CHECK FOR COLLAPSED A BOLT TORQUE I I 1 IREMOVE CONTROL VALVE ASSEMBLY INSPECT FOR NICKS ON MACHINED I IMODULATOR BELLOWS SEE INSPECTION OF MODULATOR VALVE I PISTON OR LEAK SURFACE OR...

Page 1103: ...POOR PRESSURE RESPONSEPOOR AIR CHECK DIRECT CLUTCH FOR LEAK TO OUTER CHECK FOR RESTRICTION CHECK FOR COLLAPSED AREA OF CLUTCH PISTON LEAK COULD BE AT IN VACUUM LINE AND MODULATOR BELLOWS CENTERPISTON...

Page 1104: ...LO SPRAG CLUTCH FOR DAMAGE OR LO SPRAG ICHECK OUTSIDE MANUAL LINKAGE CORRECT I I BRAKES APPLIED ENGINE AT 1000 RPM NORMAL CONTROL VALVE ASSEMBLY FORWARD CLUTCH 1 2 3 VALVE TRAIN STUCK OPEN THIS WILL A...

Page 1105: ...PIN SHORT REAR BAND BROKEN BURNED CHECK FOR CAUSE NOT ENGAGED ON ANCHOR PINS AND OR SERVO PIN I RELEASE FROMPARK I I CHECK OUTSIDE MANUAL LINKAGE CORRECT II INTERNAL LINKAGE 1 PARKING BRAKE ROD ASSY C...

Page 1106: ...E BUZZING NOISE ORIFICE CUP PLUG I N PRESSURE REGULATOR DAMAGED OR MISSING SEAL RINGS DAMAGED OR WORN I CONVERTER LOOSE BOLTS CONVERTER TO FLYWHEEL CONVERTER DAMAGE DURING ACCELERATION GROUNDED TO UND...

Page 1107: ...TUCK OPEN D DETENT FEED ORIFICE IN SPACER PLATE BLOCKED SEE FIG 7A4 8 E DETENT SOLENOID LOOSE F DETENT VALVE BORE PLUG DAMAGED G DETENT REG VALVE PIN SHORT 4 PUMP A PRESSURE REG AND OR BOOST VALVE STU...

Page 1108: ...E STUCK IN CONTROL VALVE ASSEMBLY D INTERMEDIATE CLUTCH PISTON SEALS DAMAGED OR MISSING E CENTER SUPPORT BOLT LOOSE F LOW LINE PRESSURE G INTERMEDIATE CLUTCH PLUG IN CASE MISSING H CASE VALVE BODY FAC...

Page 1109: ...MAGED OR MISSING MISPOSITION OF FILLER PIPE BRACKET TO ENGINE LOADING ONE SIDE OF THE 0 RING FILL PIPE CRACKED OR MALFORMED 0 RING GROOVE B MODULATOR ASSEMBLY 0 RING SEAL DAMAGED OR IMPROPERLY INSTALL...

Page 1110: ...oxy cement 4 Following the instructions of the manufacturer mix a sufficient amount of epoxy cement 3M SCOTCH WELD 2216 preferred Part No 1360016 Grp No 0 423 alternate or equivalent to make the repai...

Page 1111: ...TURBO HYDRA MATIC 400 AUTOMATIC TRANSMISSION 7A4 19 p chart G Oil Flow Chart...

Page 1112: ...lever by removing nut from pin 2 Adjust back drive linkageby following the procedures under COLUMN SHIFT CONTROLS 3 After adjusting column controls unlock ignition and rotate transmission range select...

Page 1113: ...e Fast idle engine for 1 minute to circulate fluid throughout transmission and move manual control lever through each range DO NOT RACE ENGINE 2 Immediately check fluid level with selector lever in Pa...

Page 1114: ...C add fluid to bring level between the two dimples located below the ADD mark CAUTION Do not overfill Foaming will result COOLER AND COOLER LINE FLUSHING PROCEDURE IMPORTANT After any failure that ge...

Page 1115: ...TURBO HYDRA MATIC 400 AUTOMATIC TRANSMISSION 7A4 23 ALIGN BUTTON SO TOP OF LETTERS ARE TOWARDS FRONT OF C THIS RING TO BE I Fig 7A4 14 Console Shift Controls Typical...

Page 1116: ...transmission to its normal position slide rearward from engine and lower it away from car CAUTION When lowering transmission k e p rear of transmission lower than front so as not to lose converter or...

Page 1117: ...4 19 7 Remove the filter and intake pipe assembly and discard filter Fig 7A4 20 8 Remove intake pipe to case O ring seal from intake pipe or case and discard CONTROL VALVE GOVERNOR SCREEN ELECTRICAL C...

Page 1118: ...apply pin selection check to determine possible cause of malfunction Fig 7A4 24 Fig 7A4 24 Checking for Correct Rear Band Pin a Attach Pin J 21370 5 and Fixture J 21370 6 to transmission case with at...

Page 1119: ...plate and gasket 8 Remove six 6 check balls from cored passages in transmission case Fig 7A4 27 NOTE Mark location of balls for aid in reassembly 9 Remove front servo piston retainer ring pin spring...

Page 1120: ...ue 082 086 Red 093 097 Brown 104 108 Green 115 119 Black 126 130N Purple NOTE An oil soaked washer may tend to discolor so it will be necessary to measure washer for its actual thickness OIL PUMP 1 If...

Page 1121: ...case rib Fig 7A4 41 i Remove parking pawl shaft and parking pawl Fig 7A4 42 9 Remove front band Fig 7A4 43 10 Remove sun gear shaft Fig 7A4 44 11 Check end play as follows a Install Bolt J 21904 into...

Page 1122: ...eel clutch plates Fig 7A4 47 15 Remove center support to case retaining snap ring Fig 7A4 48 16 Remove entire gear unit assembly by lifting with Holding Tool J 21795 with Hammer J 6125 1 Fig 7A4 49 17...

Page 1123: ...Fig 7A4 57 10 Remove output shaft Fig 7A4 4 1 Removing Cup Plug From Case Fig 7A4 42 Removing Parking Pawl and Shaft 11 If removal and installation or replacement of the speedometer drive gear is nec...

Page 1124: ...21 32 from end of output shaft to rear face of gear using Spacer J 21028 cup side up and Installer J 6133 Fig 7A4 61 12 Remove output shaft to rear internal gear thrust bearing and two 2 races 13 Rem...

Page 1125: ...TURBO HYDRA MATIC 400 AUTOMATIC TRANSMISSION 7A4 33 Fig 7A4 48 Removing Support to Case Snap Ring Fig 7A4 49 Removing Entire Gear Unit Assembly...

Page 1126: ...34 1977 PONTIAC SERVICE MANUAL Fig 7A4 50 Location of Rear Unit Selective Washer Fig 7A4 53 Removing Center Support A ssernbly Fig 7A4 5 1 Location of Support to Case Spacer Fig 7A4 52 Removing Rear B...

Page 1127: ...SMISSION 7A4 35 ORIFICE PLUG 2630 Fig 7A4 54 Removing Center Support Thrust Washer Fig 7A4 57 Disengaging Snap Ring From Output Cdrrier ROLLER CLUTCH PLASTIC GEAR Fig 7A4 55 Removing Reaction Carrier...

Page 1128: ...1977 PONTIAC SERVICE MANUAL Fig 7A4 58 Depressing Retaining Clip Fig 7A4 6 1 Installing Steel Speedometer Drive Gear I Fig 7A4 59 Installing Reatining Clip Fig 7A4 60 Removing Steel Speedometer Drive...

Page 1129: ...6 Inspect governor driven gear for nicks burrs or damage MAJOR UNITS 7 Check governor driven gear for looseness on governor sleeve 8 Inspect governor weight springs for distortion or damage 9 Check g...

Page 1130: ...opening at entry feed port with a feeler gage as shown with governor weights extended completely outward Fig 7A4 65 b Check valve opening at exhaust port with a feeler gage as shown by holding the gov...

Page 1131: ...o pin in servo piston 3 Inspect the band apply servo pin for scores or cracks 4 Inspect accumulator and servo pistons for cracks or porosity NOTE Refer to Fig 7A4 70 Do not remove the teflon oil seal...

Page 1132: ...iston and spring Fig 7A4 72 4 From the top right hand bore remove retaining pin 1 2 modulator bushing 1 2 regulator valve 1 2 regulator spring 1 2 detent valve and 1 2 shift valve Fig 7A4 73 5 From ne...

Page 1133: ...ASSEMBLY NOTE See Fig 7A4 72 Do not remove the teflon oil seal ring from the front accumulator piston unless the oil seal ring requires replacement For service the replacement oil seal ring will be c...

Page 1134: ...ll manual valve with detent pin groove to the right OIL PUMP Disassemble 1 Place oil pump assembly in hole in bench or Fixture J 6116 and Adapter J 21364 2 Compress regulator boost valve bushing again...

Page 1135: ...Check for overall flatness of pump body face P U M P C O V E R SQUARED OFF P R E S S U R E REG BOSS 2654 Fig 7A4 80 Pump Cover With Squared Off Boss RETAINING PIN WaE Y G PRESSURE REGULATOR VALVE PRES...

Page 1136: ...ng pin into opposite end of bore 8 Install previously selected front unit selective thrust washer over pump cover delivery sleeve 9 Install oil seal rings on pump cover sleeve if removed Fig 7A4 78 NO...

Page 1137: ...clutch housing for wear scoring open oil passages and free operation of ball check 6 Inspect turbine shaft a Check for open lubrication passages at each end b Check splines for damage c Check ground b...

Page 1138: ...ith the waved steel clutch plate plate with U notch 11 Install direct clutch hub and retaining snap ring Fig 7A4 89 FORWARD ClUTCH 1 HOUYNG Fig 7A4 90 Removing or Installing Forward Clutch Hub 12 Plac...

Page 1139: ...housing Fig 7A4 100 Models PA PB and OB Remove four 4 composition faced and four 4 flat steel clutch plates from the direct clutch housing Fig 7A4 100 6 Using Compressors J 4670 J 6129 and Ring J 876...

