Haynes Chevrolet Chevette & Pontiac T1000 Automotive Repair Manual 1850103437, 9781850103431

Citation preview

HEVROLET CHEVETTE ONTIAC T1000 976 thru 1987 Ul gasoline engine models 1.6 liter (98 cu .4 liter (85 cu in)

in)

Owners Workshop Manual

Chevrolet Chevette

&PontiacT1000

Owners Workshop Manual by RGO Hawes, CurtChoate and John H Haynes Member

of the Guild of Motoring Writers

Models covered: Chevrolet Chevette and Pontiac

T1000

2-door and 4-door hatchback coupes and sedans with 1.4 liter (85 cu in) and 1.6 liter (98 cu in) gasoline engines; 4-speed, 5-speed and automatic transmissions

Does not cover

diesel engines

ABCDE FGHIJ

KLMNO

AUTOMOTIVE

^m A

ASSOCIATION

MtMBtk

Haynes Publishing Group Sparkford Nr Yeovil

Somerset BA22 7JJ England

Haynes Publications, Inc 861 Lawrence Drive

Newbury Park California

91320 USA

Acknowledgements We are grateful for the help

and cooperation of the Chevrolet and Pontiac Divisions of General Motors Corporation for their assistance with technical information, certain illustrations and vehicle photos, and the Champion Spark Plug Company, suppliers of the illustrations showing various spark plug conditions.

©

Haynes Publishing Group 1987

A book

the

in

Haynes Owners Workshop Manual Series

Haynes & Co., Somerset BA22 7JJ, England Printed by J.H.

Ltd. Sparkford Nr. Yeovil,

No part of this book may be reproduced any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

All rights

reserved.

or transmitted in

ISBN

85010 343

1

Library of

Congress Catalog Card Number 87-80360

While every care

manual

is

is

correct,

taken to ensure that the information in this liability can be accepted by the authors

no

damage or injury caused or omissions from, the information given.

or publishers for loss, in,

7

by any errors

Contents Introductory pages

About

this

manual

Introduction to the Chevrolet Chevette/Pontiac T1000 Vehicle identification numbers Buying parts Maintenance techniques, tools and working facilities Booster battery (jump) starting

Jacking and towing Automotive chemicals and lubricants Safety first! Conversion factors Troubleshooting

5 5 6

8 8 15 16 17 18 19

20

Chapter 1 Tune-up and routine maintenance

27

Chapter 2 Part A 1 .4 and 1 .6 liter gasoline engines

56

Chapter 2 Part B General engine overhaul procedures

72

Chapter 3 Cooling, heating and

air

conditioning systems

Chapter 4 Fuel and exhaust systems

91

100

Chapter 5 Engine electrical systems

119

Chapter 6 Emissions control systems

130

Chapter 7 Part A Manual transmission

143

Chapter 7 Part B Automatic transmission

165

Chapter 8 Clutch and driveline

170

Chapter 9 Brakes

181

Chapter 10 Steering and suspension systems

198

Chapter

1

Body

211

Chapter 12 Chassis electrical system

233

Wiring diagrams

250

Index

271

About Its

this

manual

purpose of this

manual

is

to help

simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its For

Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered section you will be referred to any illustrations which apply to the procedures in that section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within lines.

you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. It is hoped that you will use the manual to tackle the work yourself.

The purpose

many

labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after having done the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal

that Section.

Procedures, once described in the text, are not normally repeated. it is necessary to refer to another Chapter, the reference will be given as Chapter and Section number i.e. Chapter 1/16). Cross references given without use of the word "Chapter" apply to Sections and/or paragraphs in the same Chapter. For example, "see Section 8" means in the same Chapter. Reference to the left or right side of the vehicle is based on the assumption that one is sitting in the driver's seat, facing forward. Even though extreme care has been taken during the preparation of this manual, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

When

NOTE A Note

provides information necessary to properly complete a procedure or information which the steps to be followed easier to understand.

will

make

CAUTION A Caution

indicates a special procedure or special steps which must be taken in the course of completing the procedure in which the Caution is found which are necessary to avoid damage to the assembly being

worked

on.

WARNING A Warning

indicates a special procedure or special steps which must be taken in the course of completing the procedure in which the Warning is found which are necessary to avoid injury to the person performing the procedure.

Introduction to the

Chevrolet Chevette/Pontiac This manual covers Chevrolet Chevette models manufactured from 1976 on and Pontiac T1 000 models manufactured from 1981 (the year they were introduced) on. These vehicles are very conventional in design, with the engine mounted at the front. Power passes through the transmission and drive-

T1000

locating the axle at the rear. Steering assist as an option on some models.

is

rack and pinion with power

Disc brakes are used at the front, while drum brakes are installed Power assist was available as an option on later models. The front brake pads feature audible wear indicators and the rear brakes at the rear.

shaft to the rear-mounted differential.

are self-adjusting.

The suspension system features unequal-length control arms at the

A four-speed manual transmission was standard equipment with a five-speed manual or three-speed automatic available as options.

springs with independent, front and trailing control arms

coil

'

Vehicle identification numbers Modifications are a continuing and unpublicized process in vehicle manufacturing. Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are essential to correctly identify the

component

and Registration. It contains valuable information such as where and when the vehicle was manufactured, the model year and the body

of Title

style.

required.

Body number Vehicle Identification

Number

plate

This plate is located on the front end tie-bar (see illustrations). Like the VIN, it contains valuable information concerning the production

(VIN)

This very important identification number is attached to the dashboard on the driver's side of the vehicle and is visible through the windshield (see illustrations). The VIN also appears on the Vehicle Certificate

of the vehicle as well as information about the

way in which the vehicle

equipped. This plate is especially useful for matching the color and type of paint during repair work. is

"\

The Vehicle Identification Number (VIN) is attached dashboard on the driver's side of the vehicle .

to the .

.

and

.

visible

is

through the windshield

.

BODY STYlE

BODY TYPE

ASSEMBLY Piant

Division

UNIT

MODEL year

TJ TSBOV

m

24U

ftSl

147149 ai 211 21U V

ST^

4037 uvi

&3B

DEALIU :L$co*ifOAJ$iQ*LiU Irii

rSr

JR

iQOO.

//^\

.000

BODY BY" FISHER '123456' T'6T r ,

T

A51,

11

I

U,

.11

:o) g:ne R4J. MOTORS CORi'ORAtlON CERTIFIES TO THE DEALER THAT THIS

ttiXt trill

VEHICLE

iQ4 Vi*iiCli S«t/i

CONFORMS TO ALL U S

rf'EDER AL

MOTJOR VEHICLE SAFETY BTAN )ARDS APPL CABLK AT TIME OF MANUFACTURE CODE — COMBINATION _ NUMBER

Time BUILT

T«IM

LOWER BODY COLOR UPPER BODY OR FABRIC TOP COLOR

MODULAR SEAT CODE

The body number

attached to the tie-bar at the front of the vehicle plate

is

NUMBER

Body number

plate key

OPTION DESIGNATION

Numbers

Vehicle Identification

Engine identification number The engine number is stamped into a pad located at the right front corner of the engine block, just above the oil pan-to-block joint (see illustration).

Manual transmission The

identification

number

identification is

stamped

right side of the transmission

into a

case (see

number pad centered on the lower

illustration).

Automatic transmission identification number The

identification

number

is

located on a tag attached to the right

side of the torque converter housing (see illustration).

Service parts identification label This label, found only on later models, provides valuable information needed when buying or ordering replacement parts. Included on the label are codes for regular production options (RPO's) and standard and mandatory options. It is attached to the floor of the luggage area (see illustration).

Vehicle Emissions Control Information label The Emissions Control Information label is attached to the underside of the hood (see illustration).

The engine identification number is stamped into the lower edge of the block, near the front (arrow)

VIN LOCATION

VIN LOCATION

Automatic transmission VIN number location

Manual transmission VIN number location

«HICU

EMISSION CONTROL INFORMATION

umui I

«tf.t«*>

WITH

!*•*

IT

aoion coirouucw

CATALYST ma "

[e]

'n

1W )| OffMTl I

MT HMHO UAH AND KOCI Mrvi WMWS MOHMC MCj rur. K , **l u «**» :«AHM 1 w*wit rum MHU) Ml COW «UU CUB vnir,«. IUMW14H AW WCBWlCHICWAiUfcA'KUWO AOAA! U K4WUXJW>*M>? VXPCCICD* WU^tlWCWA UACJ

u/ [w CU» CU VHP QWM) srtm nuc

i

I

lAWl )

t

The service parts

identification label

source of information

when new

is

(MO

WTTHftftl»*TOT

MjYCOU*mO*0

WM

.

>'

V-,1

MT T*-Mt II VK>IC 4TM BUT CM f M^UIY RKOMRKI *«-JUMX)« irtrTRftjTC* «TH «TO tlAM CNVOMtT *JC nift VACUUM Xftl 11 IU HAW *.•«.». JR NlUTtM II' U(t CXI VtfDOMNBN "

'

routed

move

or

get hot. The retainer must be installed with the tang secured over the head of the stud.

'

y 22.4b

22

^NECK, LOWER

Fuel tank

—

Fuel

filler

neck

—

later

models

removal and installation

Refer to illustrations 22.3, 22.4a, 22.4b, 22.6a and 22.6b

Warning: Gasoline is extremely flammable, so extra precautions must be taken when working on any part of the fuel system. Do not smoke or allow open flames or bare light bulbs near the work area. Also, do not work in a garage if a natural gas appliance equipped with a pilot light is present.

Chapter 4

Fuel and exhaust

117

systems

ANTI-SQUEAK

22.6a

The

fuel tank is held in place with

are bolted to the

24.2

Apply penetrating

remove the

1

oil

two straps

The fuel tank strap bolts are probably corroded, so apply penetrating oil to the threads (arrow) and let it soak for a few minutes before attempting to remove them 22.6b

that

mounts

to the threads, then loosen

catalytic converter flange bolts,

.

.

and

24.3

For the sake of safety and convenience, the fuel tank should be if at all possible. If circumstances permit, run

empty before removal

the tank dry, or almost dry, by driving the vehicle. Due to the fuel tank shape it will probably be impossible to siphon fuel from the filler hole — the only alternative is to pump or siphon fuel from the fuel feed line. Disconnect the battery ground cable. 2 Raise the vehicle and support it securely on jackstands. Do not work under a vehicle that is supported only by a jack. 3 Disconnect the meter assembly (sending unit) wire at the rear harness connector and the ground strap at the fuel tank reinforcement (see illustration). 4 Disconnect the fuel filler neck hose and the vent hose (see

hanger (arrow)

slide the rear

the bracket

.

.

.

off

.

must be removed and cleaned. When the tank is removed it should be flushed out with hot water and detergent or, preferably, sent to a radiator shop for chemical flushing. Warning: Never attempt to weld, solder or make any type of repairs on an empty fuel tank. Leave this work to a repair shop. 3 The use of a chemical type sealer for on-vehicle repairs is advised only in case of emergency; the tank should be removed and sent to a shop for more permanent repairs as soon as possible. 4 Never store a gas tank in an enclosed area where gas fumes could it

2

build

up and result

in

an explosion or

fire.

illustrations).

5

Disconnect the

6

Remove

fuel feed line and vapor line at the hose connection. the fuel tank strap rear support bolts and lower the tank

24

Exhaust system

— component

replacement

(see illustrations). Installation is the reverse of removal. Be sure to tighten the 7 fasteners securely and check for leaks.

