1993 Pontiac Firebird Service & Repair Manual Software

'-i..;LMES MOTORS, INC. 4CO £ast Seaonn Street iO.i:. GROVc., IOWA 51445 1883 ' S-8310-F

1993 FIREBIRD SERVICE MANUAL FOREWORD TABLE OF CONTENTS This manual provides information on diagnosis, service procedures, adjustments and specifications for the 1993 Firebird. An understanding of the material contained in this manual and in the appropriate Dealer Service Bulletins will help technicians to better serve vehicle owners. When reference is made in this manual to a brand name, number, or specific tool, an equivalent product may be used in place of the recommended item. All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice. SECTION NO. 0 1 3 4 5 6 7 8 9 10 11 SUBJECT GENERAL INFORMATION HEATING AND AIR CONDITIONING STEERING, SUSPENSION, TIRES AND WHEELS FINAL DRIVE BRAKES ENGINE TRANSMISSION ELECTRICAL - BODY AND CHASSIS ACCESSORIES BODY SERVICE BODY STRUCTURE INDEX

TABLE OF CONTENTS SECTION TABLE OF CONTENTS SECTION GENERAL INFORMATION Driveability and Emissions - General lnformatior, OA Maintenance and Lubrication OB Fuel Injection (Port) (3.4L) 6E3 (3.4L) Driveability and Emissions - HEATING AND AIR CONDITIONING 1 Fuel Injection (Port) (5.7L) 6E3 (5.7L) Exhaust System SF Heater and Ventilation 1A Heater, Ventilation and Air TRANSMISSION Conditioning 18 Automatic and Manual Transmission 7 Manual Control Air Conditioning 181 Automatic Transmission On-Vehicle HD6/HR6-HE Air Conditioning Service 7A Compressor Service or Unit Repair 102 HYDRA-MATIC 4L60 Automatic STEERING, SUSPENSION, TIRES Transmission Diagnosis RPO MD8 7A-15A HYDRA-MATIC 4L60 Automatic AND WHEELS Steering, Suspension, Tires and Transmission Unit Repair RPO MD8 7A-158 Wheels Diagnosis 3 Manual Transmission On-Vehicle Wheel Alignment 3A Service 78 Power Steering Gear and Pump On-Vehicle Service 38 Power Steering Gear Unit Repair 381A Borg-Warner (T5) 5-Speed Manual Transmission Unit Repair RPO M49 78-68 Power Steering Pump Unit Repair 3818 Front Suspension 3C Rear Suspension 30 Borg-Warner (T56) 6-Speed Manual Transmission Unit Repair RPO M28 and M29 78-108 Tires and Wheels 3E Clutch 7C Steering Wheel and Column On-Vehicle Service 3F ELECTRICAL - BODY AND CHASSIS 8 Supplemental Inflatable Restraint (SIR) Tilt Steering Column Unit Electrical Diagnosis SA Lighting Systems and Horns 88 Repair 3F5B Instrument Panel, Gages and Console SC FINAL DRIVE Propeller Shaft 4A Windshield Wiper/Washer System SE Rear Axle 48 ACCESSORIES 9 BRAKES Audio Systems 9A Cruise Control 98 Brakes 5 Master Cylinder SA Front Disc Brakes 581 Rear Disc Brakes 582 Duo-Servo Drum Brakes 5C2 Vacuum Booster System 501 Antilock Brake System 5E1 Parking Brake SF Theft Deterrent Systems 90 Engine Coolant Heater 9E Supplemental Inflatable Restraint (SIR) System Introduction 9J Supplemental Inflatable Restraint (SIR) System Diagnosis 9J-A Supplemental Inflatable Restraint (SIR) System Removal and Installation Procedures 9J-B ENGINE Engine General Description 6 Remote Keyless Entry 9K 3.4 Liter V6 Engine On-Vehicle BODY SERVICE 10 Service RPO L32 - VIN S 6A2A 3.4 Liter V6 Engine Unit Repair RPO L32 - VIN S 6A2B 5.7 Liter V8 Engine On-Vehicle Service RPO LT1 -VIN P 6A3A 5. 7 Liter V8 Engine Unit Repair General Body Service 10-1 Stationary Windows 10-2 Body Dimensions, and Underbody 10-3 Bumpers 10-4 Body Front End 10-5 Doors 10-6 RPO LT1 -VIN P 6A3B Rear Quarters 10-7 Cooling and Radiator 68 Engine Fuel SC Body Rear End 10-8 Roof 10-9 Engine Electrical 60 Battery 601 Seats and Carpet 10-10 Seat Belts 10-11 Cranking System 602 Charging System 603 BODY STRUCTURE Ignition System 604 Engine Wiring 605 Structural Body Repair and Dimensions 11 Driveability and Emissions - General Information SE INDEX' INDEX