Page 1140: ...r scratches or other damage 6 Inspect clutch piston for cracks 7 Inspect springs for collapsed coils or signs of distortion 8 Inspect housing for free operation of check ball NOTE The fourteen 14 dire...

Page 1141: ...ically opposite with no springs NOTE The fourteen 14 direct clutch release springs are not serviced If one or more of these springs require replacement discard all of them and install the sixteen 16 s...

Page 1142: ...ring Fig 7A4 100 11 Install rollers that may have come out of the roller cageby compressingthe energizing spring with forefingerand Fig 7A4 105 Installing Clutch Piston Outer Seal inserting the roller...

Page 1143: ...if necessary 2 Using your fingers compress spring retainer and remove snap ring Fig 7A4 114 3 Remove spring retainer and three 3 clutch release springs 4 Remove clutch release spring guide Fig 7A4 115...

Page 1144: ...rt 1 Install new inner and outer seals on piston with lip of seal facing away from spring pocket Figs 7A4 117 and 118 2 Install Protector J 21363 on center support hub and install piston indexing spri...

Page 1145: ...TURBO HYDRA MATIC 400 AUTOMATIC TRANSMISSION 7A4 53 2686 Fig 7A4 1 13 Center Support Assembly Exploded View...

Page 1146: ...ring Guide INTERMEDIATE CLUTC H PISTON RACE ASSEMBLY 2689 Fig 7A4 1 16 Removing lntermediate Clutch Piston INTERMEDIATE CLUTCH PISTON CLUTCH OUTER SEAL 2691 Fig 7A4 1 18 Installing Clutch Piston Outer...

Page 1147: ...Inspect roller clutch cage for damage 9 If the reaction carrier has a spacer ring in an undercut at the bottom of the roller cam ramps inspect it for damage Fig 7A4 123 NOTE The reaction carrier with...

Page 1148: ...7A4 126 Planet Pinion Exploded View 7 Place a bronze and steel washer on each side of pinion so steel washer is against the pinion and hold them in place with petrolatum 8 Place pinion assembly in po...

Page 1149: ...ct bushing for excessive wear or damage If replacement is necessary proceed as follows a Install Remover J 21465 17 and remove bushing b Using Installer J 21465 17 with Handle J 8092 install new bushi...

Page 1150: ...urn spring for deformed coils or ends 9 Inspect parking bracket for cracks or wear 10 Inspect detent roller and spring assembly CASE ASSEMBLY 1 Inspect case for cracks porosity or inter connected pass...

Page 1151: ...r leaks 2 Check converter hub surfaces for signs of roughness scoring or wear that could damage the oil pump front seal If roughness can be felt with a fingernail seal could be damaged 3 Check convert...

Page 1152: ...tch and turn the race in both directions The inner race should turn fairly freely in a clockwise direction and not turn or be very difficult to turn in the counterclockwise direction CAUTION Do not us...

Page 1153: ...output carrier non metal or metal thrust washer with tabs facing down in pockets and retain with petrolatum NOTE The production built transmissions use a non metal washer here However the service repl...

Page 1154: ...ue to 18 lb ft 6 Install rear band so that two lugs index with two anchor pins Check to make sure band is seated on lugs Fig 7A4 155 7 Install the support to case spacer against the shoulder at the bo...

Page 1155: ...nward on tool handle which will tend to rotate the center support counterclockwise as viewed from front of transmission While holding center support firmly counterclockwise against the case splines to...

Page 1156: ...all manual linkage as follows Fig 7A4 146 lnstalling Rbller Into Roller Clutch Fig 7A4 147 lnstalling Roller Clutch Assembly a If necessary install a new manual shaft seal into the transmission case u...

Page 1157: ...to Case Thrust Washer 21 Install forward clutch and turbine shaft indexing direct clutch hub so end of mainshaft will bottom on end of forward clutch hub When forward clutch is seated it will NOTE If...

Page 1158: ...s washer thickness is required to bring end play within specifications select proper washer from the chart below THICKNESS COLOR 060 064 Yellow 071 075 Blue 082 086 Red 093 097 Brown 104 108 Green 115...

Page 1159: ...FRONT SERVO ASSEMBLY AND ELECTRICAL CONNECTOR Install 1 Install two guide pins control valve assembly attaching bolts with their heads cut off into the transmission case valve body face 2 Install fiv...

Page 1160: ...emblethe front servo group as shown in Figure 91 and install this group of parts into the front servo bore in the case and hold Slip a length of straight smooth clean feeler gage or shim stock about 0...

Page 1161: ...RANSMISSION 7A4 69 Fig 7A4 166 lnstalling Forward Clutch Assembly Fig 7A4 168 Checking Front End Play Fig 7A4 167 Installing Front Seal Fig 7A4 169 Installing Rear Oil Seal Fig 7A4 170 Location of Che...

Page 1162: ...Fig 7A4 171 Location of Check Balls in Spacer Plate Fig 7A4 173 Installing Detent Solenoid and Gasket Locote feeler stock Fig 7A4 172 Installing Gasket and Spacer Plate Fig 7A4 174 Installing Front Se...

Page 1163: ...ace the long pin identified by 3 rings should be used 2 If the gage surface is between the steps the medium pin identified by 2 rings should be used 3 If both steps are above the gage surface the shor...

Page 1164: ...g bolts NOTE If transmission is in car remove shim stock or feeler gage from between spacer plate and front servo piston before tightening any control valve bolts Fig 7A4 18 1 lnstalling Rear Servo Co...

Page 1165: ...7A4 186 lnstalling Filter Retainer Bolt MODULATOR VALVE AND VACUUM MODULATOR Install 1 Install modulator valve into case stem end out 2 Install O ring seal on vacuum modulator 3 Install vacuum modulat...

Page 1166: ...fully engaged with the pump drive gear tangs and the converter installed fully towards the rear of the transmission TRANSMISSION ASSEMBLY Install Reverse the procedure for transmission removal as stat...

Page 1167: ...gine California only A Series It is very important that any communications concerning the Turbo Hydra Matic 400 transmission always contains the complete transmission serial number and the vehicle ide...

Page 1168: ...Seal Installer Seal Protector Inner Forwardand Direct Clutch Seal Protector Inner Intermediate Clutch J 21477 AND J 22731 Rear Unit Holding Fixture Adapter Converter Holding Clamp Rear Band Apply Pin...

Page 1169: ...olding Fixture Adapter Compressor Adapter Ring J 21368 Pump Body and Cover Alignment Strap J 21369 Converter Leak Test Fixture J 21371 2 1 End Play Checking Fixture Not Shown J 21409 Seal Protector Ou...

Page 1170: ...he shaft they also rotate at the time the clutch is engaged The countergear is carried on roller bearings at both ends and thrust is absorbed by thrust washers located between the countergear and thru...

Page 1171: ...Gear Thrust and Spring Washers Snap Ring Bearing to Mainshah Extension Vent Speedometer Drive Gear and Clip Mainshah Rear Oil Seal Retainer Oil Seal Snap Ring Bearing to Gear 24 Clutch Gear Bearing 25...

Page 1172: ...BearingSnap Ring Front Baarlng Drivl Gaar Pilot Baarings c a u Extanslon to Caw Gasket Rear Baaring to Extantion Rataining Ring Raar Extantion Extansion t o Caw Rauining Bolts and Wsshsrs Raar Extant...

Page 1173: ...1977 PONTIAC SERVICE MANUAL Fig 78 3 4 Speed 76mm Transmission Cross Section...

Page 1174: ...Keys Key Retslner 3rd Speed Blocker Ring 3rd Speed Gear Needle Bearings Second Speed Gear 2nd Speed Blocker Ring Mamshatt 1st Speed Blocker Ring First Speed Gear Thrust Washer Wave Washer Rear Bearin...

Page 1175: ...er shifter levers for first through fourth gears and to the reverse lever located in the rear extension The shifter lever to the rear of the transmission cover controls the 1st and 2nd speed gears whi...

Page 1176: ...onizer Ring 12 1st 8 2nd Speed Clutch Assy 13 1st Speed Synochronizer Ring 14 l st Speed Gear 15 l st Speed Gear Bushing 16 Spacer 17 Rear Main Bearing 18 Snap Ring and Washer 19 Reverse Gear 20 Snap...

Page 1177: ...Snap Ring 29 Thrust Washer 30 Rear boring 31 Rear Bearing Retoiner 32 Washer 33 Selective Fit Snap Ring 34 Reverse G r 35 Snap Ring 36 Speedometer Drive Gear 37 Reverw Idler Front Thrust Washer Flat 3...

Page 1178: ...ant mesh with the counter gear including reverse through the reverse idler gear When shifting gears the selected gear is locked to the output shaft through the synchronizer clutch hub Overdrive fifth...

Page 1179: ...78 10 1977 PONTIAC SERVICE MANUAL Fig 7B 8 5 Speed 77mm Transmission Exploded View...

Page 1180: ...H SHlFT L l N K 4TH 5TH SHlFT FORK NEEDLE ROLLERS SPACER SYNCHRONIZER BLOCKING RlNG SYNCHRONIZER SPRING SHlFT PLATE CLUTCH HUB CLUTCH SLEEVE SYNCHRONIZER BLOCKING RlNG NEEDLE THRUST BEARING NEEDLE ROL...

Page 1181: ...rnal Problems Related to Shift Effort When the above procedures have been checked and the problem still exists the transmission will have to be removed and disassembled for further diagnosis There are...

Page 1182: ...nkage linkage as required Noisy in All Gears a Insufficient lubricant b Worn countergear bearings c Worn or damaged main drive gear and countergear d Damaged main drive gear or main shaft bearings e W...

Page 1183: ...damper gear c Replace damper gear 5 Speed 77mm Trans Noisy in Reverse Only a Worn or damaged reverse a Replace reverse idler idler gear or idler bushing gear assembly b Worn or damaged reverse b Repl...

Page 1184: ...of column Adjust levers control levers High Shift Effort Floor Shift 3 Speed and 4 Speed Transmissions Improper linkage adjustment Lost motion due to damaged or worn swivels rods grommets or mountings...

