1993-2002 Pontiac Firebird Service & Repair Manual

! SERVICE MANUAL l~I Camaro lIJ Firebird VOLUME 1 OF 3 GMP /98 , f- l'F.

1998 Chevrolet Camara and Pontiac Firebird Service Manual Volume 1 This manual provides information on the diagnosis, the service procedures, the adjustments, and the specifications for the 1998 Chevrolet Camaro and Pontiac Firebird. This is the second edition of the 1998 Chevrolet Camaro and Pontiac Firebird Service Manual. This manual contains new and updated information that will help you diagnose and service vehicles. If you are in the possession of the early edition of this manual GMP/98-F Volumes 1, 2, and 3 please DISCARD it because the information is outdated. Information on transmission unit repair (overhaul) can be found in the 1998 Transmission/Transaxle/Transfer Case Unit Repair Manual (TURM), GMPT/98-TURM, available separately. The TURM manual contains information on automatic and manual transmissions, including the fluid flow and circuit description information. The technicians who understand the material~ this manual and in the appropriate Dealer Service Bulletins better serve the vehicle owners. When this manual refers to a brand name, a part number, or a specific tool, you may use an equivalent product in place of the recommended item. All information, illustrations, and specifications in this manual are based on the latest product information available at the time of publication approval. General Motors reserves the right to make changes at any time without notice.

) TABLE OF CONTENTS Volume 1 Volume 2 Preface ................................................................ 1 Cautions and Notices . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. . .. .. .. 3 General Information ....................................... 0-1 General Information ......................................... 0-3 Maintenance and Lubrication ......................... 0-33 Vibration Diagnosis and Correction ................ 0-45 HVAC ................................................................ 1-1 HVAC System - Manual .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. 1-3 Body and Accessories .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 8-1 Lighting Systems ........................................... 8-15 Wipers/Washer Systems .............................. 8-161 Entertainment .............................................. 8-195 Wiring Systems ........................................... 8-282 Body Control System ................................... 8-425 Instrument Panel, Gauges and Console ....... 8-467 Keyless Entry .. . .. . .. . .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . 8-545 Horns .......................................................... 8-560 Theft Deterrent .. . .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. . .. . .. .. 8-569 Cruise Control ............................................. 8-601 Retained Accessory Power .......................... 8-640 Exterior Trim ............................................... 8-647 Waterleaks .................................................. 8-658 Air/Wind Noise ............................................ 8-665 Squeaks and Rattles .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. 8-667 Stationary Windows .. .. .. .. .. .. .. . .. .. . .. . .. .. .. . .. .. .. . 8-683 Bumpers ..................................................... 8- 712 Body Front End ........................................... 8-734 Doors .......................................................... 8-771 Roof ............................................................ 8-825 Seats ... .. . .. .. . .. .. ... .. ... ..... .... . .. ...... .. .. .. ... ... ... .. 8-896 Interior Trim ................................................ 8-939 Body Rear End .. .. .. . .. .. .. .. .. .. .. . .. .. . .. .. .. .. .. .. . .. . 8-955 Plastic Panel Information and Repair ........... 8-987 PainVCoatings ........................................... 8-1014 Frame and Underbody ............................... 8-1022 Collision Repair ......................................... 8-1080 Restraints ......................................................... 9-1 Seat Belts .. .. . .. .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. . 9-3 SIR ............................................................... 9-20 INDEX ....................................................... .INDEX-1 Preface ................................................................ 1 Cautions and Notices .. .. .. .. . .. .. .. .. .. .. . .. . .. .. .. . .. .. .. .. . 3 Steering ............................................................ 2-1 Power Steering System .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 2-3 Steering Wheel and Column - Tilt ................. 2-51 Suspension .. .. .. . .. . .. . .. . .. . .. .. .... .. .... .. .. .. . .. .. .. ... .. . .. 3-1 Suspension General Diagnosis .. .. .. .. .. .. .. .. .. .. .. .. 3-3 Wheel Alignment ............................................. 3-7 Front Suspension .......................................... 3-12 Rear Suspension .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 3-43 Tires and Wheels .......................................... 3-58 Driveline/Axle .................................................. 4-1 Propeller Shaft . .. .. . .. .. . .. .. .. .. .. . .. . .. . .. . .. .. . . .. .. .. . .. .. 4-3 Rear Drive Axle .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. . 4-23 Brakes .............................................................. 5-1 Hydraulic Brakes .. .. . .. . .. . .. .. .. . .. . .. .. . .. . .. .. . .. . . . .. . .. . 5-5 Disc Brakes .. . .. .. . .. .. .. .. . .. .. .. . .. . . .. .. .. .. . .. . .. .. .. . .. . 5-68 Park Brake . .. . .. .. .. . .. .. . .. .. . .. . .. .. .. . . .. .. . .. .. .. . .. .. ... . 5-92 Anti lock Brake System .. .. .. .. .. . .. . .. .. .. . .. .. .. .. .. . 5-108 INDEX ........................................................ INDEX-1 Volume 3 Preface ................................................................ 1 Cautions and Notices .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. .. .. .. .. .. 3 Engine .............................................................. 6-1 Engine Mechanical - 3.8L ............. ,................ 6-13 Engine Mechanical - 5.7L ............................ 6-229 Engine Cooling ............................................ 6-580 Engine Electrical .. .. .. . .. . .. .. .. . .. . .. . .. . ... .. . .. .. . . .. . 6-665 Engine Controls - 3.8L ................................ 6-725 Engine Controls - 5.7L .............................. 6-1247 Engine Exhaust ......................................... 6-1900 Transmission/Transaxle .. .. . .. .. .. . .. .... .. . .. .. .. .. .. . 7-1 Manual Transmission - M49 ............................ 7-5 Manual Transmission - MM6 ......................... 7-28 Automatic Transmission - 4L60-E .................. 7-56 Clutch ......................................................... 7-359 INDEX ........................................................ INDEX-1