23 1

Fuel tank

If

—

cleaning and repair

the fuel tank has a build-up of sediment or rust

in

the bottom,

Refer to illustrations 24.2, 24.3, 24.4 and 24. 7

Muffler and tailpipe The tailpipe must be replaced whenever the muffler is replaced. 1 Raise the vehicle and support it on jackstands. Remove the bolts and nuts attaching the muffler and pipe assembly 2 to the catalytic converter (see illustration). Detach the tailpipe hanger by sliding the hanger off the bracket 3 (see illustration).

1

118

Chapter 4

24.4

.

.

.

Fuel and exhaust systems

and unhook the rubber hangers to detach the muffler/tailpipe assembly

Remove the muffler hangers and detach the muffler and pipe 4 assembly (see illustration). 5 Installation is the reverse of removal. Make sure that a minimum clearance of 5/8-inch exists between any part of the exhaust system and the vehicle body before tightening any fasteners.

Exhaust pipe 6

Raise the vehicle and support

it

on jackstands.

24.7

7

The exhaust pipe is attached to the exhaust manifold with two nuts (arrows)

Disconnect the front end of the exhaust pipe

at the

manifold (see

illustration).

8 9

Remove Remove

1

Lower the vehicle

the catalytic converter hanger. the two remaining bolts and nuts that attach the exhaust pipe to the converter, then detach the exhaust pipe. 1 Installation is the reverse of removal. Check the clearance between the converter and the body before tightening the nuts and bolts. to the ground.

Engine electrical systems

Chapter 5 Contents

Alternator — removal and installation Alternator brushes — replacement Battery cables — check and replacement

12 13 4 See Chapter 1 3

Battery check and maintenance Battery — emergency jump starting

Battery — removal and installation 2 Charging system — check 11 Charging system — general information and precautions .... 10 Distributor — removal and installation 8 Drivebelt check, adjustment and replacement See Chapter 1 Ignition coil — check and replacement 6 Ignition module — replacement 7 .

.

.

— check and replacement 9 check 5 Ignition general information and precautions 1 Ignition timing check and adjustment See Chapter 1 Spark plug replacement See Chapter 1 Spark plug wire, distributor cap and rotor check and replacement See Chapter 1 Starter motor — in-vehicle check 15 Starter motor noise — diagnosis and repair 18 Starter motor — removal and installation 16 Starter solenoid — removal and installation 17 Starting system — general information 14 Ignition pick-up coil

Ignition

system system

— —

Specifications

Ignition

system 1-2-3-4 1-3-4-2

Cylinder numbers (front-to-rear) Firing order Distributor direction of rotation

Clockwise

.

Charging system See Chapter

Drivebelt deflection

Ignition

1

system

—

Module (ECM), which monitors data from various engine computes the desired spark timing and signals the distributor to change the timing accordingly. The secondary (spark plug) wire used with the HEI system is a carbon impregnated cord conductor encased in an 8 mm (5/1 6 inch) diameter tronic Control

general information and precautions

The

ignition system consists of the ignition switch, the battery, the the primary (low tension) and secondary (high tension) wiring circuits, the distributor and the spark plugs. coil,

A

1

High Energy Ignition (HEI) distributor

is

used on

all

models. The

is mounted separately, to the rear of the distributor. The HEI distributor has an internal magnetic pick-up assembly which contains a permanent magnet, a pole piece with internal teeth and a pick-

ignition coil

up coil. Spark timing changes on early models are handled by a combination of vacuum and mechanical advance mechanisms built in to the distributor. On later models, advance is carried out electronically by the Elec-

sensors,

rubber core with an outer silicone jacket. This type of wire will with stand very high temperatures and provides an excellent insulator for the HEI's high voltage. Silicone spark plug boots form a tight seal on each plug (for more information on spark plug wires, refer to Chapter 1 ). Warning: Because of the very high voltages generated by the HEI system, extreme care should be taken whenever an operation involving ignition components is performed. This not only includes the distributor, coil, ignition module and spark plug wires, but related items such as the plug connections and test equipment.

120

Chapter 5

Engine electrical systems

2.3 The battery hold-down clamp bolt (arrow) must be kept tight or the battery could move around

5.2

gap,

Battery

—

removal and installation

Refer to illustration 2.3

The battery

5

is

Battery

— emergency jump

starting

Refer to the Booster battery (jump) starting procedure at the front of this manual.

4

Battery cables

—

a spark

it

Ignition

is

functioning normally and the engine should start

system

—

check

Warning: Because of the very high voltages generated by the High Energy Ignition (HEI) system, extreme care should be taken whenever an operation is performed involving ignition components. This not only includes the distributor, coil, control module and spark plug wires, but related items such as the plug connections and test equipment.

HEI system calibrated

check and replacement

ignition tester

method

the engine turns over but will not start, disconnect the spark plug lead from any spark plug and attach it to a calibrated ignition tester for the HEI system (available at most auto parts stores). Connect the clip on the tester to a ground such as a metal bracket 2 (see illustration), crank the engine and watch the end of the tester to see if a spark occurs. 3 If a spark occurs, sufficient voltage is reaching the plugs to fire 1

3

system should be checked with

is

Refer to illustration 5.2

located at the front of the engine compartment. Disconnect the battery cables from the battery — negative first, 2 then positive. 3 Remove the bolt and detach the hold-down clamp, then lift the battery out of the carrier (see illustration). 4 Installation is the reverse of removal. Be sure to tighten the holddown clamp bolt securely or the battery could be damaged. 1

ignition

calibrated for the HEI voltage output — if the ignition system produces a spark that will jump the tester

and be damaged

2

The

tester that

If

the engine. 4 If no spark occurs, remove the distributor cap and check the cap and rotor as described in Chapter 1 If moisture is present, use WD-40 or a similar product to dry out the cap and rotor, then reinstall the cap and repeat the spark test. 5 If no spark occurs at this point, the tester should be attached to the wire from the coil and the check should be repeated. If no spark occurs, Check the wire connections at the coil to make sure they are clean and tight. If sparks now occur, the distributor cap, rotor, plug wire(s) or coil-to-cap wire may be defective. If there is still no spark, have the system checked by a dealer service department or repair shop. .

Periodically inspect the entire length of each battery cable for damage, cracked or burned insulation and corrosion. Poor battery cable connections can cause starting problems and decreased engine 1

performance.

Check the cable-to-terminal connections

at the ends of the cables strands and corrosion. The presence of white, fluffy deposits under the insulation at the cable terminal connection is a sign that the cable is corroded and should be replaced. Check the terminals for distortion, missing mounting bolts and corrosion. If only the positive cable is to be replaced, be sure to disconnect 3 the negative cable from the battery first. Always disconnect the negative cable first and hook it up last. 4 Disconnect and remove the cable. Make sure that the replacement cable is the same length and diameter. Clean the threads of the starter or ground connection with a wire 5 brush to remove rust and corrosion. Apply a light coat of petroleum jelly to the threads to ease installation and prevent future corrosion. Attach the cable to the starter or ground connection and tighten 6 the mounting nut securely. 7 Before connecting the new cable to the battery, make sure that it reaches the terminal without having to be stretched. 8 Connect the positive cable first, followed by the negative cable.

2

for cracks, loose wire

Alternative

method

you are unable to obtain an HEI tester, the following method Note: will enable you to determine whether the ignition system is producing spark, but it will not tell you if there is enough voltage present to actually initiate combustion. If

the spark plug wire from a spark plug. Using an insulated wire about 1/4-inch from a good ground and have an assistant crank the engine. 7 If a spark occurs, sufficient voltage is reaching the plugs to fire

6

Remove

tool, hold the

the engine. 8 If no spark occurs, remove the distributor cap and check the cap and rotor as described in Chapter 1 If moisture is present, use WD-40 or a similar product to dry out the cap and rotor, then reinstall the cap .

Chapter 5

6.1

Depress the tab and detach the

coil

121

Engine electrical systems

6.2

cover.

.

.

then spread the retainers (arrows) on the connector

.

and unplug the wire harness from the

ignition coil

FUEL

PUMP BOLTS

6.9

The

ignition coil

is

attached to the engine just to the

rear of the distributor,

6.5

distributor cap, rotor, plug wire(s) or coil-to-cap wire

there

is still

may be

no spark, have the system checked by

Ignition coil

—

defective.

a dealer service

check and replacement

Refer to illustrations

6. 1,

6.2, 6.5

Remove

3

Disconnect the coil-to-distributor cap lead

An ohmmeter will be required to check the coil. With the ohmmeter range selector on the High scale, connect

ohmmeter

leads to terminal

1

(upper

at the coil.

the

(see illustration) and the metal should indicate infinite resistance.

left)

frame around the coil. The ohmmeter Attach the meter leads to terminal 2 (upper right) and the large 6 secondary coil wire terminal (5). The ohmmeter should NOT read infinite

resistance.

Put the ohmmeter range selector on the Low scale and connect the leads to terminals 3 (lower left) and 4 (lower right). The ohmmeter should read very low or zero. If the results of the test are not as described, the coil is probably 8 faulty and should be replaced with a new one. However, since electrical parts generally cannot be returned after they are purchased, have the test results verified by a repair shop before buying a new coil. 7

and 6.9

Check the coil cover by depressing the locking tab and pulling the cover off the coil (see illustration). Disconnect the multi-wire connector from the coil (see illustration). 2 Later models may have wires attached to the coil terminals with individual connectors. 1

pump

4 5

the the the the

department or repair shop.

6

fuel

Ignition coil terminal locations

and repeat the spark test. 9 If no spark occurs at this point, disconnect the coil wire at distributor, hold it about 1/4-inch from a good ground and crank engine again. If no spark occurs, Check the wire connections at coil to make sure they are clean and tight. If sparks now occur, If

above the

Replacement 9

Remove

the bolts/nut that secure the coil to the side of the engine coil (see illustration). is the reverse of removal. Tighten the coil mounting bolts/nut securely and make sure the wires are securely attached to the terminals.

and detach the 10 Installation

.

Chapter 5

122

Engine electrical systems

The wire connectors are attached to both ends of the module and the mounting screws (arrows) thread into the distributor body - DON'T FORGET to coat the rear of the new module with silicone grease prior to installation!

7.3

HI Remove

8.5a

7

Ignition

module

—

the hold-down bolt and clamp (arrow).

replacement

Refer to illustration 7.3 1

to

Refer to Chapter

work on the

1

and remove the air cleaner to provide more room Detach the distributor cap and wires as an

distributor.

assembly, then lay them aside. 2 Remove the screws and lift off the rotor. Carefully detach the wire connectors from the module terminals 3 (see illustration). If the wires are attached with a plastic connector, release the locking tab before pulling the connector off the terminals. If the wires are difficult to remove, you may find it easier to remove the module mounting screws first, detach the module and then pull off the wires. Caution: Do not pull on the wires or the connectors may

be damaged. 4 Remove the screws and

lift out the module. the reverse of removal. Be sure to apply the silicone dielectric grease supplied with the new module — do not use any other type of grease — to the rear of the module before installing it in the distributor. If the grease is not used, the module will overheat and destroy itself.

5

8

Installation

Distributor

is

—

removal and installation

Refer to illustrations 8.5a and 8.5b 1 Refer to Chapter 1 and remove the air cleaner to provide room to work around the distributor. Refer to Chapter 4 and remove the fuel pump and pushrod. Refer to Section 6 and remove the ignition coil.