Page 1185: ...he metal plate of the mount or if the tailshaft moves up but not down mount bottomed out replace the mount If there is relative movement between a metal plate of the mount and its attaching point tigh...

Page 1186: ...on hoist 2 Loosen lock nuts at swivels on the shift rods Rods should pass freely through the swivels 3 Set transmission shift levers in neutral 4 Set shift control lever in neutral position Align cont...

Page 1187: ...WITH SHIFT 250 249 GAGE PIN MUST FIT PATTERN ALIGNED TO FRONT AND FREELY THROUGH LEVERS IN TIGHTEN NUT TO MAINTAIN ALIGNMENT NEUTRAL POSITION TRANS LEVERS SHIFT CONTROL CHASSIS LUBRICA CONTROL RO CONT...

Page 1188: ...AL TRANSMISSIONS 78 19 LUBRICATE WITH CHASSIS LUBRICANT C 15 LB FT 20 LB FT BUSHING GROMMET STEERING COLUMN UPPER ROD 1 SUPPORT ASM 1 SWIVEL 2216 Fig 78 12 3 Speed Floor Shift Back Drive Controls Typi...

Page 1189: ...OD TRANS LEVERS IN NEUTRAL POSITION TRUNNION LEVERS MUST BE IN NEUTRAL POSITION AT TIME OF ADJUSTMENT REV LEVER OF RODS 114 GAGE PIN MUST FIT 1ST 2ND LEVER FREELY THROUGH LEVERS VIEW A IN NEUTRAL POSI...

Page 1190: ...MANUAL TRANSMISSIONS 76 21 Fig 78 14 4 Speed Floor Shift Back Drive Controls Typical r SHIFT ROD 3RD 4TH SHIFT ROD Fig 78 15 4 Speed Floor Shift Controls H Series...

Page 1191: ...on hoist and remove propeller shaft as outlined in Section 4A 2 Inspect Remover J 4830 02 over mainshaft and tighten screw 3 Attach Slide Hammer J 2619 Fig 7B 17 and using hammer pull bushing and oil...

Page 1192: ...hicle disconnect battery and release parking brake 1 Raise vehicle on hoist and remove propeller shaft as outlined in Section 4A 2 Pry out oil seal with screwdriver 3 Wash counterbore and inspect for...

Page 1193: ...control rods up to floor pan Move shift control assembly rearward and to left until it clears rear extension then tip rear of shift control assembly downward and remove shift control assembly from veh...

Page 1194: ...59 CAUTI0N Do not excessivelyforce seal against seat in extension 6 Reinstall propeller shaft CASE COVER R R Before raising vehicle disconnect battery and release parking brake 1 Raise vehicle on hois...

Page 1195: ...nstall case cover attaching bolts evenly to 18 lb ft torque 14 Install shifter levers flat washers lock washers and nuts on shifter shafts Torque nuts to 20 lb ft 15 Connect control rods to shifter le...

Page 1196: ...port transmission in order to prevent distortion of the clutch driven plate hub while removing transmission 8 Slide transmission straight back on guide pins until main drive gear splines are free of c...

Page 1197: ...aning solvent 2 Blow out bearings with compressed air CAUTION Do not allow the bearings to spin turn them slowly by hand Spinning beanngs will damage the race and balls 3 Make sure beanngs are clean t...

Page 1198: ...g 7B 28 The tanged end of each synchronizer spring should be installed into different key cavitieson either side Slide the sleeve onto the hub aligning the marks made before disassembly NOTE A groovea...

Page 1199: ...end of the countergear Use heavy grease to hold them in place Fig 78 29 2 Place countergear assembly through case rear opening along with a tanged thrust washer tang away from gear at each end and in...

Page 1200: ...mbly of Mainshaft 7B 32 Cleaning and Inspection 7B 33 Transmission Case 7B 33 Bearings 7B 33 Bearing Rollers 7B 33 Gears 7B 33 Reverse Idler Gear Bushing 7B 33 Countergear Anti Lash Plate 7B 34 Repair...

Page 1201: ...countershaft drive the shaft and its woodruff key out the rear of the case Tool J 22246 will now hold the roller bearings in position within the countergear bore Remove the gear and thrust washers fro...

Page 1202: ...race and balls 3 Make sure bearings are clean then lubricate with light engine oil and check them for roughness by slowly turning the race by hand Removing Fig 78 38 Removing First and Second Synchron...

Page 1203: ...ifies the end that must be opposite the fork slot in the sleeve when assembled This groove indicates the end of the hub with a greater recess depth Extension Oil Seal or Bushing If bushing in rear of...

Page 1204: ...the synchronizer assembly 4 Install synchronizer hub to mainshaft snap ring Both synchronizer snap rings are identical Turn the rear of the mainshaft upward Install the following components on the mai...

Page 1205: ...ilot Bearings 3 4 Synchronizer Assembly Third Speed Gear Second Speed Gear 1 2 Synchronizer and Reverse Gear Assembly First Speed Gear Thrust Washer Spring Washer Rear Bearing Speedo Drive Gear Mainsh...

Page 1206: ...bolts and catalytic converter to transmission bracket bolts Tighten all bolts to specified torque 5 Install shifter assembly to shifter support and secure with two 2 shifter assembly to support bolts...

Page 1207: ...ion to take weight off support and remove crossmember from vehicle 7 Remove upper transmission to clutch housing bolts and install aligning Guide Pins J 1126 or 1 2 13 x 2 threaded headless bolts NOTE...

Page 1208: ...eeth face toward front of transmission 15 Using Loader J 24658 drive countergear shaft out of countergear Fig 7B 52 and remove countergear and tanged thrust washers from case Check bottom of case for...

Page 1209: ...ar chips or cracks and replace any that are worn or damaged Fig 78 55 Removing Rear Bearing Retainer 2 Check the front and rear facesfor burrs and if Dresent dress them off with a fine mill file 3 Mak...

Page 1210: ...cement 1 Pry seal from rear of extension 2 Remove bushing using Tool J 21465 17 with Handle J 8092 Drive bushing into extension housing Fig 7B 59 3 Using a new bushing and Tool J 21465 17with Handle J...

Page 1211: ...removed to perform these operations To remove the cover on the vehicle simply drain the transmission disconnect the lst 2nd cross shaft and 3rd 4th linkage and remove the attaching bolts and case cov...

Page 1212: ...per toward rear hub to front on the mainshaft together with a synchronizer ring on both sides of the cultch assemblies 3 Position the 1st gear sleeve on the shaft and press the sleeveonto the mainshaf...

Page 1213: ...aging the splines with the portion of the gear within the case 10 Place new rear bearing retainer to case extension gasket into position on rear face of bearing retainer Slide reverse gear on shaft In...

Page 1214: ...ke 1 From inside vehicle remove screws that hold chrome bezel ring to tunnel and remove bezel by slipping over boot and shift lever 2 With transmission shift lever in Neutral hold boot out of way remo...

Page 1215: ...ained in needle case Catch loose needles if they fall out during disassembly so they can be replaced in mating race during assembly 7 Remove rail selector pin and remove rail selector Fig 7B 73 8 Remo...

Page 1216: ...AR BEARING EXTENSION HOUSING CENTER SUPPORT COUNTERGEAR BEARING T I T 9 64 m I4581 61661 INPUT SHAFT ROLLER BEARING INSIDE 1 BEHIND 1ST GEAR THRUST WASHER 1 BEHIND SPEEDOMETER DRIVE GEAR 1 IN FRONT OF...

Page 1217: ...and slide link out Remove shift fork 16 Position interlock pawl to the outboard position to permit the fourth and fifth shift link and shift fork to be removed Fig 7B 80 17 Lift link from shift fork...

Page 1218: ...ve second gear and blocker ring Fig 7B 86 26 Remove snap ring then remove second and third gear synchronizer assembly and blocker ring from output shaft Fig 7B 87 Fig 78 82 Removing Needle Thrust Bear...

Page 1219: ...in slots of hub with radius side out and springs in grooves of keys 5 Install sliding sleeve onto hub aligning the marks made before disassembly Depress keys for ease of installation REPLACEMENT OF CA...

Page 1220: ...edle jearing out of center support Fig 7B 96 Fig 78 91 Installing lnput Shaft Needle Bearing Into Case Fig 78 92 Removing Countergear Needle Bearing from Case NOTE Drive needle bearing out from front...

Page 1221: ...01 Fig 7B 95 Installing Seal into Case Fig 78 96 Removing Output Shaft Needle Bearing from Center Support Removal and lnstallation of Oil Seal 1 Pry oil seal from extension housing Fig 7B 102 2 For in...

Page 1222: ...econd and third gear synchronizer assembly Fig 78 99 Installing Countergear Needle Bearing into Center Support HOUSING 5118 Fig 78 100 Removing Countergear Needle Bearing from Extension Housing 3 Inst...

Page 1223: ...ed to shift keys on the fourth and fifth synchronizer gear assembly Fig 7B 110 10 Install on output shaft with chamfered edge of sleeve toward front of transmission 11 Install needle thrust bearing on...

Page 1224: ...reverse gear and bushing assembly over output shaft and against center support 19 Install reverse idler gear and bushing assembly over reverse idler shaft to mesh with reverse gear Fig 7B 115 I Fig 7...

Page 1225: ...I Output Shaft 30 Install snap ring in shaft groove Fig 7B 119 31 Install blocker ring and first speed gear over output shaft behind first and reverse synchronizer assembly Align notches on blocker r...

Page 1226: ...ase check to be sure that a fifth speed gear spacer for needle rollers did not fall down between fifth speed gear and synchronizer 40 Drive roll pin into shifter head and shift rail Fig 7B 125 NOTE Co...

Page 1227: ...mperature Vulcanizing sealer inboard of bolt pattern to extension housing 45 Place transmission and shift lever in neutral and install shift lever and cover Fig 7B 128 46 Install four 4 screws and tor...

Page 1228: ...59 Fig 78 122 lnstalling Selector Lever Shift Rail and Shifter Head POLL PIN I Fig 78 125 lnstalling Shifter Head Roll Pin Fig 78 126 lnstalling Plunger Poppet Spring and Plunger Fig 78 127 lnstallin...