Preface Table of Contents -1 Cautions and Notices Cautions and Notices ......................................... 3 SIR lnflator Module Disposal Caution ................ 5 Definition of Caution, Notice, and Important ...... 3 SIR lnflator Module Handling and Storage ABS Handling Caution ......................................3 Caution .........................................................5 Battery Disconnect Caution ...............................3 SIR Special Tool Caution ..................................5 Brake Dust Caution .......................................... 3 Vehicle Lifting Caution ...................................... 5 Brake Fluid Caution ......................................... .4 Window Removal Caution .................................5 Clutch Dust Caution ......................................... .4 Window Retention Caution ................................5 Electric Coolant Fan Caution ........................... .4 Work Stall Test Caution ....................................6 Fuel and EVAP Pipe Caution ........................... .4 Fuel Gauge Leak Caution ................................ .4 Fuel Pipe Fitting Caution ................................. .4 Fuel Storage Caution ....................................... .4 Gasoline/Gasoline Vapors Caution ................... .4 Lower 0-Ring Removal Caution ....................... .4 Moving Parts and Hot Surfaces Caution .......... .4 Relieving Fuel Pressure Caution ...................... .4 Road Test Caution .......................................... .4 Safety Glasses and Compressed Air Caution .... 5 Safety Goggles and Fuel Caution ..................... 5 Seat Belt Replacement Caution ........................ 5 Defective Scan Tool Notice ............................... 6 Fastener Notice ................................................6 Fuel Pressure Notice ........................................6 Handling ESD Sensitive Parts Notice ................ 6 Handling IAC Valve Notice ............................... 7 Ignition OFF When Disconnecting Battery Notice ...........................................................7 Latched OTC 81018, 81024 Notice (SDM-RSD) ...................................................7 Nylon Fuel Lines Notice .................................... 7 OBDII System Description Notice ...................... 7 SIR Caution ......................................................5 PCM and ESD Notice .......................................7 SIR Handling Caution ....................................... 5 Servicing and Replacing Seat Belts Notice ....... 7 )