Unplug the wiring harness connectors attached to the wires leading to the distributor, then refer to Chapter 1 and detach the cap and spark plug wires. Lay them aside, out of the way. 3 On early models with vacuum advance, disconnect the vacuum hose from the distributor. 4 Refer to Chapter 2 and position the number one piston at TDC on the compression stroke, then mark the distributor base and the engine block so the distributor can be reinstalled in the same position relative to the block (this will prevent drastic changes in ignition timing). Disconnect the negative battery cable from the battery. 5 Remove the distributor hold-down bolt and clamp, then pull straight out on the distributor to separate it from the engine (see illustrations). Caution: Do not turn the crankshaft at any time while the distributor is out of the engine. Check the condition of the O-ring at the base of the distributor. 6 If it is damaged or deformed, oil leaks may develop. 7 To install the distributor, provided that the crankshaft has not been 2

8.5b

.

.

.

then

pull straight

up on the distributor to remove

it

disturbed, turn the rotor about 1 /8-turn clockwise, past the alignment mark made when positioning the number one piston at TDC.

8 Push the distributor into the block until it is seated. The distributor gears have to mesh properly and the oil pump driveshaft must engage in the end of the distributor shaft. The rotor should turn slightly as the gears mesh and come to rest pointing at the mark made when positioning the number one piston at TDC. 9 The remainder of the procedure is the reverse of removal. Check the ignition timing as described in Chapter 1

9

Ignition pick-up coil

—

Refer to illustrations 9.3, 1

2

Remove Remove

module.

check and replacement 9. 7

and

9.

10

the distributor from the engine (Section 8). the rotor and disconnect the pick-up coil wires from the

Chapter 5

123

Engine electrical systems

DETACH LEADS

FROM MODULE

\

OHMMETER OHMMETER

9.7 The roll pin (arrow) must be driven out to detach the gear from the distributor so the shaft can be removed

coil, hook the ohmmeter leads and ground, one at a time, and note the ohmmeter reading (1); the second check (2) requires one ohmmeter lead to be attached to each pick-up coil wire

To check the pick-up

9.3

to each wire

VACUUM

hammer and punch (see illustration). the gear, shim and tanged washer, then check the shaft for burrs. If none are found, pull the shaft from the distributor. 9 Remove the washer from the upper end of the housing (not all models). 10 Remove the C-clip (see illustration) and detach the pick-up coil assembly. The magnet and pole piece (held in place with three screws) should not be separated from the coil. Install the new pick-up coil assembly. Make sure the C-clip is seated 1

the 8

UNIT

ATTACHING SCREWS

C-CLIP

the groove. Install the washer and shaft. Make sure that it's clean and lubricated. 1 Install the tanged washer (with the tangs facing up), the drive gear and the roll pin. 1 4 Spin the shaft to ensure that the teeth on the distributor shaft do not touch the teeth on the pick-up coil pole piece. 1 5 If the teeth touch, loosen, adjust and retighten the pole piece to eliminate contact. 16 Install the distributor in the engine (Section 8). 1

ATTACHING

SCREW

2 3

MODULE

GROUND SCREW

10 9.10

Check

The pick-up coil and pole piece assembly can be removed after carefully prying out the C-clip

(later

models only)

value within the 500 to 1 500 ohm range as the wires are flexed. it doesn't, the pick-up coil is defective. If the pick-up coil fails either test, replace it. 5

If

7

same

distributor shaft

is contained within the alternator housing. The charging system does not ordinarily require periodic maintenance. However, check the drivebelt (Chapter 1 ), the wires and the connec-

tions at periodic intervals.

Be very careful when making electrical circuit connections equipped with an alternator and note the following: a)

b)

Replacement Mark the

driven by a drivebelt at the front of the engine. The purpose of the voltage regulator is to limit the alternator's voltage to a preset value. This prevents power surges, circuit overloads, etc., during peak voltage output. On all models with which this manual is

concerned, the voltage regulator

defective.

the

general information and precautions

is

4 Connect the ohmmeter between both terminals or wires of the pickup coil connector. If a vacuum advance unit is attached to the distributor, apply vacuum from an external source and watch the ohmmeter for indications of intermittent opens (if no vacuum unit is used, flex the wires by hand). The ohmmeter reading should indicate one steady

in

—

The charging system includes the alternator, voltage regulator, batand connecting wires. These components work together to supply electrical power for the ignition system, lights, radio, etc. The alternator

Connect an ohmmeter to each terminal of the pick-up coil connector or wire and ground (one terminal at a time) (see illustration). The ohmmeter should indicate infinite resistance. If it doesn't, the pick-up coil

6

Charging system

tery

3

is

pin with a

Remove

in

CAPACITOR

MODULE CONNECTOR

roll

and gear so that they can be reassembled

position.

Secure the distributor shaft housing

c)

d) in

a

bench vise and drive out

to a vehicle

When making

connections to the alternator from a battery,

always match

polarity.

Before using arc welding equipment to repair any part of the vehicle, disconnect the wires from the alternator and the battery. Never start the engine with a battery charger connected Always disconnect both battery leads before using a battery charger.

Chapter 5

124

Engine electrical systems

INSERT SCREWDRIVER

GROUND

TAB TO

END FRAME

12.3

Label the wires (arrows) before detaching the rear of the alternator

them from

11.4 Be sure to locate the correct hole when attempting ground the tab inside the alternator and DO NOT prolong the test or alternator damage could occur!

to

The adjustment and pivot removed to free the

12.4a

Charging system

1 1

Refer If

1

ly

to illustration

7 7

—

bolts (arrows) alternator

check

.4

a malfunction occurs in the charging circuit,

assume

that the alternator

is

do not immediateFirst check the

causing the problem.

following items:

The battery cables where they connect to the battery. Make sure the connections are clean and tight. b) Check the external alternator wires and connections. They must be in good condition. c) Check the drivebelt condition and tension (Chapter 1). d) Make sure the alternator mounting bolts are tight. Run the engine and check the alternator for abnormal noise. e) 2 Using a voltmeter, check the battery voltage with the engine off. a)

It

should be approximately 12-volts.

12.4b

must be

Typical alternator mounting bracket

components — exploded view Start the engine and check the battery voltage again. It should now 3 be approximately 14 to 15-volts. 4 Locate the test hole in the back of the alternator and ground the tab inside the hole by inserting a screwdriver blade and touching the tab and the case at the same time (see illustration). Caution: Do not run the engine with the tab grounded any longer than is necessary to obtain a voltmeter reading. If the alternator is charging, it is running unregulated during this test. This condition may overload the electrical

system and cause damage to the components. The reading on the voltmeter should be 1 5-volts 5

or higher with

the tab grounded. 6 If the voltmeter indicates low battery voltage, the alternator is faulty and should be replaced with a new one (Section 12). con7 If the voltage reading is 1 5-volts or higher and a "no charge" dition is present, the regulator or field circuit is the problem. Remove the alternator (Section 1 2) and have it checked further by an auto electric

shop.

Chapter 5

13.2

alternator end frame housings to ensure correct alignment during reassembly

Mark the

13.3 Insert a paper clip through the hole next to the bearing boss (arrow) to hold the brushes in the retracted position

13.6b

13.6a

12

Alternator

—

Remove

125

Engine electrical systems

.

.

.and

lift

out the brush holder assembly

the three screws

removal and installation

Refer to illustrations 12.3, 12.4a and 12.4b 1

2

3

Disconnect the cable from the negative terminal of the battery. Remove the alternator drivebelt (Chapter 1). Disconnect the two wires from the rear of the alternator (see illus-

tration).

Remove the alternator adjustment and pivot bolts alternator from the engine (see illustrations). 4

and detach the

Installation is the reverse of removal. Refer to Chapter 1 for the 5 drivebelt adjustment procedure. DO NOT hook up the battery ground

13.7

The brushes can be separated from the holder and the new ones installed

cable until after the wires are reconnected to the alternator terminals.

13

Alternator brushes

Refer to

—

illustra tions 13.2,

Remove

replacement

1

3. 3,

1

3. 6a,

1

3.

6b and

1

3. 7

the alternator from the vehicle (Section 12). Scribe or paint marks on the front and rear end frame housings 2 of the alternator to facilitate reassembly (see illustration). From the rear of the alternator, insert a paper clip through the rear 3 1

end frame to hold the brushes in place (see illustration). 4 Remove the four through-bolts holding the front and rear end frames together, then separate the drive end frame from the rectifier end frame with the paper clip still in place. Remove the nuts holding the stator leads to the rear end frame 5 (rectifier bridge) and separate the stator from the end frame. Remove the screws holding the regulator/brush assembly to the 6 end frame and detach the brush holder (see illustrations) 7 Remove the brushes from the holder by slipping the brush retainer off (see illustration).

126

Chapter 5

Engine electrical systems

Remove

the springs from the brush holder. is the reverse of the removal procedure. 10 When installing the brushes in the brush holder, install the brush closest to the end frame first. Slip the paper clip through the rear of the end frame to hold the brush, then insert the second brush and push the paper clip in to hold both brushes while reassembly is completed. 8 9

Installation

The paper clip should not be removed have been bolted together.

14

Starting

system

—

until

the front and rear end frames

general information

MOTOR TERMINAL

The function of the starting system is to crank the engine. The starting system is composed of the starter motor, solenoid, battery, switch and connecting wires. The battery supplies the electrical energy to the solenoid, which then completes the circuit to the starter motor, which does the actual work of cranking the engine. The electrical circuits are designed so that the starter motor can only

GROUND ON ENGINE MOUNTING BRACKET

15.10

be operated when the clutch pedal is depressed (manual transmission) or the transmission selector lever is in Park or Neutral (automatic trans-

Voltmeter hookup for starter motor cranking voltage test

mission).

Never operate the starter motor for more than 30 seconds at a time without pausing to allow it to cool for at least two minutes. Excessive cranking can cause overheating, which can seriously damage the starter.

1

5

Starter

motor

—

Refer to illustration

1

in-vehicle

check

5.10

If the starter motor spins but the engine is not cranking, then the 3 overrunning clutch in the starter motor is slipping and the starter motor must be removed from the engine and disassembled. If, when the switch is actuated, the starter motor does not operate 4 at all but the solenoid clicks, then the problem lies with either the battery, the main solenoid contacts or the starter motor itself. If the solenoid plunger cannot be heard when the switch is actuated, 5 the solenoid itself is defective or the solenoid circuit is open. To check the solenoid, connect a jumper lead between the battery 6 + and the S terminal on the solenoid. If the starter motor now operates, the solenoid is OK and the problem is in the ignition switch, Neutral start switch or the wiring. 7 If the starter motor still does not operate, remove the (

Note: Before diagnosing starter problems, is fully charged.

make sure

that the battery

all when the switch is operated, Park (automatic transmission) or that the clutch pedal is depressed (manual transmission). 2 Make sure that the battery is charged and that all cables, both at the battery and starter solenoid terminals, are secure. 1

If

the starter motor does not turn at

make sure

that the shift lever

is in

)

starter/solenoid assembly for further testing and repair.

8

If

first

the starter motor cranks the engine at an abnormally slow speed, sure that the battery is charged and that all terminal con-

make

nections are tight.

If

the engine has a mechanical problem, or has the

NEGATIVE BATTERY CABLE C

OIL PRESSURE SENDING UNIT

The oil pressure sending threaded into the engine under the intake manifold note the solenoid wire

16.3 unit

16.1

The

starter motor is attached to the side of the engine and is held in place with two bolts

is

mounting

left rear

STARTER VIEW A

details)

Chapter 5

wrong viscosity oil in it, it will crank slowly. Run the engine until normal operating temperature is reached, then 9 disconnect the coil wire from the distributor cap and ground it on the engine.