Page 1229: ...Gear 1 84 to 1 Third Speed Gear 1 00 to 1 Reverse Gear 3 22 to 1 LUBRICANT Use SAE 90 multi purpose gear lubricant Capacity 3 5 U S Pints 56 fluid ounces MUNCIE TRANSMISSION TORQUE Transmission Case...

Page 1230: ...ransmissions 4 SPEED 7 6 M M LT DUTY MUNCIE TRANSMISSION TRANSMISSION IDENTIFICATION ZN H with 140 L 4Engine ZR H with 151 L 4Engine Except California Code Series ZS H with 231 V6 Engine Except Califo...

Page 1231: ...ort to xtension Bolts 30 lb ft Shifter Assembly to Support Upper Bolts 45 lb ft Shifter Assembly to Support Lower Bolt 30 lb ft Lubricant Filler Plug 30 lb ft Frame to CrossmemberBolts 25 lb ft SPECIA...

Page 1232: ...resins or similar binding agents Very often copper wires are woven or pressed into material to give it additional strength Clutch Cable Replacement 7C 6 Unit Repair 7C 8 Clutch Assembly Replacement 7...

Page 1233: ...terchange the two bearings The longer bearing if used with the bent finger spring clutch will cause inability to obtain proper free pedal travel resulting in slippage and rapid wear CLUTCH OPERATION I...

Page 1234: ...quence before removing the clutch or transmission for repairs CLUTCH ADJUSTMENT A Clutch Free Pedal Travel I The clutch free pedal travel adjustment should be made as outlined in Maintenance and Adjus...

Page 1235: ...ge or release bearing b Springs weak in pressure plate c Springs being over traveled a Bind i n linkage b Driven plate worn CORRECTION a Adjust linkage b Trim bumper stop and adjust linkage c Replace...

Page 1236: ...ter end of clutch fork rearward until clutch release bearing lightly contacts pressure plate fingers 4 Install push rod in gage hole and increase length until all lash is removed from system 5 Remove...

Page 1237: ...haft to the left until it clears the pedal support Insert dummy shaft in support to hold brake components in place while removing pivot shaft Remove pivot shaft pedal arm and bushings from vehicle Fig...

Page 1238: ...CLUTCH PEDAL PIVOT SHAFT RUBBER BUMPER BRAKE CLUTCH PEDAL PIVOT BOLT NUT FULL DRIVEN SEATED AND NOT STRIPPED Fig 7C 7 Clutch Pedal Linkage A Series CLUTCH BRAKE PEDAL MOUNTING BRACKET BUMPER 4464 Fig...

Page 1239: ...rk 5 Remove flywheel housing from engine 6 A F or X series Slide clutch fork from ball stud and remove fork from dust boot Install Tool J 5824 to support the clutch assembly during removal H Series To...

Page 1240: ...d insert a used or dummy transmission drive gear shaft or Tool J 5824 through the cover and driven plate 2 Position the complete assembly against the flywheel and insert the dummy shaft or tool into t...

Page 1241: ...stment Section 9 Install transmission shift levers to transmission and adjust shift linkage as outlined in transmission section 10 Lower vehicle and remove from hoist Check operation of transmission a...

Page 1242: ...ssary 6 Examine splines in hub and make sure they slide freely on splines of transmission clutch shaft If splines are worn the clutch disc or clutch gear should be replaced as necessary 7 Inspect clut...

Page 1243: ...On Car Service 8 70 Remove and Replace 8 70 Headlamps 8 70 All Other Front Bulbs 8 70 Rear Bulbs 8 70 Seat Belt Warning System General Description 8 70 Diagnosis 8 70 Windshield Washer and Wiper Syste...

Page 1244: ...n is provided in all battery feed circuits and other selectedcircuits by a fusible link This link is a short piece of copper wire approximately 4 long inserted in series with the circuit and acts as a...

Page 1245: ...CHASSIS ELECTRICAL 8 3 WIRE HARNESS NOTE B SERIES GROUND STRAP C 350 403 W1A C TO LEFT SIDE OF ENGINE ENGINE R K 3321 I Fig 8 8 Engine Wire Harness Installation All Series V 8...

Page 1246: ...8 4 1977 PONTIAC SERVICE MANUAL VIEW A ELECTRIC CHOKE 3169 Fig 8 9 Engine Wire Harness Installation V 6 and 15 1 L 4 All Series...

Page 1247: ...Installation V I N code Ud and LV 8 s X Series RIGHT SIDE VlEW HEATER BLOWER FRONT END HARNESS I S T A T E TO GENERATOR AND OIL PRESSURE SWITCH LEFT SlDE VlEW IDLE STOP WIPER MOTOR SOLENOID OIL P R E...

Page 1248: ...checking if desired of the fuse block by a center bolt This makes for easy The front end and engine harnesses are firmly attached disconnection allowing quick diagnosis of electricalproblems to the bu...

Page 1249: ...CHASSIS ELECTRICAL 8 7 W S WIPER MOTOR ASM TO HORN Fig 8 13 Front End Wire Harness Installation A and G Series...

Page 1250: ...8 1977 PONTIAC SERVICE MANUAL TO WINDSHIELD WIPER MOTOR TO WINDSHIELD WASHER VIEW A 3885 Fig 8 14 Front End Wire Harness Installation F Series 3883 Fig 8 15Front End Wire Harness Installation X Serie...

Page 1251: ...vWINDSHIELD WASHER MOTOR L VERTICAL SUPPORT LAMP 3884 Fig 8 16 Front End Wire Harness Installation H Series WINDSHIELD ENG HARNESS WASHER MOTOR VIEW A VIEW B 4 CYL ONLY Fig 8 17 Front End Wire Harness...

Page 1252: ...L VIEW A TO STARTER MOTOR V I N CODE R AND K V4 S SEE FIG 8 24 FOR ENGINE ATTACHMENT NEGATIVE CABLE V I N CODE Y P OSlTlVE CABLE AND 2 V 8 s A C COMPRESSOR MOUNTING BRACKET ATTERY CABLE V 6 I Fig 8 18...

Page 1253: ...CHASSIS ELECTRICAL 8 11 SEE FIG 8 25 FOR ATTACHMENT WITH POWER STEERING TO STARTER MOTOR 4018 Fig 8 19 Battery Cable Routing A Series V 6...

Page 1254: ...8 12 1977 PONTIAC SERVICE MANUAL G SERIES R AND K V 8 S STARTER ASM Fig 8 20 Battery Cable Routing A and G Series V 8...

Page 1255: ...Y P AND 2 VS S f SEE FIG 8 24 L H SKIRT FOR ENGINE AlTACHMENT VIEW A ENGINE WIRE HARNESS 4020...

Page 1256: ...8 14 1977 PONTIAC SERVICE MANUAL Fig 8 22 Battery Cable Routing X Series...

Page 1257: ...G POSITIVE CABLE TO STARTER MOTOR TO FRONT OF ENGINE 151 L 4 POSITIVE CABLE NOTE CABLE MUST ROUTE ABOVE THE ENGINE MOUNT V 6 LESS POWER STEERING 4044 Fig 8 23 Battery Cable Routing H and HM Series FRO...

Page 1258: ...8 16 1977 PONTIAC SERVICE MANUAL TRANSMISSION VIEW A A BODY OIL FILTER WITH MESH TRANS FRONT OF CAR SYNCHRO TRANSMISSION n a ti t EXC SYNC 3 0 D Y MESH TRANS Fig 8 26 Redundant Ground Cables...

Page 1259: ...25 Battery Cable t o Engine Attachment V 6 Positive Cable TO TEST FOR BLOWN MINI FUSE PULL FUSE OUT AND CHECK VISUALLY USE A TEST LIGHT TO CHECK FOR CONTINUITY AS SHOWN MINI FUSE COLOR CODES RATING 5...

Page 1260: ...WINDOW DEFOG BLOl 1A B F TAILGATE U A R A INST LIGHTS I4 AMP INST PANEL ILLUM LIGHTS ASH TRAY ILLUM LIGHTS WINDOW CONTROL RELAY CLOCK LIGHT IACTUATING COIL AUTO TRANS SHIFT IND LIGHT CRUISE CONTROL IN...

Page 1261: ...AL SIGNALS LOW BRAKE TELL TALE SEAT BELT WRNG TELL TALE SEAT BELT WRNG BUZZER SEAT BELT BUZZER TIMER ACTUATING COIL HAZARD LIGHTS LOW COOLANT MODULE AlC ANTI DIESELING RELAY 151 HEATED REAR GLASS TACH...

Page 1262: ...ARNING BUZZER ACTUATING COIL FEED SEAT BELT BUZZER TIMER ACTUATING COIL PULSE WIPER ENGAGEMENT SW FEED DIGITAL A W F M CLOCK RECEIVER 17 TAILLIGHTS 20 AMP TAIL LIGHTS PARK LIGHTS CORNERING LIGHTS SIDE...

Page 1263: ...I INDEX FRONT END HARNESS VlEW LOOKING TERMINALS OF FRONT END S T U V VlEW LOOKING AT TERMINALS FRONT SlDE OF DASH FRONT END AS HEADLIGHT FEED GI NOT USED A F X AT NOT USED AU TO HlGH BEAM HEADLIGHTS...

Page 1264: ...ED AUTO TRANS FX BIUP LP SW FEED MANUAL TRANS NOT USED AUTO TRANS FY IDLE STOP SOLENOID NOT USED AUTO TRANS FZ NOT USEP VIEW LOOKING AT TERMINALS VIEW LOOKING AT FRONT SIDE OF DASH TERMINALS OF FRONT...

Page 1265: ...O PLUS TERMINAL ON HlGH ENERGY IGNITION H E I EZ DIAGNOSTICS TO IGN SWITCH BATTERY FEED FW NOT USED FX NOT USED FY NOT USED FZ BATTERY FEED TO HEADLIGHT SWITCH INDEX FRONT END HARNESS VlEW LOOKING ERM...