2 - Table of ,Contents Preface ( BLANK ( (

Preface Cautions and Notices Definition of Caution, Notice, and Important The diagnosis and repair procedures in the GM Service Manual contain both general and specific Cautions, Notices, and lmportants. GM is dedicated to the presentation of service information that helps the technician to diagnose and repair the systems necessary for the proper operation of the vehicle, however, certain procedures may present a hazard to the technician if they are not followed in the recommended manner. Cautions, Notices, and lmportants are elements designed to prevent these hazards, however, not all hazards can be foreseen. This information is placed at strategic locations within the service manual. This information is designed to prevent the following from occurring: • Serious bodily injury to the technician • Damage to the vehicle • Unnecessary vehicle repairs • Unnecessary component replacement • Improper repair or replacement of vehicle components. Any caution or notice that appears in general information is referenced from the individual service categories. CAUTION Defined When encountering a CAUTION, you will be asked to take a necessary action or not to take a prohibited action. If a CAUTION is not heeded, the following consequences may occur: • Serious bodily injury to the technician • Serious bodily injury to other technicians in the workplace area • Serious bodily injury to the driver and/or passenger(s) of the vehicle, if the vehicle has been improperly repaired NOTICE Defined Notices call special attention to a necessary action or to a prohibited action. If a NOTICE is not heeded, the following consequences may occur: • Damage to the vehicle • Unnecessary vehicle repairs • Unnecessary component replacement • Improper operation or performance of the system or component under repair • Damage to any systems or components which are dependent upon the proper operation of the system or component under repair • Improper operation or performance of any systems or components which are dependent upon the proper operation or performance of the system or component under repair • Damage to fasteners, basic tools, or special tools • The leakage of coolant, lubricant, or other vital fluids Cautions and Notices -3 IMPORTANT Defined IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure. IMPORTANT statements are designed to do the following: • Clarify a procedure • Present additional information for accomplishing a procedure • Give insight into the reason or reasons for performing a procedure in the manner recommended • Present information that will help to accomplish a procedure in a more effective manner • Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater ease ABS Handling Caution Caution: Certain components in the Antilock Brake System (ABS) are not intended to be serviced individually. Attempting to remove or disconnect certain system components may result in personal injury and/or improper system operation. Only those components with approved removal and installation procedures should be serviced. Battery Disconnect Caution Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. Brake Dust Caution Caution: A void taking the following actions when you service wheel brake parts: • Do not grind brake linings. • Do not sand brake linings. • Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne.

4 .. Cautions and Notices Brake Fluid Caution Caution: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: • Eye contact-rinse eyes thoroughly with water. • Skin contact-wash skin with soap and water. Clutch Dust Caution Caution: When servicing clutch parts, do not create dust by grinding or sanding the clutch disc or by cleaning parts with a dry .brush or with compressed air. A water-dampened cloth-NOT SOAKED-should be used. The clutch disc contains asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. Electric Coolant Fan Caution Caution: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan. Fuel and EVAP Pipe Caution Caution: In order to reduce the risk of fire and personal injury observe the following items: • Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes • Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak. • Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose .the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. • Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the 0-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) Fuel Gauge Leak Caution Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Preface Fuel Pipe Fitting Caution Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the 0-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. Fuel Storage Caution Caution: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Gasoline/Gasoline Vapors Caution Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Lower 0-Ring Removal Caution Caution: Verify that the lower (small) 0-ring of each injector does not remain in the lower manifold in order to reduce the risk of fire and personal injury. If the 0-ring is not removed with the injector, the replacement injector with new 0-rings will not seat properly in the injector socket. Improper seating could cause a fuel leak. Moving Parts and Hot Surfaces Caution Caution: While working around a running engine, avoid contact with moving parts and hot surfaces to prevent possible bodily injury. Relieving Fuel Pressure Caution Caution: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Road Test Caution Caution: Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury. ( (

