127 50 22MB
English Pages 280 Year 1987
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 "
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'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
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T
THKVTMIOICOMIOIAUIOJ
1
fP»
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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)
^
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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
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Ot
2
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),
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rtL a [i cbn
10 10 l
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mr
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BUt/TCL III CRN TtL/BL« • BSN • »L«/U CRN
10
BLK HOT ten l
bl«/pn«
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pn«
—
.
.
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"S
•
CRN
e
In »«l
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• 8
• »LI LT GR GRN LT CP
o
bh/tei
• I i
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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
•
*