Connect a voltmeter positive lead to the starter motor terminal of 1 the solenoid and then connect the negative lead to ground (see illustration).

Actuate the ignition switch and take the voltmeter readings as soon 1 as a steady figure is indicated. Do not allow the starter motor to turn for more than 30 seconds at a time. A reading of 9-volts or more, with the starter motor turning at normal cranking speed, is normal. If the

more but the cranking speed is slow, the motor the reading is less than 9-volts and the cranking speed is slow, the solenoid contacts are probably burned. reading is

16

9-volts or

is

faulty.

If

Starter

motor

—

removal and installation

Refer to illustrations 16.1, 16.3

and 16.28

located on the lower left side of the engine, under the intake manifold, to the rear of and slightly above the engine mount (see illustration). Disconnect the cable from the negative terminal of the battery. 1

The

starter

is

1976 through 1979 models Vehicles without power brakes 2 Remove the air cleaner (Chapter 1). 3 Detach the wire and remove the oil pressure sending unit from the side of the engine (see illustration). 4 Disconnect the wires from the starter solenoid. Label the wires and terminals with pieces of numbered tape to ensure correct reinstallation. 5 Remove the brace bolt from the bottom of the starter housing. It may be easier to raise the vehicle when this is done — if so, be sure to support it securely on jackstands. 6 Remove the starter mounting bolts. 7 Detach the starter from the engine and remove it by tipping it past the engine mount bracket and pulling it up past the intake manifold

and wheel 8

well.

Installation

is

the reverse of removal.

Vehicles with power brakes/without A/C 9 Refer to Paragraphs 1 and 2 above and follow the instructions. 10 Refer to Chapter 1 and remove the distributor cap and wires. Lay them aside, out of the way. 1 Refer to Chapter 4 and detach the fuel line between the pump and carburetor.

16.28

Later

models require a

unique combination of extensions and a universal joint to reach the upper starter

mounting

bolt

127

Engine electrical systems 12 13 1 4 15 16

Refer to Section 6 and remove the ignition coil. Disconnect the vacuum hose at the distributor (early models). Refer to Paragraphs 3 through 6 above and follow the instructions. Slide the starter forward and lift it out of the vehicle. Installation

is

the reverse of removal.

Vehicles with power brakes and A/C 17 Refer to Paragraphs 1 and 2 above and follow the instructions. 18 Remove the two screws that secure the steering column lever cover. Remove the mast jacket lower bracket screw. Remove the steering column upper mounting bracket. Unplug the four connectors in the column wiring harness. 19 Raise the vehicle and support it securely on jackstands. 20 Disconnect the steering column flexible coupling (lower end of column) and tuck it out of the way to one side. 21 Refer to Paragraphs 4 through 6 above and follow the instructions. 22 Using a floor jack, raise the left side of the engine about 1-1/2 inches for added clearance. 23 Detach the starter and lower it past the engine. 24 Installation is the reverse of removal.

1980 and

later

models

Vehicles without power brakes 25 Refer to Paragraphs 1 and 2 above and follow the instructions. 26 Refer to Chapter 4 and detach the fuel line from the carburetor. Label the vacuum hoses and disconnect them from the carburetor. 27 Refer to Section 6 and remove the ignition coil cover. 28 Using a 6-inch and 1 2-inch extension, universal joint and socket attached to a ratchet, remove the upper starter mounting bolt (see illustration).

29 Remove the lower mounting bolt, then slide the starter forward and disconnect the wires from the terminals. 30 Refer to Chapter 9 and remove the master cylinder, but do not detach the brake

room 31

to

lines.

remove the

Installation

is

Move

the master cylinder aside slightly to allow

starter.

the reverse of removal.

Vehicles with power brakes 32 Refer to Paragraphs 1 and 2 above and follow the instructions. 33 Refer to Chapter 4 and detach the fuel line from the carburetor. 34 Refer to Section 6 and remove the ignition coil cover. 35 Remove the upper starter mounting bolt as described in Paragraph 28 above. 36 Remove the steering column cover screws and detach the cover. Remove the upper mounting nuts and the toe pan screw. 37 Raise the vehicle and support it securely on jackstands. 38 Disconnect the steering column flexible coupling (lower end of col-

128

Chapter 5

17.3

Engine electrical systems

Remove

the nut or screw (arrow) to detach the large motor lead strap from the solenoid

Turn the solenoid 90° in a clockwise direction to disengage it from the starter motor

17.5

SHIM SOLENOID

BODY

TO HOLD

IN

CONTACT FINGER

SCREW DRIVER

18.7

Meshing the

starter pinion with the starter ring gear

teeth on the

fly

wheel driveplate

MOTOR CONNECTOR STRAP TERMINAL

END COVER

However, the cover can be removed and the contact ring position changed to move any burned areas out of the way of the terminals and restore operation (see illustration). 17.6

Starter solenoid

components — exploded view Installation

Make

sure that the return spring is in position on the plunger, then body into the starter housing and turn the solenoid counterclockwise to engage the flange. Install the two solenoid screws and connect the motor strap. 8 7

insert the solenoid

umn) and move the steering column from

inside the vehicle to allow

access to the starter. 39 Disconnect the wires from the terminals on the the lower mounting bolt and detach the starter. 40 Installation is the reverse of removal.

starter,

then remove

18

Starter

motor noise

—

diagnosis and repair

Refer to illustrations 18. 7 and 18.8

17

Starter solenoid

—

removal and installation

Refer to illustrations 17.3, 17.5 and

1

7.6

Removal 1

Disconnect the cable from the negative terminal of the battery.

2

Remove

3

the starter motor (Section 16). Disconnect the strap from the solenoid terminal to the starter motor

1 Excessive or abnormal noise when the starter motor is operating indicates a problem which should be identified and corrected before costly damage occurs. 2 Noise problems can be grouped into four major categories, each having a probable cause which can be corrected. The categories are

as follows: a)

Remove the two screws which secure the solenoid to the starter motor. Rotate the solenoid 90° in a clockwise direction to disengage the 5 flange from the starter body (see illustration). The solenoid is normally replaced as an assembly if it is faulty. 6

high pitched whine during cranking before the engine starts, in a normal start, is probably due to excessive play starter pinion and flywheel ring gear teeth. A high pitched whine after the engine fires as the key is being released, which results in a normal start, is probably caused by insufficient play between the starter pinion and flywheel.

which results between the

(see illustration).

4

A

b)

Flywheel runout tends to make

this

as "starter hang-up") intermittent.

problem (sometimes known

Chapter 5

129

Engine electrical systems

3 Excessive or insufficient play between the starter pinion and flywheel can be corrected by shimming the type 5MT starter as follows. 4 Remove the flywheel lower housing cover and check for obvious things such as a distorted flywheel ring gear, abnormal wear and so on. Start the engine and carefully touch the outer edge of the flywheel 5 gear teeth lightly with a piece of chalk or crayon to mark the point of highest runout. Stop the engine and turn the flywheel until the marked

5f

teeth are adjacent to the starter pinion. Disconnect the battery ground cable. 6 7 Insert a screwdriver into the small hole

in the bottom of the starter (see illustration) and move the starter pinion until it meshes with the flywheel. If necessary, turn the flywheel until a starter pinion tooth is directly between two flywheel teeth and on the centerline of the

two gears (see illustration 18.8). Check the pinion-to-flywheel clearance with 8 3"

1/4-1/2"

—

APPROXIMATE

SUGGESTED WIRE GAUGE 18.8

c)

d)

A

The flywheel-to-pinion clearance can be checked with a wire gauge

loud "whoop" after the engine fires, while the starter is still engaged, is probably due to a defective starter clutch, which should be replaced. If the engine is revved before the starter is disengaged, the noise produced resembles a siren. A rumble, growl or loud knock as the starter coasts down after starting the engine is probably due to a bent or unbalanced starter armature. Replace the motor to correct the problem.

0.020-inch

a

gauge made from

diameter (see illustration). 9 If the clearance is less than the diameter of the wire, the starter must be shimmed away from the flywheel. If the clearance is very excessive (say 0.060-inch or more), then the starter will have to be moved towards the flywheel. Excessive clearance of this order is often the cause of broken flywheel teeth or a cracked starter housing. 10 Standard shims are available from Chevrolet and Pontiac dealers. Decreasing the clearance is done by shimming only the outer starter mounting pad. Shims can be made up from plain washers or other materials. A 1 shim 0.015-inch thick across both mounting pads to increase the clearance will equal 0.005-inch at the crest of the starter pinion tooth. Similarly, a shim 0.015-inch thick at the outer mounting pad will decrease the clearance by about 0.0 1 0-inch at the crest of the starter pinion tooth. More than one shim may be required. 1 2 When measuring the clearance and when checking the adjustment, you must keep the starter pinion tooth centered between the two flywheel teeth and make the check at that point — not in the corners — or a misleading measurement will result. a piece of wire

in

Chapter 6

Emissions control systems

Contents Air injection (AIR/PAIR) systems Computer Command Control (CCCS) System Computer Controlled Catalytic Converter (C-4) system Early Fuel Evaporation (EFE) system

Exhaust Gas Recirculation- (EGR) system Fuel control system General information ft Positive Crankcase Ventilation (PCV) system Thermostatic Air Cleaner (THERMAC) Transmission Converter Clutch (TCC)

6 .

2

3 7 5 9

Electronic Spark Timing (EST)

Evaporative Emission Control System (EECS)

.

8 4 1

10 11

12

Specifications

Torque specifications

FMbs

Nm

Oxygen sensor Thermal vacuum switch (EGR system)

30 120 110

41 12 12

.

.

Coolant temperature switch (EFE system)

1

in-lbs

in-lbs

Air Injection Reaction (AIR)

General information

Refer to illustration 1.6

To prevent pollution of the atmosphere from burned and evaporating gases, a number of emissions control systems are incorporated on the vehicles covered by this manual. The combination of systems used depends on the year in which the vehicle was manufactured, the locality to which it was originally delivered and the engine type. The major systems incorporated on the vehicles with which this manual is concerned include the:

Pulse Air Injection Reactor (PAIR) Catalytic converter Early Fuel Evaporation (EFE) Exhaust Gas Recirculation (EGR) Evaporative Emission Control (EECS) Transmission Converter Clutch (TCC) Positive Crankcase Ventilation (PCV)

Electronic Spark Timing (EST) Thermostatic Air Cleaner (THERMAC) On later models, all of the systems are

I

nked, directly or indirectly,

LABEL CODE ENGINE SIZE

EXHAUST EMISSION FAMILY * EVAPORATIVE EMISSION FAMILY

ADJUSTMENT PROCEDURE

ENGINE ADJUSTMENT SPECIFICATIONS

r XJD

VEHICLE EMISSION

CONTROL INFORMATION

U

cimiii MO'Oii (Oiroimo* irr

>i».»o

fin txo hock omvt wmtLt

« u>Afti»iNn wiin imcim a' axtui opiutmc nunu'uti coi tun on CllANd I'-.", TMtlMAt VACUUM SOU*Cf CAl*l AMD All CJMD'TlOMlMC |« !OUlP»»IOl BCP' WNIII MOMD K.lilD4«ID