) ) ) Preface Safety Glasses and Compressed Air Caution Caution: Wear safety glasses when using compressed air in order to prevent eye injury. Safety Goggles and Fuel Caution Caution: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash. Seat Belt Replacement Caution Caution: To help avoid personal injury from unrepaired crash damage to a restraint system: • Replace each seat belt system worn during a crash unless the crash was minor. • Perform the seat belt check for each seat belt system. Replace the seat belt system if there is any doubt about the condition of system components. SIR Caution Caution: This vehicle has a Supplemental Inflatable Restraint (SIR) System. Refer to SIR Component Views in order to determine whether you are performing service on or near the SIR components or the SIR wiring. When you are performing service on or near the SIR components or the SIR wiring, refer to Repair Instructions in SIR. Failure to follow the CAUTIONS could cause air bag deployment, personal injury, or unnecessary SIR system repairs. SIR Handling Caution Caution: When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs. SIR lnflator Module Disposal Caution Caution: In order to prevent accidental deployment of the air bag which could cause personal injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed inflator module contains substances that could cause severe illness or personal injury if the sealed container is damaged during disposal. Use the following deployment procedures to safely dispose of an undep/oyed inflator module. Failure to dispose of an inflator module as instructed may be a violation of federal, state, province, or loci Jaws. Cautions and Notices -5 SIR lnflator Module Handling and Storage Caution Caution: When you are carrying an undeployed inflator module: • Do not carry the inflator module by the wires or connector on the lnflator module • Make sure the bag opening points away from you When you are storing an undeployed inf/ator module, make sure the bag opening points away from the surface on which the inf/ator module rests. When you are storing a steering column, do not rest the column with the bag opening facing down and the column vertical. Provide free space for the air bag to expand in case of an accidental deployment. Otherwise, personal injury may result. SIR Special Tool Caution Caution: In order to avoid deploying the air bag when troubleshooting the SIR system, use only the equipment specified In this manual and the instructions given in this manual. Failure to use the specified equipment as instructed could cause air bag deployment, personal injury to you or someone else, or unnecessary SIR system repairs. Vehicle Lifting Caution Caution: To avoid any vehicle damage, serious personal injury or death when components are removed from the vehicle and the vehicle is supported by a hoist, perform the following steps: • Chain the vehicle to the hoist at the same end as the components that are being removed. • Support the vehicle at the opposite end from which the components are being removed. Window Removal Caution Caution: When working with any type of glass, use approved safety glasses and gloves to reduce the chance of personal injury. Window Retention Caution Caution: When replacing stationary windows, Urethane Adhesive Kit GM PIN 12346392, or a urethane adhesive system meeting GM Specification GM3651 M, must be used to maintain original installation integrity. Failure to use the urethane adhesive kit will result in poor retention of the window which may allow unrestrained occupants to be ejected from the vehicle resulting in personal injury.

6 - Cautions and Notices Work Stall Test Caution Caution: One or more of the following guidelines may apply when performing specific required tests in the work stall: • When a test requires spinning the drive wheels with the vehicle jacked up, adhere to the following precautions: - Do not exceed 56 km/h (35 mph) when spinning one drive wheel with the other drive Wheel stopped. This limit is necessary because the speedometer indicates only one-half the actual vehicle speed under these conditions. Personal injury may result from excessive wheel spinning. If all of the drive wheels are spinning at the same speed, do not exceed 112 km/h (70 mph). Personal injury may result from excessive wheel spinning. All persons should stay clear of the rotating components and the balance weight areas in order to avoid possible personal injury. - When running an engine in the repair stall for an extended period of time, use care not to overheat the engine and the transmission. • When a test requires jacking up the vehicle and running with the wheels and brake rotors removed, adhere to the following precautions: - Support the suspension of all drive wheels at normal ride height. - Do not apply the brake with the brake rotors removed. - Do not place the transmission in PARK with the drive wheels still spinning. - Turn Off the ignition in order to stop the powertrain components from spinning. Defective Scan Tool Notice Notice: Do not use a scan tool that displays faulty data. Report the scan tool problem to the manufacturer. Use of a faulty scan tool can result in misdiagnosis and unnecessary parts replacement. Preface Fastener Notice Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubrican1s, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Fuel Pressure Notice Notice: Do not allow the fuel pressure to exceed !he specified value because damage to the fuel pressure regulator or the fuel pressure gauge may result. Handling ESD Sensitive Parts Notice Notice: Electrostatic discharge (ESD) can damage many solid-state electrical components. ESD susceptible components may or may not be labeled with the ESD symbol. Handle all electrical components carefully. Use the following precautions in order to avoid ESD damage: • Touch a metal ground point in order to remove your body's static charge before servicing any electronic component; especially after sliding across the vehicle seat. • Do not touch exposed terminals. Terminals may connect to circuits susceptible the ESD damage. • Do not allow tools to contact exposed terminals when servicing connectors. • Do not remove components from their protective packaging until required to do so. • Avoid the following actions unless required by the diagnostic procedure: - Jumpering or grounding of the components or connectors. - Connecting test equipment probes to components or connectors. Connect the ground lead first when using test probes. • Ground the protective packaging of any component before opening. Do not rest solid-state components on metal workbenches, or on top of TVs, radios, or other electrical devices. (

1993-2002 Pontiac Firebird Service & Repair Manual

You're Reading a Preview

Recently Viewed