Page 1266: ...tch parking brake switch stop lamp switch body harness ignition switch and air conditioning harness 7 Disconnect vacuum harness and temperature control cable at control panel Disconnect radio wires an...

Page 1267: ...CHASSIS ELECTRICAL 8 25 Fig 8 35 B Series lnstrument Panel Attaching Parts Fig 8 36 B Series lnstrument Cluster and Trim Plates...

Page 1268: ...8 26 1977 PONTIAC SERVICE MANUAL STEERING COLUMN SUPPORT ASM INSTRUMENT PANEL PAD ASM Fig 8 37 A Series lnstrument Panel Pad UPPER INSTRUMENT ASM 24 Fig 8 38 A Series lnstrument Panel Attaching Parts...

Page 1269: ...CHASSIS ELECTRICAL 8 27 Fig 8 39 A Series lnstrument Cluster Fig 8 40 G and AG Series lnstrument Panel Pad...

Page 1270: ...MANUAL UPPER INSTRUMENT PANEL COVER RADIO TRlM PLATE WITHOUT TRlM PLATE PLATE WITH CONSOLE VIEW A GLOV E BOX ASM GLOVE BOX DOOR PANEL ASM 6 CYLINDER ESCUTCHEON VIEW B Fig 8 41 G and AG Series Instrum...

Page 1271: ...CHASSIS ELECTRICAL 8 29 Fig 8 42 G and AG Series lnstrument Cluster Fig 8 43 F Series lnstrument Panel Pad...

Page 1272: ...c Remove instrument cluster d Remove hush pane1 A C only one on each side e Remove radio f Remove glovebox and door g Remove lower and middle A C ducts if equipped h Remove two steering column nuts a...

Page 1273: ...pad 4 Sharply rap lower right edge of pad upward with palms of hands to disengage three retaining clips at top right of pad 5 To replace instrument panel pad align three right side upper clips with ho...

Page 1274: ...rier and cluster assembly forward disconnect printed circuit and cluster ground connectors and all remaining wiring 9 Place carrier assemblyon bench Removewire harness and carrier assembly 4 screws an...

Page 1275: ...fuse block from under dash 5 Disconnect all harness connectors 6 Remove wire harness clips retaining wire harness 7 Remove wire harness 8 To replace reverse removal procedure F Series Fig 8 61 1 Disco...

Page 1276: ...lamp connectors 4 Remove radio includes remove knobs bezels nuts and disconnect antenna lead in and connectors 5 Disconnect the following connectors heater or A C control clock printed circuit at main...

Page 1277: ...ng column radio brake switch and other miscellaneous connectors 9 Remove instrument panel harness from car 10 To replace reverse removal procedure HUSHMPANEL Many 1977 Pontiacs with air conditioning w...

Page 1278: ...Cluster LEGEND OF CONNECTOR PADS lLLUMlNATlON HIGH BEAM INDICATOR LEFT TURN SIGNAL INDICATOR RIGHT TURN SIGNAL INDICATOR GENERATOR TELLTALE FUEL GAGE SENDER OIL PRESSURE TELLTALE TEMPERATURE TELLTALE...

Page 1279: ...30 FUEL GA SENDER 31 OIL TELLTALE 33 BRK WARNING INDICATOR 35 TEMP TELLTALE 39 IGNITION I 4 0 CLOCK 150 GROUND 160 FAT BELT TELLTALE GROUND 237 IGNITION FOR SEAT BELT WARNING TELLTALE Fig 8 53 A and F...

Page 1280: ...FOR SEAT BELT TELLTAL Fig 8 55 F Series Printed Circuit Without Rally Gages Early Cluster LEGENDOF CONNECTOR PADS i50 GROUND 150 SEAT BELT TELLTALE GROUND 237 IGNITIONFOR SEAT BELT TELLTALE WlDE CONN...

Page 1281: ...50 GROUND 237 IGNITION FOR SEAT BELT TELLTALE 150 SEAT BELT TELLTALE GROUND TAILGATE AJAR AG WAGON ONLY LO COOLANTWARNING LAMP 151 XONLY NOTE WITH RALLY GAUGES NO BULBS ARE INSTALLED IN SPOTS 25 31 AN...

Page 1282: ...8 40 1977 PONTIAC SERVICE MANUAL Fig 8 60 A Series Instrument Panel Wire Harness...

Page 1283: ...CHASSIS ELECTRICAL 8 41 CIGAR BACK UP NEUTRAL SAFETY TO PA HORN RELAY WARN FUSE BLOCK DIMMER SWITCH Fig 8 61 F Series Instrument Panel Wire Harness...

Page 1284: ...8 42 1977 PONTIAC SERVICE MANUAL 3891 Fig 12 62 G and AG Series Instrument Panel Wire Harness...

Page 1285: ...LIGHTER VIEW A STOP LAMP SWITCHJ LTO PARK BRAKE SWITCH DIMMER 2 SWITCH CONN HAZARD FLASHER 7 ASH T R A Y ASM n FISHER CONNECTOR CIRCUIT BREAKER CONNECTOR KEY WARNING CIRCUIT BREAKER SIGNAL 1 SEAT BELT...

Page 1286: ...Y WARN BODY CONN IP BUZZ corm I awl I un d N N Iu 3 HORN RELAY CONN STOP LAMP DIMMER SWITCH CONNECTOR HORN RELAY I R A I G CONN NEUTSAFETY DIMMER SWITCH C0NN COL SHFT BACKING LAMP ARM SWITCH SWITCH CO...

Page 1287: ...TALE BLACK LT GREEN HARNESS ASM FUELGAGECONNECTOR LOW COOLANT TELLTALE PINK DARK GREEN L H TURN INDICATOR LIGHT BLUE BLACK CIGARETTE LIGHTER LOW COOLANT MODUL CONN FLASHER CONN DIRECTIONAL SIGNAL STOP...

Page 1288: ...TELLTALE LOW COOLANT MODULE CONN ACK GRAY DIRECTIONAL SIGNAL R lLLUMlNATlON SWITCH CONN CONN 4006 Fig 8 67 H Series Instrument Panel Wire Harness GT Cluster WER WIPER CONTROL lLLUMlNATlON HEATER OR AI...

Page 1289: ...CHASSIS ELECTRICAL 8 47 BODY CONN HM SERIES GROUND WIRE IIP HARN H SERIES 4008 Fig 8 69 H and HM Series steer olurnn d Fuse Panel...

Page 1290: ...FORWARD EDGE OF PANEL IN CHANNEL AS SHOWN PRIOR TO INSTALLING SCREWS 4011 Fig 8 70 Hush Pane1 B Series L H FUSE BLOCK REST PANEL O N ACCELERATOR BRKT MOUNTING TAB I VIEW A t I 1 BRAKE PEDAL 1 I An1 7...

Page 1291: ...LY INSTALLED WITH FLANGE BETWEEN PROJECTIONS AND RETAINER GUIDES ON CLOSE OUT PANEL AS SHOWN VIEW A 401 5 Fig 8 74 HushWPanel HM Series L H COURTESY LAMP ACCELERATOR F LINKAGE BRACKET ACCESS BRAKE PED...

Page 1292: ...HM Series temperature and oil pressure lamps are combined Operation of this system is covered in Section 6C Carburetion and Fuel Systems and the wiring diagram is shown in Fig 8 76A If the cooling sys...

Page 1293: ...one end and the speedometer head at the other rotates both mechanisms whenever the transmission main shaft propeller shaft and wheels rotate For cruise control equipped cars there are two cables one f...

Page 1294: ...CORRECTION Temperature warning lamp stays on if Check sender for abnormal ground electrical failure Check for short between bulkhead and sender Check for short from bulkhead to printed circuit Check...

Page 1295: ...METER On all series except X the speedometer can be removed as follows 1 Remove upper trimplate 2 Remove cluster lens will require removal of knob for clock or trip odometer 3 Remove shift indicator p...

Page 1296: ...that bend radius does not exceed 6 inches unless the cable has a pre formed radius Also insure that the cable is not positioned near exhaust pipes or is not routed where it could be pinched or chaffe...

Page 1297: ...Attachment at Transmission INSTRUMENT CLUSTER ape SHAFT ASM FOR SERVICE DEPRESS RETAINER REMOVE CABLE VIEW D DASH DASH I I VlEW B WITH CRUISE CONTROL EXCEPT CRUISE CONTROL L VIEW A T ASM CLOSE CLIP AR...

Page 1298: ...SE CONTROL 82mm 4 SPEED NOTE SEE SECTION 9 FOR AUTO TRANS CRUISE CONTROL CABLE INSTALLATION 4049 Fig 8 8 1 Speedo Cable Routing F Series INSTRUMENT CLUSTER I DEFROSTER DUCT u n w IIVI ROUTE SHAFT AS S...

Page 1299: ...horns The relay reduces length Each horn utilizes a solenoid actuated diaphragm to of heavy gage wire required and provides a more direct develop a resonating air column in horn projector See Fig con...

Page 1300: ...8 58 1977 PONTIAC SERVICE MANUAL Fig 8 84 Horn Mounting...

Page 1301: ...59 INSTRUMENT H AND HM SERIES CONNECTOR PART OF I P WIRE HARNESS E I P LAY INSTRUMENT PANEL WIRE HARNESS HORN RELAY w d G A d G SERIES B SERIES HORN RELAY IS A SERIES MOUNTED ON THE FUSE BLOCK Fig 8 8...

Page 1302: ...or on relay 2 Repalr open clrcult In wlre from relay to turn slgnal connector Remove horn button pad or cup and touch test llght lead wire from relay LAMPON 0 LAMP OFF 0 Repalr open In wlre from turn...

Page 1303: ...front door If car regularly carries an unusually heavy load in rear compartment or trailer these loads should be on car when headlamps are checked Some states have special requirements for headlamp a...

Page 1304: ...straight ahead position automatically turns off signal lamps When the system is operating correctly the frequency of turn signal is about 60 120 flashes per minute If either a front or rear signal bul...