Of

CAM

ADJUST (AST lOU

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r

ai wid ion aojuv CAnutrrat iou vw> saw» to atfAx i'TMIC \P1(0 COMTtCA .««.Cl(i W'TM A C) DISiOMMKT (iKTI A C COMPKVSOt AND TUtN A C iMf T(t*0M C MK I Ut ThAI Th S IUll> D'lXOlC ADWV ACTUATCM iOH» TO Of AiM VK » HO IP A C COMPt(Vy)t KKTITCA. .!*[ ANO IUIN A ( SWltC* »' A C, OIVCOMMIC AMDPlUC VACUUM NOV AT Ut Al *' « C OMNH UUtCI IN HC MIN TO AHUATOt AMD C HfO '0 Vfi T*>t iT Q T UU » d'TNTv; Ab>UST ACTUATOI Uin* TO OBTAIN IPK IIDIPM UMPlUC AMC IKOMNKT MOU^ TO CAMI^Tfl AMO OM VfMKm W'TMOU' A C 'Ml Ml UMLAP Ut ACIUATO* UMLAP VACUUM iOUlU 10* tO* AMD IK OMNK VACUUM TjOUtCt KM THIIMAC IKONMKTMnU AMO If PtJUTI All CUAMd -

'

|

II

•

T

THKVTMIOICOMIOIAUIOJ

1

fP»

HOUU

'

OMJ l/MMCAAVJ

1

TO ll«4M00V

FUEL FEED LINE

VAPOR LINE

8.17

FUEL FEED LINE

Rear brake

line routing details

194

Chapter 9

Brakes

PEDAL BRACKET-RH

BRAKE PEDAL BRACKET-LH

PEDAL PIVOT

PUSHROD ATTACHMENT

9.4a

Early

BRAKE PEDAL

model brake pedal and related components

9.4b

CLIP

Later

model brake pedal and

related

components

SWITCH

BRAKE PEDAL IN RELEASED POSITION

PEDAL POSITION WHEN ELECTRICAL

CONTACT

IS

9.14

TV

MADE

Brake

light

3/8 to 5/8-INCH

switch adjustment details

4 Remove the brake pedal-to-pushrod retainer and detach the pushrod from the pedal (see illustrations). Working under the dash, remove the right-hand pedal support-to5 dash bolt and remove the support. Remove the pedal, bushing, wave washer and flat washer. 6 7 Inspect all parts for wear, particularly at the bushings and pivot. Replace parts as necessary. Wipe all parts clean and apply a small amount of grease to the brake 8 (and clutch) pedal bushings. Install the bushings in the pedal hub(s). 9 10 Install the flat washer, wave washer and the pedal and bushing assembly on the shaft. 1 1 Place the pedal support on the shaft, guide the support stud through the dash and then install the support-to-dash bolts. Working under the hood, install the stud nut and plenum-to-support bolt and tighten all fasteners. 1 2 Connect the pushrod to the pedal pin and install the retainer. Reconnect the battery ground cable. 1 3 To adjust the brake light switch, with the mounting clip in position in the switch support, depress the brake pedal and push the switch into the clip until the shoulder on the switch bottoms on the clip. 14 Allow the pedal to return to the released (up) position. Electrical contact should be made when the pedal still has 3/8-to-5/8 inch of travel to reach the fully released position (see illustration).

10.2 The parking brake return spring and equalizer (arrows) are attached to the threaded adjustment rod near the rear of the vehicle

Parking brake cable

—

the brake cable from the underbody mounting brackets

(see illustration). 4 Remove the parking brake cable from the lever

in

each

rear brake

assembly. the spring clip, push out the cable grommets at the backing and withdraw the cable from each rear brake.

Remove

5

plate hole

6 Installation is essentially the reverse of the removal procedure. After the cable is installed, apply the parking brake two or three times with extra force to pre-stress the cable. 7 To adjust the parking brake, apply the hand lever one notch from the fully released position. 8 Tighten the equalizer adjusting nut until a slight drag is felt when the rear wheels are rotated forwards. 9 Release the parking brake lever and rotate the rear wheels; no drag should be

felt.

Lubricate the cable at the equalizer and at all the Delco Brake Lube no. 5450032 or equivalent. 1

1

10

Remove

3

1

Lower the

grommets with

vehicle.

removal, installation and adjustment

Refer to illustrations 10.2 and 10.3 1 Raise the vehicle and support it securely on jackstands. Remove the rear wheels and brake drums (Section 5). Disconnect the parking brake return spring and remove the nut from 2 the rod. Remove the equalizer (see illustration).

1 1

Parking brake lever

Refer to illustration

1

—

removal and installation

1.4

Disconnect the battery ground cable, then raise the vehicle and support it securely on jackstands. 1

Chapter 9

10.3

11.4

195

Brakes

Parking brake cable routing and mounting details

Parking brake lever mounting details

The wire (arrow) must be detached from the brake pressure differential warning switch for the check

12.3 2 Disconnect the parking brake return spring and remove the nut on the parking brake rod; remove the equalizer (see Section 10).

Remove Remove

front seat and seat belts (Chapter 1 1). door opening trim plate. Pull back the carpet or floor mat between the driver's seat and the floor tunnel to expose the two parking brake lever mounting bolts (see illustration). Remove the bolts that secure the parking brake lever assembly to 5

3 4

the the

left

left

the floor tunnel. Lift the assembly up far enough to expose the parking brake switch. 6 Disconnect the switch wire, then remove the parking brake assembly. 7 Check the condition of the lever rod-to-underbody seal before reassembly; replace it if it is cracked, loose or deteriorated. Lubricate the lever pivots with Delco Brake Lube no. 5450032 or equivalent. Installation is basically the reverse of removal. Connect the parking 8 brake switch wire before lowering the assembly into position and reconnect the battery so that the switch can be checked before installation is complete. Tighten all fasteners securely. Adjust the parking brake as described in Section 10.

12

Brake pressure differential warning switch — check and replacement

Refer to illustration

1

2.3

The brake pressure differential warning switch incorporates a piston which normally remains in a central position (in balance) when the front and rear brake circuit pressures are equal. In the event of a failure in either circuit, the piston moves and completes an electrical circuit through a switch terminal, causing the warning light on the dash to 1

come

on.

The switch cannot be repaired. If it is defective, it must be replaced. Carry out the following checks before replacing the switch. 3 Disconnect the wire from the switch terminal and ground it (see 2

illustration).

196

Chapter 9

Brakes

The

13.9

POWER BRAKES 13.3

Typical

power brake booster

in

3

tration).

finished (Section 14).

in

unit

—

Remove

the

air

cleaner to improve access to the

line

power brake booster

is

and can be detached by off the hoses

installed

pulling

rod (see

illus-

the remaining nut that secures the master cylinder to the

power booster. 5 it

the master cylinder clear of the mounting studs and support one side of the power brake unit.

Pull

to

pin.

Remove the nuts that secure the booster to Remove the pushrod-to-pedal retainer and slip Remove the booster.

8 9

Installation is the reverse of removal. After installation, check the brake operation and replace the

6 7

the

vacuum hose

the dash. the pushrod off the

filter

(see illustration).

Brake system bleeding

Refer to illustrations 14.2a, 14.2b and 14.7

power brake

booster.

2

Remove

4

14

removal and installation

Refer to illustrations 13.3 and 13.9 1

for the

two filter bracket bolts. Remove the master cylinder/power booster brace

Turn the ignition switch on. The brake failure warning light should light up. If it doesn't, check for a burned out bulb or faulty wire. The operation of the switch can be checked by turning on the ig5 nition and bleeding first a front caliper and then a rear wheel cylinder as described in Section 1 4. The warning light should come on as soon as the bleeder screw is released and heavy pressure is applied to the brake pedal. To remove the switch, disconnect the wire and the brake lines, 6 then remove the mounting bolt. Installation is the reverse of removal. Bleed the brake system when

4

Power brake

filter

vacuum

installation details

the

13

the

Disconnect the vacuum hose from the check valve and remove

14.2a Each rear wheel cylinder is equipped with a bleeder screw (arrow) located just above the brake line fitting

Note: Bleeding the hydraulic system that

manages

to find its

during removal

14.2b

way into

is

and installation of a hose,

The

necessary

the system line,

when

remove any

air

has been opened caliper or master cylinder.

screw (arrow) the brake hose fitting

caliper bleeder

to

is

it

located near

Chapter 9

Brakes

197

5 Remove any residual vacuum from the power brake booster by applying the brake several times with the engine off. 6 Remove the master cylinder reservoir cover and fill the reservoir with brake fluid. Reinstall the cover. Note: Check the fluid level often during the bleeding operation and add fluid as necessary to prevent the fluid level from falling low enough to allow air bubbles into the

master cylinder. 7 Have an assistant on hand, as well as

a supply of new brake fluid, an empty clear plastic container, a length of 3/16-inch plastic, rubber or vinyl tubing to fit over the bleeder screws and a wrench to open and close the bleeder screws (see illustration). 8 Beginning at the right rear wheel, loosen the bleeder screw slightly, then tighten it to a point where it is snug but can still be loosened quickly

and

TUBE MUST BE

SUBMERGED

IN

BRAKE FLUID

14.7 When bleeding the brakes, a clear piece of tubing attached to the bleeder screw fitting and submerged in brake fluid — air bubbles can be easily seen in the tube and container (when no more bubbles appear, the air has been purged from the caliper or wheel cylinder)

is

will probably be necessary to bleed the system at all four brakes has entered the system due to low fluid level, or if the brake lines have been disconnected at the master cylinder. If a brake line was disconnected at only one wheel, then only that 2 caliper or wheel cylinder must be bled (see illustrations). If a brake line is disconnected at a fitting located between the 3 master cylinder and any of the brakes, that part of the system served by the disconnected line must be bled. 4 Bleed the right rear wheel cylinder, the left rear wheel cylinder, the right front caliper and the left front caliper in that order when the 1

if

It

air

entire

system

is

involved.

easily.

9 Place one end of the tubing over the bleeder screw and submerge the other end in brake fluid in the container. 10 Have the assistant pump the brakes a few times to get pressure in the system, then hold the pedal firmly depressed. 1 While the pedal is depressed, open the bleeder screw just enough to allow a flow of fluid to leave the valve. Watch for air bubbles to exit the submerged end of the tube. When the fluid stops flowing after a couple of seconds, close the valve and have your assistant release the pedal. 1 2 Repeat Steps 1 and 1 1 until no more air is seen leaving the tube, then tighten the bleeder screw and proceed to the left rear wheel. Repeat the procedure. Be sure to check the fluid in the master cylinder reservoir frequently. 1 3 Never use old brake fluid. It contains moisture which will deteriorate the brake system components. 14 Refill the master cylinder with fluid at the end of the operation. 1 5 Check the operation of the brakes. The pedal should feel solid when depressed, with no sponginess. If necessary, repeat the entire process. Warning: Do not drive the vehicle if you are in doubt about the effectiveness of the brake system. 16 If any difficulty is experienced in bleeding the hydraulic system, or if an assistant is not available, a pressure bleeding kit is a worthwhile investment. If connected in accordance with the instructions, each bleeder screw can be opened in turn to allow the fluid to be pressure ejected until it is clear of air bubbles without the need to replenish the master cylinder reservoir during the process.

Steering and suspension systems

Chapter 10 Contents

5 suspension balljoints — removal and installation 4 suspension coil spring — removal and installation 6 suspension control arm — removal and installation .... 19 wheel alignment — general information wheel bearing check and maintenance .... See Chapter 1 1 General information 14 Rack-and-pinion steering gear — overhaul 13 Rack-and-pinion steering gear — removal and installation .... Rear suspension arm — removal and installation 9 8 Rear suspension coil spring — removal and installation 10 Rear suspension track rod — removal and installation Shock absorbers — removal and installation 2

—

removal and installation 3 — removal and installation 18 flexible coupling — removal and installation 16 11 gear and linkage — inspection knuckle — removal and installation 7 lock cylinder — removal and installation 17 15 wheel — removal and installation Suspension and steering check See Chapter 1 12 Tie-rod assembly — removal and installation Tire and tire pressure checks See Chapter 1 Tire rotation See Chapter 1 Stabilizer bar

Front Front Front Front Front

Steering Steering Steering Steering Steering Steering

column

Specifications

General Wheel bearing/hub endplay

0.001 to 0.005

Torque specifications

Ft-lbs

Nm

33 29 48 47 49

45 39 65 64

in

Front suspension

Upper Upper Lower Upper Lower

balljoint-to-knuckle nut balljoint-to-control

arm bolts/nuts

balljoint-to-knuckle nut

arm pivot bolt arm pivot bolts Stabilizer-to-control arm bolt/nut Stabilizer-to-body clamp bolts Shock absorber upper mounting nut Shock absorber lower mounting nut Wheel lug nuts control

control

15 14 .

.

.

.

.

.

7

67 20 19 10 58

43 65

88

33

45

Rear Suspension

Suspension arm pivot Shock absorber Upper nut

bolt nuts

Lower nut

7

10

21

29

Track rod

67 34

Body bracket nut Axle bracket nut Stabilizer bar

Wheel

mount

bolts/nuts

lug nuts

Steering - 1976 through 1979 Steering column (standard) Flexible coupling pinch-bolt Shaft-to-flexible coupling bolt Steering column-to-dash cover screws

15

65

36 22 18

91

46 20 88

49 30 24

(see Chapter

1

Steering and suspension systems

Chapter 10

18

screw screw

Ignition switch-to-jacket

Lock cylinder retainer Steering column (tilt) (where different from standard) Lockbolt spring retaining screw

5

7

3 3.5

4 4.5

3

4

Support-to-jacket screws Housing cover screws (3)

4

Lock cylinder retainer screw

2

5.5 9 2.5

30

41

18

24

1.5

2

20 22 20

27 30 27

1.5 5.2

2

30

41

50 14

68

7

Steering — 1980 on (where different from earlier models) Steering column pinch bolt Intermediate shaft-to-flexible coupling bolts/nuts Steering column-to-dash cover screws Steering column -to-toe pan screw Steering column-to-instrument panel bolts Steering colum bracket-to-instrument panel nuts Steering column shroud-to-housing screws Steering column housing and shroud-to-jacket screws

.

.

.

Steering — all models Steering wheel-to-column nut Rack-and-pinion Tie-rod jam nuts Rack-and-pinion mount bolts

1

27 30 27 24

20 22 20

Column-to-toe pan screw Column-to-bracket bolts Column-to-bracket nuts Column shroud-to-housing screws Column housing and shroud-to-jacket

The

1

.

front suspension

7

19

are located between brackets on the axle tubes and spring seats on the frame. They are held in place by the weight of the vehicle and the shock absorbers, which limit rebound. A stabilizer bar is attached to

General information

Refer to illustrations

1

and

is

1

.2

a conventional design with a short

upper

arm and long lower arm. Coil springs and double-acting hydraulic shock absorbers complete the suspension package (see illustration). A stabilizer bar is standard equipment. The rear suspension is a solid axle with coil springs (see illustration). The axle is attached to the body by two trailing control arms, a straight track rod, two shock absorbers and a bracket at the front of the axle extension. The two trailing arms, mounted between the axle assembly and the frame, maintain the fore-and-aft relationship of the axle to the chassis and the axle holds the rear wheels in alignment. The rear springs control

the axle and body by links and brackets. Lateral control is handled by a track rod. Steering is by rack-and-pinion, with power assist as an option. The steering column is an energy absorption design and a tilt version is available.

Many of the procedures in

this Chapter require working under has been raised and supported. If a hoist is not available, be sure to use high quality jackstands to support the vehicle and position them at the recommended points (see the front of this manual). Do not work under a vehicle that is supported only by a jack

Warning:

the vehicle after

or blocks of

it

wood

1

1.1

199

Front suspension components

or concrete.

.2

Rear suspension components

200

c

o Q.-Q -Q

&«.»« r(5

1)

^

"S -§

1)

.N

^ I

Q

CC CO

A CH|

vj

••

KVUI

.~

M

-80 PNK DBL BLK STR-

50 TAN DBl WMT STRI201O4B8

CONN l"X)

80 I. RAY tO PPL —

V

VT*

err

» -80 PPl-

-80

fll

K OBl

hi

WhT STR-C-U.

mosuoconh

Wiring diagram

v^

WSW S* OH COL vi» cOMNtcrfo

CONN

-80 PNK

—

instrument cluster (1982 models)

•m

vit'iao ccMNicrts

vi .»ocoNMcrto »«i'V ijwiti[i

m |

"\

268

LAMP

f TO CLCC

HODUlC

I-l-l

S

ii s

I

LLJ

I

^

«*

r

MAtM

rWW

f

—

•

ot

iiu—

Q) ST

tl»1l0 CltCUH

Wiring diagram

—

instrument cluster (1983 and

later

models)

(typical)

KELT

a uii*

269

1

RTSEAT

SENSOR

O

O

8905800 CON~

DOME LP PRONT

166

8900863 CONN

Wiring diagram

- body and

rear lights

(1976 through 1982 models)

270

•-1

— »***—

an

o

'

If IT

St »!

cy

J

O

p«I¥bb« NMT

I

il»«

I

Sl> NOIIOllSfl 0W.T) PNK IT CIN C 111

I

i

I

-

O

$

E^iihfo

I

—I

m ON

Ot

2

.

o

•O

),

0«"«»'»

.0

I

CBN

OH t

BRN ~ t,LK

AJ2

b

-»«

0«'"»» MIJUT •

!0 ;

rtL a [i cbn

10 10 l

i.O

I

I

mr

ce ED-

BUt/TCL III CRN TtL/BL« • BSN • »L«/U CRN

10

BLK HOT ten l

bl«/pn«

•

pn«

—

.

.

Qoj

/ (

"S

•

CRN

e

In »«l

Mil

• 8

• »LI LT GR GRN LT CP

o

bh/tei

• I i

^-
»

fi»

Wiring diagram

-

body and

rear lights

""

(1983 and

later

models)

(typical)

J

Index

About

manual

this

—

operating rods — 226 spring clips — 226 trim panel — 223

5

—

water deflector doors - 223

50, 141 Air conditioning Air cleaner

check — 97 maintenance removal and

— 97 — 99

installation

— 44 Alignment — 210 Air filter

fender - 213 fender liner — 21 3 front seat — 231 general information

— 211 221, 223, 225, 229

-

glass

Alternator

headlight bezel

brushes — 1 25 removal and installation Antifreeze — 91 Automatic transmission

hood - 215 maintenance number plate

—

diagnosis fluid

- 34

fluid

and

1

— 125

radiator grille

65

rear

change

filter

shift lever

—

shift linkage

— 52 — 169

1

— 168 — 166 —

1

-

window

78

78

—

1

78

B light

switch

212, 213 231, 232 regulator

— 226

windshield - 221 Booster battery jump starting Brake fluid - 1 7, 34 Brake light switch - 245 Brake system bleeding — 1 96 caliper

—

1

5

1

check

Battery cables

1

- 120 check — 37 electrolyte — 34 jump starting — 5 maintenance — 37

general information

removal and installation Belts — see Drivebelts Block cleaning — 80 inspection — 81

Body bumpers — 220 door

lines

—

1

20

- 225 - 226 - 225 striker - 227

181

-

45, 193

master cylinder — 191 pad replacement — 183 parking brake cable — 194 parking brake lever — 194 pedal - 193 power brake unit - 196 pressure differential warning switch

- 185 shoes - 187 rotor

glass

—

hoses — 1 93 light switch - 245

1

handle

Break-in

lock

Bumpers

lock

— 229

- 232

— 85 - 39 drum shoes — 87 fluid level - 34

— 245

- 204

Balljoints

231

removal and installation rear seat

seats

removal and installation

Back-up

-

lock

repair

—

— 229

- 231 support - 230

Axle

seals

regulator

striker

speedometer driven gear

oil

door

window

66 — 166

bearings — 1 79 general information

— 21 2 — 6 - 220

rear hatch

1

throttle valve cable

- 220

glass - 229 lock - 228

general information — 165 output shaft oil seal — 168

removal and installation

— 228

- 90

Buying parts

220 8

— 195

7

1

272

Index Disc brake

— 185 - 183 - 185

caliper

pads

63

Camshaft

Carburetor adjustments

rotor

112

Distributor

cap — 46 removal and

choke check - 50, mounting torque check — 39 removal and installation - 107 servicing — 108 1

1

1

Dome

—134 — 123

- 227 — 242 trim panel — 223 water deflector — 228 window regulator — 226, 229 Drivebelts — 35 Driveline — 70 Driveplate - 69 switches

1

1

1

components —

1

73

Driveshaft 1

70

— 88 9

choke — 1 1 system alternator — 1 25 light

-

switch

— 245 120

15, 34, 37,

—

96

brake bulbs

light

dome

light

— 242 — 240

front lights

fuses

— 234 — 234

fusible links

—

91

93 — 47

temperature sender — 96 thermostat — 92 water pump — 94 Crankcase front cover — 68 Crankshaft

— 84 installation — 87 oil seals — 67, 87 removal — 80 inspection

general information — hazard flasher — 238 headlight

switch — 242 warning buzzer headlights horn - 239

233

— 243

239

key warning switch — 243 switch — 243 instrument panel — 234 multi-function switch — 243 neutral start switch — 245 parking brake warning light switch — 246

ignition ignition

Cylinder head

— 78 — 76 disassembly — 76 inspection — 76

— 241

assembly

rear lights

cleaning

seat belt warning — 249 troubleshooting — 234

removal and installation Cylinder honing — 82

turn signals

— 65

-

238, 244

windshield washer — 248, 249 wiper motor — 247 wiper/washer switch — 244 wiring diagrams Electrolyte

— 250

Differential

change

oil

level

—

air

—

51

41

Dimmer switch — 243

to

270

- 34

Emission control label Emissions system oil

177

switch — 245 - 240, 241 clutch starter switch — 246 dimmer switch — 243 door switches — 242

—

servicing

—

Electric

battery

Coolant temperature sending unit Cooling system check — 39

radiator

131

back-up

78

coolant level — 32 general information

76

1

Electrical

84

1

—

EGR system - 138

—

Oonnecting rod

Control arms — 204 Conversion factors —

76

removal and installation Drum brake shoes — 1 87 wheel cylinder — 1 90

Computer Command Control System Compression check — 58 bearing inspection — bearings — 84, 88 inspection — 83

1

description

removal and installation — 173 starter switch — 246 Clutch pedal free play — 38 Clutch starter switch — 246 Coil - 121 Coil springs - 203, 205

—

—

check

171

general information — pedal - 38, 176 pilot bearing — 1 75

removal

— 223

— 226

striker

— 73 — 71

installation

,

removal and installation spring clips

Chassis lubrication — 40 Chemicals -17 Choke 50, 111 Cleaners 1 Clutch adjustment — 171

—

'