Page 1305: ...r lamps flash with the turn signals in operation while the rear side marker lamps are illuminated only by the headlamp switch The circuit is fused with the tail cornering and park lamps DIAGNOSIS Trou...

Page 1306: ...e common signal switch system troubles If the system is still not operating correctly determine whether the chassiswiring or the signal switch itself is at fault To check the electrical function of th...

Page 1307: ...en dimmer switch and headlights If bulb will not light at one of the dimmer switch headlight terminals replace dimmer switch Circuit short Follow diagnosis shown above under All Headlights Inoperative...

Page 1308: ...do not operate use 12 volt test lamp to check voltage at lamp socket If test bulb lights repair open ground connection If not repair open wiring between bulb socket and turn signal switch Improper bul...

Page 1309: ...ot light on either side of connector repair open circuit between flasher and connector If test bulb lights only on feed side of connector clean connector contacts If test bulb lights on both sides of...

Page 1310: ...en ground connection at bulb socket or Jumper bulb base socket connection to ground wire terminal ground If lamp lights repair open ground circuit Both Sides Inoperative CAUSE CORRECTION Tail lamp fus...

Page 1311: ...e check open circuit from battery to fuse Adjust With ignition on check voltage at terminals with switch in back up position If bulb lights at pink wire terminal but not at output terminal replace ign...

Page 1312: ...twisting Then replace the bulb and reinstall the socket Check the system for proper operation Refer to Section 2C for lamp housing removal and replacement Rear Bulbs Information on rear bulbs and hou...

Page 1313: ...LLOW WIRES AND TO TEST LlGHT OFF I I TEST LlGHT ON 1 I I REPLACE TlMER CHECK CONTINUITY BETWEEN GROUND I TERMINAL AND BODY GROUND I r 1 LlGHT AND BUZZER ON CONTINUOUSLY BUT BUCKLING BELT WILL TURN OFF...

Page 1314: ...n the windshield while the washer switch is depressed and stops when the switch is released This system is used on H HM F and X Series The second type used on A G and B Series will operate for a pre d...

Page 1315: ...ly Light Switch to Fuse Radio Feed Rear Seat Speaker Feed from Radio Single or Rt Stereo M a p Light Warning Light Brake Alarm Back up Switch or Parking Brake Alarm Feed Over Speed Warning Light H o r...

Page 1316: ...ple Dark Blue White Tan Light Green Purple White Yellow Light Green Tan Gray Yellow Black Light Green Tan Black Gray Black Light Blue Tan White Circuit Number Circuit Name ELECTRICALLY POWERED ACCESSO...

Page 1317: ...og or Drive Lamp Telltale Temp Gauge H o t or Std Temp Readable Gauge C i r c u i t N u m b e r C i r c u i t C o l o r Light Green Dark Blue Pink Black Orange Brown White Yellow Dark Green Black Dark...

Page 1318: ...Control L R Down Window Control R R U p Circuit Number 171 172 173 174 175 I76 177 I78 179 180 181 I82 I83 I84 I85 186 I87 188 I89 I90 191 192 193 194 I95 I96 197 198 199 200 20 1 239 240 24 1 340 Ci...

Page 1319: ......

Page 1320: ......

Page 1321: ......

Page 1322: ......

Page 1323: ...RH RR D m R JAMB SWTCH I...

Page 1324: ...TEMP SW TDIP SW FIG 8 2 A SERIES WIRING DIAGRAM...

Page 1325: ...PRESSURE swrrcn J TAM...

Page 1326: ...r L m u L T L...

Page 1327: ......

Page 1328: ......

Page 1329: ......

Page 1330: ......

Page 1331: ......

Page 1332: ...a CONN DCEP CR a nr C O W BUS BU s CPM D m w c or mrcn ccr 4 PIN C UN...

Page 1333: ...GRAND PRlX OK FIG 8 3 G AG SERIES WIRING DIAGRAM...

Page 1334: ...FIG 8 4 F SERIES WIRING WGRAM...

Page 1335: ...V 6 CYL ENGINE Sf w 4 I W B R A B RUDW...

Page 1336: ......

Page 1337: ......

Page 1338: ......

Page 1339: ......

Page 1340: ......

Page 1341: ......

Page 1342: ......

Page 1343: ...FIG 8 6 X SERIES WIRING DIAGRAM riiiu2...

Page 1344: ...FIG 8 8 H SERIES WIRING DIAGRAM...

Page 1345: ......

Page 1346: ......

Page 1347: ......

Page 1348: ......

Page 1349: ...i J...

Page 1350: ...1 REGULATOR ALTERNATOR...

Page 1351: ......

Page 1352: ......

Page 1353: ...FIG 8 7 HM SERIES WIRING DIAGRAM...

Page 1354: ...6 Radio Dial Light 9 36 Radio Suppression Equipment 9 36 Antenna Lead In 9 36 Remove and Replace CB Radio 9 41 Power Antenna General Description 9 46 Diagnosis 9 47 On Car Service 9 49 Overhaul Proced...

Page 1355: ...OR COMPONENTS The major components of the cruise control system are 0 pushbutton engaging switch a regulator assembly 0 vacuum servo release switches electric and vacuum size of the opening being vari...

Page 1356: ...O M B L A C K WlRE TO GROUND DEPRESS ENGAGE M E N T SWITCH CONNECT T E S T L A M P F R O M B L U E WlRE A T 3 WIRE C O N N E C T O R O N STEERING C O L U M N C I R C U I T I N B L U E WlRE B E T W E...

Page 1357: ...K ACCESSORY CONNECTOR 2520 Fig 9 3 Cruise Control Wiring Schematic CRUISE CONTROL DOES NOT ENGAGE CAUSE CORRECTION Fuse blown Brake switch out of adjustment No current to terminal No 2 Engaging switch...

Page 1358: ...o 1 grounded Replace or repair wire harness CARBURETOR DOES NOT RETURN TO NORMAL IDLE CAUSE CORRECTION Faulty Cruise Control linkage cable Replace cable Improper accelerator linkage adjustment Adjust...

Page 1359: ...schematics are shown in Figs 9 21 and 9 22 and show the CRUISE CONTROL TEST PROCEDURE ROAD TEST AS FOLLOWS 1 ON A LEVEL ROAD DRIVE AT A STEADY SPEED OF 55 M P H 2 PUSH AND RELEASE ENGAGE BUTTON RELEA...

Page 1360: ...nnect ohmmeter between terminal 1 brown wire and terminal 2 blue wire Continuity shall be maintained until switch is depressed all the way in Test 2 Connect ohmmeter between terminals 1 brown wire and...

Page 1361: ...NE UP WlTH THE PIN MOVE THE STEEL TUBE REARWARD UNTIL THE NEXT CLOSEST CROSS HOLE LINES UP AND CONNECT TO THE PIN CAUTION DO NOT STRETCH CABLE SO AS TO MAKE A PARTICULAR CROSS HOLE CONNECT TO THE PIN...

Page 1362: ...m pump For further diagnosis refer to Figs 9 12 and 9 13 ON CAR SERVICE The components of the Cruise Master system are designed to be replaced if they become inoperative The regulator is calibrated in...

Page 1363: ...IES 1 DIMMER SWITCH WlRE WlRE PROTECTOR PART OF STEERING COLUMN ASM I SECTION A A S INSTALLED POSITIONT A I SECURE WlRE IN POSITION SHOWN AFTER ASM OF WIRE PROTECTOR 0 CRUISE LEVE SWITCH ASM P I TILT...

Page 1364: ...TERMINAL TO WIRE AND PULL WIRE RUlSE CONTROL WIRES INSERT WIRE INTO OPENING ROUTE THROUGH COLUMN MAlN WlRE PROTECTOR AS SHOWN INSTALL LEVER I N SEOUENCE SHOWN STARTING WlTH I SECTION A A Fig 9 9 Crui...

Page 1365: ...9 12 1977 PONTIAC SERVICE MANUAL Fig 9 1 1 Cruise Master Wiring Schematic...

Page 1366: ...NG RADIUS NOT LESS THAN 6 RADIUS CHECK DRIVE CABLE FOR DISTORTED OR BENT TIPS FERRULES MUST BE SNUG 4 CHECK FOR A BINDING THROTTLE LINKAGE CONDITION 5 CHECK ADJUSTMENT OF BRAKE RELEASE SWITCH 81VACUUM...

Page 1367: ...Y VOLTAGE A T THE DISCONNECTED BROWNIWHITE WlRE TERMINAL A T REGULATOR CONNECTOR I ENGINE DOESNOT ACCELERATE NORMAL RESULT V A C U U M L E A K O R R E S T R I C T I O N I S IF 1 or 2 ARE OK I N O l C...

Page 1368: ...e replacement is required Note the condition of the hoses and replace any which are cracked or deteriorated BRAKE RELEASE SWITCHES FIG 9 10 Electric The Cruise Master brake release switch electrical c...

Page 1369: ...R SWIVEL AND CHAlN ASSEMBLY RETAINER MUST BE POSITIONED TO REST BETWEEN BALLS VlEW 6 CUT OFF CHAlN FLUSH WlTH SlDE OF SWIVEL TO REMOVE EXCESS LENGTH CHAlN SLACK NOT TO EXCEED ONE HALF DIAMETER OF BALL...

Page 1370: ...ACCESSORIES 9 17...

Page 1371: ...UNTIL THE NEXT CLOSEST FRONT TAB HOLE LINES UP AND CONNECT PIN TO TAB WlTH RETAINER 2AUTION DO NOT STRETCH CABLE SO AS TO MAKE A PARTICULAR TAB HOLE CONNECT TO THE PIN THIS WlLL PREVENT ENGINE FROM R...

Page 1372: ...ACCESSORIES 9 19 3180 Fig 9 19 Cruise Master Regulator Mounting Y V8 B X Series...

Page 1373: ...EN LINES UP WlTH THE CABLE PIN CONNECT PIN TO TAB WlTH RETAINER 4 IF A TAB HOLE DOES NOT LINE UP WlTH THE PIN MOVE THE CABLE AWAY FROM POWER UNlT UNTIL THE NEXT CLOSEST TAB HOLE LINES UP AND CONNECT P...