'

locks - 225, 228operating rods — 22*6

general information precautions - 123

description

225, 229

- 226

handles

Charging system check - 124

check

-

glass

Catalytic converter

cable

- 242

Door

212

Carpets

— 122

installation

light

injection

system

catalytic converter

—

7

— 135

—134

computer command control system - 131 early fuel evaporation system — 137

273

Index electronic spark timing — 135 evaporative control system — 52, 140 exhaust gas recirculation system — 138

—

1

— 78 — 76 disassembly — 76 inspection — 76 assembly

cleaning

—130

general information

oxygen sensor

Head

— 134

system

fuel control

34

positive crankcase ventilation

— 140 — 50

removal and installation Headlight

system

positive crankcase ventilation valve 142 transmission converter clutch

—

Engine assembly sequence

— 85

— 90 —

general information

57,

Hood adjustment — 21 5 removal and installation Horn - 239 Hose removal tips — 1 1

73

— 74

installation

dead center — 57 mounts — 69 numbers — 7 overhaul — 74 rebuilding alternatives — 74 removal — 73, 74 Evaporative Emissions Control System locating top

I

—

52

— 59

—

1 1

7

system - 120

Ignition

-

121

- 122 — 46

general information

removal and installation

checks

— 213

— 32

Front wheel bearings

— 53

check - 106 removal and installation Fuel system

— 106

carburetor - 39, 107, 108, 112 carburetor mounting nut torque — 39

— 55 - 50, filter - 38 fuel pump —

— —

1

1

spark plug wires — 46 spark plugs — 45 switch - 243 timing — 51 start-up — Intake manifold

90

— 59 — 58 Introduction — 5 installation

removal

Jacking

06

lines

and hoses

tank

-

—

— 105

Jump

—

1

6

starting

15

45, 108

117

-

1 1

7

- 234 Fusible links - 234 Fuses

- 240, 241 208, 225, 228, 231

Light bulbs

Locks

-

Lubricants Lubrication

— 17,27 — 40

Gas tank - 1 1 7 Gauges - 234

M

H

Main bearing clearance check inspection

Hatch

- 231

removal and installation

- 231 support - 230 striker

9

111

general information

lock

22

1 1

— 46

Initial

pump

119

122

pick-up coil precautions rotor

- 27 Flywheel - 69 Front oil seal — 69 Front springs — 203 Fluids

Fuel tank

-

module

— 213

check choke

6

10

distributor cap

8

Fender

Fuel

1

speed adjustment

coil

Fluid level

—

Idle

distributor

liner

—

mixture

44, 109 stop solenoid — 1 1 2 Ignition key warning switch — 243 Ignition switch — 243 Idle

check

—

numbers

Identification Idle fuel/air

removal — 58 Exhaust pipe — 1 18 Exhaust system check — 41 Exhaust system component replacement

Fasteners

— 215

— 45

Hoses

Exhaust manifold installation

243

- 82

Honing

— 90

start-up

initial

— 243

warning buzzer — Headlights - 239 Heater - 96

compression check — 58 disassembly sequence — 76

— 65

- 220

bezel

dimmer switch switch — 242

block cleaning — 80 block inspection — 81 break-in

- 238

Hazard flasher

- 229

— 87

— 84

Maintenance - 28 Maintenance techniques Manual transmission general information oil

change

— 52

143

274 oil

Index level

Rear springs — 205 Rings - 20, 85

— 50

check

output shaft oil seal — 145 overhaul - 147, 158 rear

mount

Rod bearing clearance check bearings — 84 inspection — 83

144

-

removal and installation

— 146

— 145

shift lever

speedomcttM gear — 145 91 Master cylinder 9 Metric conversion Motor mounts 69 117 Muffler

installation

— 88

removal — 78 Rotor (brake) - 185 Rotor (ignition) — 46 Routine maintenance

1

1

— 88

,

— 28

N Neutral start switch

Safety - 18 Sealants — 1 7 Seat belt warning system Seats

— 245

o

front

27, 32

Oil

rear

— 249

- 231 - 232

Service parts label — 7 Shift lever - 145, 166 Shock absorbers — 202 Solenoid - 128 Spark plug wires — 46 Spark plugs — 45 Speedometer gear — 145 Stabilizer bar - 203

change — 42 change — 42 Oil pan — 66 Oil pump — 67 Oil seals - 69 Oxygen sensor — 134

Oil

Oil filter

Starter

check

PCV system

— 140

valve — 50 Parking brake cable - 194 general information lever

warning

light

installation

26

—

solenoid Steering

— 40

column knuckle

switch

— 246

lock

— 175

bearing Piston inspection

1

1

— 127

28

— 209 — 205

— 207

check — 48 column — 209

— 85 removal — 78 Polishes — 7

flexible coupling

Power brake unit — 1 96 Power steering fluid — 35

lock cylinder — rack and pinion tie-rods

—

— 208 — 199

general information inspection — 206 knuckle — 205

1

glass

26

Steering system alignment — 210

— 83 — 88

window

1

- 208

wheel

rings

Quarter

—

removal and installation

— 194

Pilot

—

general information noise — 1 28

208 — 207

— 206

wheel — 207 Suspension system

221, 223

- 204 — 48 coil springs — 203, 205 control arms — 204 front springs — 203 general information — 199 rear arm — 205 rear track rod — 206 shock absorbers — 202 stabilizer bar — 203 track rod — 206 balljoints

check

Rack-and-pinion overhaul — 207 removal and installation — 207 Radiator - 93 Radiator grille — 220 Rear axle axleshaft removal and installation bearings — 1 79 extension — 1 79 general information — 1 78 oil seals - 178, 180 pinion seal

—

1

80

removal and installation Rear hatch lock - 231 removal and installation striker

—

231

support — Rear oil seal

230

—

69, 87

—

1

78

Tailpipe

—180 — 229

—

1 1

7

Temperature sending Thermostat — 92

unit

— 96

Thermostatically controlled Throttle cable - 1 1 6 Throttle linkage — 47 Throttle valve cable — 166 Tie-rods — 206

air

cleaner

-

50, 141

275

Index Timing — 51 Timing belt — 59 Tire rotation

— Tools Tires

— 48

31

inspection installation

removal

1

Top dead center locating — 57 Towing — 1 6 Track rod - 206 Transmission (automatic) — see Automatic transmission Transmission converter clutch — 142 Transmission identification numbers — 7 Transmission (manual) — see Manual transmission Transmission mount — 144 Trouble codes — 1 33 Troubleshooting — 20

servicing

— 77 — 78

— 76 — 78

Vehicle identification numbers

Water pump

Waxes —

1

94

Weatherstrip adhesive

u

Window

check

—

1

76

—

1

76

replacement — 1 77 Undercoating — 1 7 Upholstery - 212

1

V-belts

- 35

Vacuum hoses — 45

—

1

7

90

glass - 221, 223, 225, 229 Windshield - 221 Windshield washer - 244, 248, 249 Windshield washer fluid — 34 Windshield wiper

arm

- 247

blades — 35 general information

— 247 — 247 switch — 244 transmission — 248 Wiper blades — 35 Wiring diagrams - 250 to 270 Working facilities — motor

V

6

7

Wheel cylinders — Wheel bearings front — 53 rear - 179

U-joints

—

w

Tune-up — 31 Turn signals - 238, 244

description

— 63

Valve lash adjusters Valves

1

HAYNES AUTOMOTIVE MANUALS NOTE: New manuals are added

to this list on a periodic basis. If you do not see a listing for your vehicle, consult your local Haynes dealer tor the latest product information.

206

2402 2602 & 280Z Coupe &

563

2802X Coupe & 2 > 2 '79 thru 300ZX see NISSAN II 137) 310 all models 78 thru 82 610 & PL521 Pick up '68 thru 510 all models '78 thru '81 610 all models '72 thru 76 620 Series Pick up all models

679 123

ALFA ROMEO 531

Alfa

Rniw

430 372 277

Sudan & Coupe 73 thru 80

AMC -rr J..P CJ Mid >i» mcKlo-

694

235

\ot.

•771

•934

& Encore

iRanaulli Alliance

•376

351 •1221 160

'73

633 297

all

124 models '69 thru 77 4000 an modal! 80 thru '87 5000 all models 77 thru 83 5000 ail models 8-t thru 86 Fox all models 73 ihru 79

100

162

615 428 •1117 207

all

368

•601

gasoline models

•723

.ill

MG

see

•1231

Midget

699

BLMC 260

1100

MM MM

527 •646

236 419

1300 & Austin America

all all

140

610

Caravan & Plymouth Voyager Mini-Vans all models 84 thru '86 Challenger & Plymouth Sapporo all models '78 thru '83 Colt all models '71 thru '77 Colt (rear-wheel drivel all models Colt

3201 all 4 cyl models 75 thru 83 528i & 530i all models 75 thru '80 1500 thru 2002 all models except Turbo

348

&

Bavaria

234

•1140

models

all

—

GENERAL MOTORS ACars •627

see

CAPRI

MK Coupe

2000 2300

205

2600 & 2800 V6 Coupe

1

479 •273

models

all

71 thru '75

MK

all

2800 Mk

375

models

all

thru '75 II

V6 Coupe

all

engines

in-line

— see FORD

334 359

'81

•754

-

see GENERAL MOTORS J-Cars (7661 Celebrity - see GENERAL MOTORS A Cars 1829) Chevelle. Malibu & El Camino all

V6 & V8 models

'69 thru

Chevette & Pontiac T1000

449

all

319

'72 thru '82 Monte Carlo '70 thru '86

•626

420

Pick

& •

86 models

773

831

•345 208

6

all

V6,

•558

V8 & Turbo models

cyl

2WD

&

4WD

'67 thru '87 S 10 & GMC S 15 Pick-ups 82 thru '87

•1418 357

models

231

models

all

204 649

•344 front

wheel drive '82 thru '86 see

DODGE

Aries/Plymouth

Reliant (723)

Laser - see DODGE Daytona & Chrysler Laser 11140)

•766

DATSUN models '77 thru '79 models 80 thru '83 8-210 all models '73 thru '78 210 all models '79 thru '82

200SX 200SX

Listings

& Mercury Zephyr all in-line & V8 models '78 thru '83 Fiesta all models '77 thru '80 Granada & Mercury Monarch all in-line. 6 cyl & V8 models '75 thru '80 Ford & Mercury Full-size. FORD LTD ('75 thru '821; Custom 500. Country Crown

Victoria Marquis ('75 thru '821;

Ford

& Mercury

all

all all

shown

GMC

Gran

to include later

Haynes Publications

models

Elite;

Pinto Pinto

all

984

all

II

all

all

Vans

all

V8

Fuego

085

drive)

all

900

all

RX2 RX3

1100. 1300. 1400 & 1600 79

237 drive)

all

P.O.

models

Park,

models

models

all

'80 thru '86

all

TOYOTA

437 •935

230. 250 & 280 Sedan Coupe & Roadster all 6 cyl sohc models '68 thru '72 280 123 Series

all

680 1139 201 all

thru '80

123 Series 200D. 220D. 240D. 240TD, 300D, 300CD, 300TD, Diesel

&

5-cyl incl.

all models 78 thru '81 all models except front-wheel and Supra '82 thru '85 Celica Supra all models '79 thru '81 Celica Supra all models 82 thru 86 Corolla 1100. 1200 & 1600 all models 67 thru '74 Corolla all models 75 thru '79 Corolla all models (rear wheel drive)

Celica Celica drive

gasoline models

350 & 450 Sedan. Coupe & Roadster '71

Carina Sedan all models 71 thru '74 Celica ST. GT & liftback all models '71 thru '78

150 229

Turbo '76 thru '85

listing

•1025 •636 230

111

265

MG

360

models '56 thru '62

all

Roadster &

GT Coupe

all

models

'62 thru '80

Midget & Austin Healey Sprite Roadster '58 thru '80

MITSUBISHI

-

see Dodge D-50 1556)

•532 313

200 •1339 304 •656 787

'80 thru '82 Corolla all models (front wheel drivel Corolla Tercel

1

984

models 80 thru 82 4 cyl sohc models

all

MK

Corona &

all

II

74 models '74 thru '82 models '78 thru '82 Land Cruiser all models '68 thru '82 MK all 6 cyl models '72 thru '76 MR2 all models '85 thru '87 Pick-up all models '69 thru 78 Pick-up all models '79 thru '85 Starlet all models 81 thru 84 Corona

all

Cressida

(Austin) Marina 1.8 '71 thru '75

024

Minor 1000 sedan & wagon '56 thru '71

all

II

GT6 & Spitfire

031 322

TR250 & TR6 Roadsters 67 TR7 all models 75 thru '81

TR2

Vitesse

3.

'52 thru

•981

models 84 thru '86 300ZX Pulsar all models '83 thru '86 Sentra all models 82 thru '86 Stanza all models '82 thru '86 all

Cutlass

all

standard gasoline

091

036 039 159

V6 & V8

models '74 thru '87 Cutlass Ciera - see GENERAL MOTORS ACars 18291 Firenza - see GENERAL MOTORS J-Cars (766)

157

see PONTIAC Phoenix (551)

all

110

238 •884

all all

Arrow

gasoline models '68 thru '79 diesel models '74 thru 83

all

models

80

Convertible

&

listing

120. 130 Series

diesel

models

all

& 1800 Sports

61 thru 73 140 Series all models 66 thru 74 164 all models 68 thru 75 240 Series all models 74 thru 86 260 Series oil models 75 thru 82

MOTORS

(818)889-5400

all

models

Vanagon all air cooled models 80 thru 83

T1000 - see CHEVROLET

•

all

85

'63 thru '73

76 thru 80

PONTIAC

CA 91320

thru

Pick-up

Transporter 1700. 1800 & 2000 models 72 thru 79 Type 3 1500 & 1600 all models

For other Plymouth models see

DODGE

thru '76

windshieldl '70 thru '72 Dasher all gasoline models '74 thru '81 Rabbit Jetta. Scirocco. & Pick up all gasoline models '74 thru 84

Transporter 1600 68 thru '79

504 504

Roadsters

67

Rabbit. Jetta "77 thru '84

models

PLYMOUTH 425

4A

3A. 4 &

411 & 412 all 103 cu in models '68 thru 73 Bug 1200 all models 54 thru '66 Bug 1300 & 1500 65 thru 70 Bug 1600 all basic, sport & super (curved windshield) models '70 thru '74 Bug 1600 Super all models (flat

&

Mama Coupe 1900

(Buickl '70 thru '74

all

VW

OLDSMOBILE •658

all models 62 thru '74 models 62 thru '81

112

113 028

models

NISSAN •1137 •876 •982

all

TRIUMPH

074

Over 100 Haynes motorcycle manuals

—

Box 978, Newbury

2WD & 4WD

1600 & 1800

model coverage as of this printing. These titles will be periodically consult your Haynes dealer for more information. model years

Inc.,

all

'71 thru

•681

models '71 thru '75 models '72 thru '76 models '79 thru '85

all

all

RX-7

Chevette 1449) J 2000 - see GENERAL J Cars (766)

(420. 831. 345)

models including Turbo

'69 thru

161

Vans & Pick-ups - see CHEVROLET

all

'79 thru '85

(front-wheel drive)

MGA MGB

475

663

Chevrolet Celebrity, Buick Century, Pontiac 6000 & Oldsmobile Cutlass Ciera all models '82 thru 87 J-Cars - Chevrolet Cavalier, Pontiac J 2000, Oldsmobile Firenza, Buick Skyhawk & Cadillac Cimarron all models '82 thru '87

engines

SUBARU

PEUGEOT

ACars -

in

models '76 thru '84

all

'69 thru '80

•980

OPEL

Econoline models

19341

thru '85

Omega & Omega

models

AMC

models '82 thru '85

95 & 96 V4 all models '66 thru '75 99 all models including Turbo

247

gas models

GLC Hatchback Irear-wheel models '77 thru '83

GLC

in

SAAB

B1600. B1800 & B2000 Pick-ups

Pick-up

gasoline models

& Encore - see

all

3500 SDI V8

198

wheel

& 95 5 cu

'68 thru '76

•365

Irear-wheel drivel models '79 thru '82 (front

in

models

3500 & 3500S Sedan 215 cu

II,

626 Sedan & Coupe 626

all

ROVER

MA. & III all 4 cyl gasoline models '58 thru '86 Diesel all models '58 thru 80 Series

MG

II;

& Mercury Bobcat

18i & Sportwagon '81 thru '86

Alliance

See FORD

models '70 thru '74

Ranger & Bronco

models including Turbo 86

16 all models 89 7 cu engines '65 thru '72

598

MORRIS

FORD; Torino; Ranchero, LTD

Mid-size.

4 cyl. in-line 6 cyl. V6 & V8 models 75 thru '80 Mustang & Mercury Capri all in-line models & Turbo '79 thru '87 Mustang & Mercury Capri all V6 & V8 models '79 thru '87 Tempo & Mercury Topaz all gasoline models '84 thru '87 Mustang V8 all models '65 thru '73 Mustang II all 4 cyl, V6 & V8 models

with an asterisk (') indicate

updated

all

Coupe & HPE

Lancia Beta Sedan,

4-

V8 models

GENERAL MOTORS •829

768 081

MERCURY

Fairmont

models including Turbo

all

engines '62 thru '72 12 Saloon & Estate all models 1289 cc engines 70 thru '80 15 & 17 all models '73 thru '79

097

1500 & 1600

1200, 1300

models

697

'69 thru '86

& Plymouth Mid-size

-

346

4 cyl models '69 thru '76

all

5 Le Car all models '76 thru '83 8 & 10 all models with 58 4 cu in

141

079

MERCEDES BENZ

'83 thru '86

CHRYSLER K Cars

109

096 460

698

'75 thru '80

•1026

6

models '49 thru '86

all

'81

'74 thru '78

Vans - Chevrolet & GMC. V8 & in-line 6 cyl models '68 thru '85 Vega all models except Cosworth

Chrysler

370

all

RENAULT

models

cyl

77 thru '81

('83 thru '841; Thunderbird ['75 thru '821. MERCURY: Montego; Comet, Marquis ('83 thru '861; Cougar ('75 thru '821; LINCOLN: Versailles, all

•654

all

'72 thru '84

cyl

LTD

'70 thru '77

•1337

•267

X-car

'83 thru

'83 thru '87

'64 thru '74 Strada all models 79 thru '82 X1/9 all models '74 thru '80

Gran Torino;

all

in-line

•1082

757

Marquis; Colony Park, '75 thru '84

V8 models '69 thru '79 ups - Chevrolet & GMC. all V8

Nova

241

models

124 Sedan & Wagon all ohv & dohc models '66 thru '75 124 Sport Coupe & Spider 68 thru 78 128 all models '72 thru '79 131 & Brava all models '75 thru '81 850 Sedan. Coupe & Spider

MERCURY

87 Citation all models '80 thru '85 Corvette all V8 models '68 thru '82 Corvette all models '84 thru '87 Full-size Sedans Caprice. Impala. Biscayne, Bel Air & Wagons, all V6 & V8 models '69 thru '86 Luv Pick-up all 2WD & 4WD models

550 274

all

Vans - Dodge & Plymouth V8 & 6 models '71 thru '86

Squire;

'76 thru

•1336 •704

'72 thru '85 XK-E 3.8 & 4.2 '61 thru '72

CJ

944

'.

XJ6 all 6 cyl models '68 thru '86 XJ12 & XJS all 12 cyl models

all

'70 thru '76 Courier Pick-up all models '72 thru '82 Escort & Mercury Lynx all models '81 thru '87

(558)

Camaro V8 all models '70 thru Camaro all models '82 thru '87

•625

648

all

Coupe & Targa models except 85

all

914 924

•1027

Sedans,-

MAZDA

268 •789 560

Mercury V6 and V8 engines — see

FORD Mustang CHEVROLET Cavalier

529

models

Bronco and Pick-ups '73 thru '79 Bronco and Pick-ups '80 thru '86 Cortina MK III 1600 & 2000 ohc

Mustang 1654)

554 •866

cyl

models

788 •880 295

models

'75 thru '78

Mercury

240 & 340

II.

I

FORD

models

7 4 thru '78 '71

314

983 Coupe

II

533

Omega

Turbo '65 thru

LAND ROVER

6

all

•912

094 087 310 038

GENERAL MOTORS

296

all

Daytona & Chrysler Laser

911

239 397

LANCIA

FIAT

CAOILLAC

283

'79 thru '86 Dart & Plymouth Valiant '67 thru '76

"264

including Riva '74 thru '86

Pick-ups

'78 thru '84 Pick-ups all full size models '74 thru '86

080

MK &

(front-wheel

models '78 thru '87

Omni & Plymouth Horizon

•349

Skyhawk - see GENERAL MOTORS J-Cars (766) Skylark ill X car models 80 thru '85 Cimarron - see J-Cars 1766)

all

D50 & Plymouth Arrow

•545

18291

Mid sire all rear drive Regal & Century models with V6. V8 and Turbo 74 thru '87

552

•413

models '82 thru '87

PORSCHE

LADA

'84 thru '86

BUICK Century front-wheel drive

JEEP 412

81 all

Phoenix & Oldsmobile models '80 thru '84

'76 thru '82

models '76 thru '80

& Plymouth Champ

drive)

•556

59 thru '77 2500. 2800. 3 69 thru 76

models

all

'77 thru '80

models 59 thru 69 models 69 thru '87

BMW 276 •632 240

Reliant

Firebird

551

models

'55 thru '69

•242 •478

'81 thru '86

68 Heeley Sprite Roadster i265l

& Plymouth

•867

'75 thru '79 all models except 16-valve CRX & 4 Wagon '84 thru '86 Prelude CVCC all models 79 thru '82

098

1200 models '70 thru '73 F10 all models ',76 thru '79

Aries

all

all

'70 thru

JAGUAR

see NISSAN (8761 Sentra - see NISSAN (982) Stanza - see NISSAN 1981)

3000 Roadster

Healev 100 6 &

CVCC

models '84 thru '87 V8 models except Turbo

all

Firebird

all

1500

Civic

DODGE

049

Fiero

555

all models '76 thru '83 models '84 thru '85 Civic 1200 all models '73 thru '79 Civic 1300 & 1500 CVCC all models

CVCC

Accord Accord

WD

Pulsar

AUSTIN

•1232

Civic

models

'80 thru '85

4WDI

8 10 Maxima

models

all

'80 thru '83

77

thru all

600 & Z Coupe

360,

'67 thru '75

'77 thru '84

AUDI

402 •647 228 525

710 all models '73 720 Series Pick-up (including

models

all

85

U

138 '83

79

Ihru

J'.

..•:•'

I

6000 - see GENERAL MOTORS A Cars (8291

HONDA

2

2

78

70 thru

also available

•

*