Page 1374: ...ACCESSORIES 9 21 NOTE WITH C60 ROUTE HOSE THRU CLIP FRONT Fig 9 20 Cruise Master Regulator Servo Mounting U L V8 X Series...

Page 1375: ...Y ENGINE B X SERIES C7FORWARD VACUUM SOURCE AT DASH PANEL PVACUUM RELEASE VALVE INSIDE CAR R AND K ENGINES BSERIES V 6 B X SERIES uFRONT VACUUM RELEASE VALVE NSlDE OF CAR DASH ENGINE VACUUM SOURCE SER...

Page 1376: ...D VACUUM INSIDE OF CAR TUBING ASSEMBLY Y ENGINE F SERIES P AND 2 ENGINES F SERIES FRONT ENGINE VACUUM SOURCE SERVO ASM ENGINE COMPARTMENT FRONT SERVO FORWARD SERVO ASM DASH PANEL ENGINE COMPARTMENT WI...

Page 1377: ...of the rear speaker diminishes and the volume of the front speaker increases After the desired relative speaker volume is obtained both speakers total volume can be regulated by the volume control kn...

Page 1378: ...ge pull gently out of the radio face F Series uses a console mounted tape player separate from the radio see Fig 9 27 It has a separate program button and separate volume and stereo separation control...

Page 1379: ...t channel by turning it slowly clockwise until the background noise disappears The receiver will resume operation automatically when a station comes on the air If the control is turned further clockwi...

Page 1380: ...ther it occurs with engine off or running and whether it occurs with car stationary or moving will help to pinpoint the problem CB UNITS A number of common problems can prevent good transmission and r...

Page 1381: ...the car must be at least 20 feet away from any building Make certain that the ignition and the C B radio are turned off Disconnect the C B antenna from the C B radio Connect one end of the antenna ju...

Page 1382: ...NT SWISH SOUND A5 BLOWER MOTOR NOISE USE PROCEDURE 6 TAPE ONLY WEAK 9 FM ONLY WEAK ANOTHER C W WlTH AN FM R I D 0 TUNE N A WEAK AADIO WORXS I 1 STILL WEAK 1 i T yGiLy 1g e T CHECK ANTENNA AN0 LEAD IN...

Page 1383: ...NING AM AND FM DEAD ALL MODES DEAD u CHECK FUSE 9 I CHECK THAT ANTENNA IS PLUGGED INTO RADlO MAKE SURE PLUG ISN T LOCKED I FUSE OK I FUSE BLOWN I 1 GOOD CONNECTION BAD CONNECTION I 1 CHECK AT M E RADI...

Page 1384: ...TAPE DOOR YOU CAN LEAVE THE TAPE PLAYER IN THE CAR TO CLEAN THE HEAD AND CAPSTAN USE A COTTON SWAB DIPPED IN ORDINARY RUBBING ALCOHOL WIPE THE HEAD AND CAPSTAN AS SHOWN IN FIGURE c MOST STORES THAT S...

Page 1385: ...FEED WIRES FROM BACK OF RADIO 2 CONNECT FILTER PACKAGE PIN 12234801 TO A RADIO FIGUREfl CONNECT THE GROUND LEAD TO A RADIO CASE SCREW 3 CONNECT RADIO FEED WIRES TO OTHER END OF FILTER PACKAGE PROCEDU...

Page 1386: ...nd continue the NOTE If antenna is not trimmed the set will have weak adjustment and fading AM reception Antenna trimming should always be performed after any radio or antenna repair Place radio t o A...

Page 1387: ...Radios A Series Fig 9 39 and 9 40 1 Disconnect battery 2 Remove radio knobs and bezels 3 Remove I P lower trimplate 4 Remove I P upper trimplate 5 Remove 2 radio front retaining screws 6 Remove radio...

Page 1388: ...ANTENNA LEAD ACCESSORY LEAD AM FM RADIO OR AM FM STEREO RADIO I ANTENNA LEAD AM RADIO CONVECTOR POWER LEAD REAR SEAT FRONT SPEAKER LEAD POWER LEAD SPEAKER LEAD FRONT SEAT SPEAKER LEAD SPEAKER LEAD TAP...

Page 1389: ...with integral tape players allow access to the dial light bulb through the tape door Radio dial lights can be replaced by removing the radio as previously described on B H HM and X Series with integr...

Page 1390: ...RS ONLY AM FM RADIO WlTH AM FM WITH AM FM STEREO OR TAPE STEREO OR T 1 TO RECEIVER THIS LEAD WlTH POWER LEAD EAR SPEAKER AD OPTIONAL AM FM RADIO AM FM STEREO RADIO FRONT SPEAKERS REAR SPEAKERS AM FM S...

Page 1391: ...FRONT SPEAKER CONNECTOR FRONT SPEAKER VIEW A AM FM RADlO VIEW CONNECTOR A M RADlO TO REAR SEAT CONNECTOR POWER LEAD FRONT SPEAKER VIEW A CONNECTOR AM FM RADlO WlTH REAR SPEAKER A M RADlO WlTH REAR SP...

Page 1392: ...CESSORIES 9 39 TRIM PLATE TO REAR SEAT FRT SPEAKER AM RECEIVER STEREO TAPE PLAYER AM FM AM FM STEREO RECEIVER TAPE PLAYER TAPE PLAYER WIRE ASM ROUTING fAuAQEu Fig 9 43 Stereo Tape Installation F Serie...

Page 1393: ...NFORMATION 4066 Fig 9 44 Radio Installation X Series REAR FRONT LCAU IAR SPE SPEAKER LE IF FRONT SPEAKER FRONT LEAD REAR SPEAKER LE REAR SPEAKER LEAD IP J HARNESS RECEIVER ASSEMBLY AMITAPE AM FM STERE...

Page 1394: ...NEL REINFORCEMENT REAR SPEAKER LEA IF USED 4088 Fig 9 46 Radio Installation HM Series NOTE TAB MUST INSTALL INTO SLOT RECEIVER TYPICAL 4090 1 REMOVE AND REPLACE CB RADIO CB radio installation is shown...

Page 1395: ...2APACITOR SSEMBLY A G SERIES HOOD CLIP HEATER OR A C BLOWER MOTOR 2494 Fig 9 48 Radio Suppression Equipment Typical ANTENNA BASE SHIPPED IN TRUNK ATTACHED TO DECK LID BY DEALER SCREWS VIEW B DEALER IN...

Page 1396: ...A LEAD DEALER INSTALLED EXlSTlNG BRACKET INSTALLED I N CAR TRANSCEIVER ASM RT OF TRANSCEIVER A G AND B SERIES TRANSCEIVER ASM EXlSTlNG FRONT SEAT SPEAKER EXlSTlNG REAR SEAT SPEAKER TO SHIFTER BRACKET...

Page 1397: ...9 44 1977 PONTIAC SERVICE MANUAL VIEW A AG G SERIES F SERIES L 60 VIEW B B SERIES Fig 9 5 1 Microphone Mounting B F G AG Series...

Page 1398: ...ESS TO IN DASH RADIO B SERIES TO TRANSCEIVER ASSEMBLY MICROPHONE 4 4 HEAD IN DASH RADIO e M 4 I DUCT SCREWS LEAD AG INSIDE A C DUCT TAB I A M CROPHONE LEAD RADIO HARNESS L CLIP B 3 i n w s a f IID Fig...

Page 1399: ...ch Refer to Fig 9 55 for the electrical wiring circuit The drive gear unit used on this system consists of a drive gear and pulley assembly and a spool for storing the excess nylon drive cable when th...

Page 1400: ...use and recheck antenna operation ANTENNA RUNS OK End of test ANTENNA INOPERATIVE Recheck antenna fuse Blown Go to Step 3 OK Go to Step 4 STEP 3 Disconnect wiring at antenna unit replace fuse and actu...

Page 1401: ...Fig 9 56 Step 4 ANTENNA RUNS OK Black wire ground connection at antenna support tube loose or wire is broken ANTENNA DOESN t RUN Go to Step 5 STEP 5 Disconnect wiring from antenna unit and try ANTENN...

Page 1402: ...move If drive cable does not appear to be worn freely or damaged replace c mplete antenna assembly NOTE If antenna has been extended for a length of time and will not retract try cleaning the mast be...

Page 1403: ...the gear box Refer to Fig 9 60 NOTE If mast fails to extend and or drive cable does not move out of gear box manually assist mast or cable while motor is running Assembly la Refer to Fig 9 61 and sta...

Page 1404: ...ACCESSORIES 9 51 Fig 9 59 Power Antenna Wiring...

Page 1405: ...dication of the charging systems ability to keep the battery charged Continuous readings in either the high or low voltage red bands can indicate improper voltage regulation broken or slipping alterna...

Page 1406: ...use thereby eliminating accumulation of errors With the direct current system no such control is possible therefore automobile electric clocks will accumulate errors day by day the same as handwound s...

Page 1407: ...now read below 0 3 If gage reads properly in steps 1 and 2 replace the sending unit If it does not the trouble is either in the gage or the wiring to the gage 4 Noticeably improves FM reception shoul...

Page 1408: ...per trimplate removing the cluster lens and removing the gage from the front see Section 8 Fig 9 71shows the digital clock removal which requires only trimplate removal and Fig 9 72 shows fuel economy...

Page 1409: ...CONNECTOR THRU HOL N CARRIER ASM TO rERMlNALS ON LUSTER ASM GRAND PRIX GRAND LE MANS TACHOMETER TACHOMETER WIRE PINK Jy I P HARNESS LE MANS TACHOMETER WIRE TO TACH TERMINAL R VIEW A NITION CAVITY FUSE...

Page 1410: ...ACCESSORIES 9 57 DIGITAL CLOCK Fig 9 7 1 Digital Clock B Series rCLUSTER ASM PWR BRAKE MASTER CYL A 3237 Fig 9 72 Fuel Economy Gage Hose Routing B Series...

Page 1411: ...1977 PONTlAC SERVICE MANUAL RETAINER VIEW A A F SERIES AG G SERIES WITHOUT TACH SPEEDOMETER SHAFT Fig 9 70 Fuel Economy Gage Hose Routing...

Page 1412: ...ACCESSORIES 9 59 Fig 9 73 Rally Gage and Tach Installation F Series...

Page 1413: ...LE AT DISTRIBUTOR TACHOMETER LUG INTO IGN CAVITY 4072 Fig 9 74 Tach Wiring X Series INSTRl INST CLUSTER CLUSTER I INSTRUMENT CLUSTER HARN CONN HARNESS CONNECTOR HM SERIES H SERIES JMENT CLUSTER ASM VI...

Page 1414: ...s not to damage the grid contact the bare wire to the grid adjacent to the garnish molding The test lamp should glow at full brilliance Contact the same grid line midway across the window The lamp sho...

Page 1415: ...CONSOLE ASM I P WIRE HARNESS LAMP ASM LIGHT GUIDE TO ASH TRAY LAMP ASM ASH TRAY TRIM PLATE BOX CONSOLE ASH TRAY LAMP SHIFT INDICATOR LAMP AUTOMATIC TRANSMISSION...

Page 1416: ...UNDER CARPET I MANUAL TRANSMISSION AUTOMATIC TRANSMISSION X SERIES ONLY WITHOUT A ROUTE UNDER CARPET ROUTE UNDER CARPET RADIO FEED BEHIND HEATER AND TRIM PLATE ASM THRU V OF DEFROSTER A SERIES 1 INSTA...

Page 1417: ...UTCHEON ASM J kt CONSOLE ASM INSTALLS SAME AS MAN TRANS MANUAL TRANSMISSION AUTOMATIC TRANSMISSION INSTRUMENT PANEL HARNESS LEAD WIRING HARNESS AUTO TRANS ONLY ASM ESCUTCHEON ASM REAR SEAT CONSOLE Fig...

Page 1418: ...h any time the deck lid is opened The lamp should not illuminate until the lid is opened 6 to 8 inches DECK LID RELEASE An electric deck lid release is available on A G B and F Series The switch is wi...

Page 1419: ...E MANUAL R AND K V 8 s B SERIES U AND L V 8 s X SERIES REAR HOLE ELEMENT UP FIRST HOLE ELEMENT FIRST HOLE 2ND HOLE FROM FRONT ELEMENT DOWN ll R AND K V 8 s F X SERIES R AND K V 8 s A SERIES Fig 9 81 E...

Page 1420: ...NlT IN POSITION ELEMENT UP AND CAREFULLY INSTALL IN AND CLAMP CONTACTING CYLINDER CYLINDER BLOCK AS SHOWN BLOCK WALLS TIGHTEN SCREW I DO NOT SCUFF OR OTHERWISE DAMAGE THE 0 RING OR SEAL 0 RING SEAL IN...

Page 1421: ...ONTIAC SERVICE MANUAL LINE CONNECTOR TO I P HARNESS AG G SERIES VlEW A VIEW C 7 BODY LEAD TO DEFOGGE J BULKHEAD COVER DEFOGGER CONNECTOR RETAINER OPENING VlEW B 4067 Fig 9 85 Rear Window Defogger A an...

Page 1422: ...TE POINT A TO BE COMPARTMENT MEASURED FROM IEWA CENTER OF LIGHT SWITCH HOLE H A W ASM T FL 12H SEE DETAIL L FUSE PANEL ORCEMENT I II1L 4091 Fig 9 87 Rear Window Defogger H Series BEZEL NOTE CIRCUIT P...

Page 1423: ...9 70 1977 PONTIAC SERVICE MANUAL INSTR PANEL 1 4068 Fig 9 86 Rear Window Defogger F Series...

Page 1424: ...ACCESSORIES VIEW A LFUSE BLOCK Fig 9 89 Controlled Cycle Wiper B Series...

Page 1425: ...ONTIAC SERVICE MANUAL AG G SERIES T O WlPER MOTOR T O WIPER MOTOR FUSE BLOCK WIPER MOTOR 4073 I Fig 9 90 Controlled Cycle Wiper A and G Series RELAY MTG BRKT T T _ _ 4074 Fig 9 91 Controlled Cycle Wip...

Page 1426: ...TROLLER STEERING SUPPORT TURN SlGNA CONNECTOR FUSE PANEL H SERIES TYPICAL HM SERIES 4077 Fig 9 92 Controlled Cycle Wiper H and HM Series ROUTING FOR AIR I CONDITIONEDCARS 1 I w 4070 Fig 9 93 R H Rear...

Page 1427: ...UIT THRU THRU l DOOR GROMMET TRIM PLATE EXTENSION AD RETAINER I 080 R TYP I l l t HOLE RL J P PAD RETAINER VIEW AA Fig 9 94 R H Rear View Mirror G Series IRROR CABLE BY BODY BUILDER R H MIRROR OPENING...

Page 1428: ...RN OFF WHEN DECK LID TRAVELING FROM OPEN TO CLOSED POSITION IS 14 00 TO 20 00 INCHES FROM REAR DECK WITH CAR ON LEVEL SURFACE EXISTING BODY SECTION A A 7 Fig 9 96 Luggage Compartment Lamp Typical Fig...

Page 1429: ...AG G SERIES I GLOVE BOX 7 BODY WIRE T O DECK L I D RELEASE I A SERIES LOOPBIRE ASM HOLD IN POSITION WITH EXIST I P CLIP T O TAKE UP EXCESS HARNESS E C K LID RELEASE SWITCH F SERIES VIEW A 2525...

Page 1430: ...PICAL SWITCH INSTALLATION USE THE FOLLOWING GENERAL GUIDELINES FOR LOCATING SWITCHES 1SWITCH MOUNT AT B 4 SWITCHES ALL FOUR LOCATIONS 2 SWITCHES MOUNT AT B AND C NOTE REMOTE MIRROR IS ALWAYS 3 SWITCHE...

Page 1431: ...01 Tailgate Release A Series Wagon id SWITCH EXISTING LEAD INSTRUMENT FUSE PANEL INSTRUMENT PANEL WIRE HARNESS INSTRUMENT PANEL WIRE HARNESS BLOCK CIRCUIT BREAKER IGN EXISTING FISHER LEAD INSERT INTO...

Page 1432: ...INTO DEFLECTOR SUPPORTS BYAPPLYING SlDE PRESSURE ON SlDE RAILS AND DEFLECTOR SUPPORTS 4 CHECK CENTER SUPPORT ALIGNMENT WlTH HOLE IN DEFLECTOR BLADE AND HOLE MARKED ON ROOF ADJUST HOLE ACROSS CAR IF R...

Page 1433: ...OGGER IC4Ul lVlN CODE C R K ENGINES ONLY GRD A RADIO GROUND 0150 18 BLK B DIAL LP FEED 4 1 8 GRA STEREO RADIO C RADIO PWR FEED 1 3 1 8 YEL 0 LR SPKR GRD 0118 18 VEL MONAURAL OR STEREO U RF SPKR e m 2...

Page 1434: ...CLOCK PWR ON FUSE BLOCK REAR WINDOW ELECTRIC DEFOGGER m 9 H I D RR GLASS TIMER RELAY LKHEADCOVER AG G SERIES 1 2 1 L 0ACK WINDOW GLASS CENTER FRONT SPEAKER 0 RADIOGRD 1W I0 BLK B DIAL LP FEED 4 1 0 GR...

Page 1435: ...N LT BALANCE BALANCE V RR SPKR CRO U150A 20 BLK CDNTROL CONTROL W RR SPKR 478 18 BLU OK Y TAPE PLYR GRD U150B 20 BLK Z RR SPKR GRD 477 18 BLK MONAURAL RADIO WlTH FRONT STEREO TAPE PLAYER REAR SPEAKER...

Page 1436: ...6 G SERIES I PULSE WlS WlPER SWITCH 1 L 2 0 B L K 18 OK B L U ION CAVITY IIP WIRE H A R N PULSE WIS WIPER CONTROLLED CYCLE WlPER SYSTEM C M X SERIES Fig 9 107 Accessory Wirini VISOR VANITY MIRROR OM...

Page 1437: ...INDOW DEFOOGER 10 RED U 9 PART OF ENGINE HARN 1151 L4l PART OF POSITIVE BATTERY CABLE IV 61 150b 16 ELK c 39A1193A 18 GRN DK GLASS INSTR PNL GROUND CIRCUIT BREAKER 150 REAR WINDOW DEFOGGER 2 U 9 HM SE...

Page 1438: ...1 37 50 Carburetor Air Cleaner and Silencer 6C 7 Carburetor Service Specifications 6C 13 30 41 55 73 Carburetor 5210 6C 8 Carburetor 2GC 2GE 6C 21 Carburetor M2MC 6C 37 Carburetor M4MC 6C 50 Carbureto...

Page 1439: ...d 6A1 15 6A2 6 6A 3 4 6A4 6 6A5 5 6A 6 5 Exhaust System 6F 1 Exploded Service Procedures Front and Rear Bumpers 2B3 15 Exploded ServiceProcedures Front End Fenders and Hood 2C 8 20 Fan 6B 4 Fan Belt 6...

Page 1440: ...B 16 Lift Points Frame OB 12 13 Lock Cylinder OA 3 Locking Code OA 3 Lower Ball Joint 3C 8 9 Lower Control Arm Front 3C 12 13 Lower Control Arm Rear 3D 7 Lower Control Arm Bushing Front 3C 12 13 Lower...

Page 1441: ...anel Heights 3A 10 11 Roof Rack 9 79 Rotor 5 35 Safe T TrackDifferential 4B 1 Seat Belts see Fisher Body Manual Seat Belts WarningSystem 8 70 Secondary Cables Plus Wires 6D 26 37 38 39 Serial Numbers...

Page 1442: ...Universal Joints 4A 10 Universal Joint Steering 3B4 47 48 49 Upper Ball Joint 3C 7 16 17 Upper Control Arm Front 3C 10 11 Upper Control Arm Rear 3D 3 Upper Control Arm Busing Rear 3D 7 Urethane Part...

Page 1443: ......

Reviews:

No comments