1993 SERVICE MANUAL COMMENT FORM * Use this form to advise us of any errors you might find in this manual. We also welcome suggestions for improving the Service Manuals. Service Manual(s) that have the error ---------------·---- Page number(s) that have the error ___________________ _ Figure number(s) that have the error ___________________ _ VIN (if available) or model and applicable options ______________ _ Describe in detail, the error found or the suggestion(s). Attach additional pages if necessary. From: Dealer Firm Name ____________ Dealer Code _____ _ Cityfl'own State Zip Code ____ _ Name of Person Submitting This Comment Form ___________ _ Signature Date ____ Phone ( ) Mail To: Service Technology Group Service Information Production (030-5) C.C.O. Building 30007 Van Dyke Ave. Warren, Mi. 48090 * Additional comment forms at back of manual. ST'& Service Technology Group

1993 FIREBIRD GENERAL INFORMATION OA· 1 SECTION OA GENERAL INFORMATION CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring Location view in Section 9J before performing service on or around SIR components or wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs. CONTENTS Supplemental Inflatable Restraint (SIR) Handling ............................... OA-1 Disconnecting the Battery Negative Cable Assembly .............................. OA-1 Handling Electrostatic Discharge (ESD) Sensitive Parts .................................. OA-1 Special Tool Ordering Information ............ OA-2 Body Identification ........................ OA-2 Federal Vehicle Theft Prevention Standard ...... OA-2 Vehicle Identification Number ................ OA-2 Model Identification ....................... OA-4 Engine Identification ....................... OA-4 Transmission Usage ........................ OA-5 Transmission Identification .................. OA-5 Differential Ratios and Tire Information ........ OA-6 General Vehicle Lifting and Jacking ........... OA-6 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) HANDLING Refer to CAUTIONS and the SIR Component and Wiring Location view in Section 9J when performing service on or around SIR components or SIR wiring. SIR equipped vehicles can be identified by: • Steering wheel hub marked "INFLATABLE RESTRAINT." • "INFLATABLE RESTRAINT" indicator lamp in instrument cluster. • Code "2," "3" or "5" for the seventh digit of the vehicle identification number (VIN). DISCONNECTING THE BATTERY NEGATIVE CABLE ASSEMBLY CAUTION: Before removing or instal· ling any electrical unit or when a tool or equipment could easily come in con- tact with "live" exposed electrical terminals, disconnect the battery negative cable assembly to help prevent personal injury and/or damage to the vehicle or components. Unless in- structed otherwise, the ignition switch must be in the "OFF" or "LOCK" position. -- Lock Cylinder Coding ...................... OA-6 Key Identification and Usage .............. OA-6 Cutting Keys ........................... OA-6 Replacement Lock Cylinders . . . . . . . . . . . . . . . OA-6 Assembling and Coding Lock Cylinders ...... OA-8 Metric Fasteners ........................... OA-9 Fastener Strength Identification ............... OA-9 Prevailing Torque Fasteners .................. OA-9 English-Metric Conversions . . . . . . . . . . . . . . . . OA-11 Decimal and Metric Equivalents . . . . . . . . . . . . . OA-11 Standard Nomenclature for Electrical/Electronic Components and Systems ................ OA-11 Abbreviations ............................ OA-16 Replacement Labels . . . . . . . . . . . . . . . . . . . . . . . OA-19 Service Parts Identification Label . . . . . . . . . . . . OA-19 Option Codes ............................ OA-19 Option and Process Codes .................. OA-21 HANDLING ELECTROSTATIC DISCHARGE (ESD) SENSITIVE PARTS Figure 1 NOTICE: When handling an electronic part that has an ESD sensitive label (Figure 1) or is identified as ESD sensitive in the list that follows, the service technician should follow these guidelines to reduce any possible electrostatic charge buildup on the service technician's body and the electronic part in the dealership: 1. Do not open package until it is time to install the part. 2. Do not touch electrical terminals of the part or its pigtail connector(s) with a finger or tool. 3. Before removing the part from its package, ground the package to a known good ground on the vehicle. 4. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across the seat, sitting down from a standing position or walk- ing a distance. Not all parts that can be damaged by ESD have an ESD label. Components that can be damaged by ESD are: Inflatable restraint diagnostic energy reserve module (DERM) and resistor module Engine control module (ECM) Instrument panel cluster I

OA·2 GENERAL INFORMATION Solid state components also can be damaged if they are bumped or dropped, or if they are laid on a metal work bench or on an electrically operated item such as a radio, a TV or an oscilloscope. SPECIAL TOOL ORDERING INFORMATION Special service tools that are shown in this service manual that have tool product numbers beginning with "J" or "BT" are available for worldwide distribution from: Kent-Moore SPX Corporation 29784 Little Mack Roseville, MI 48066-2298 1-800-345-2233 Monday through Friday 8:00 a.m. through 8:00 p.m. EST Telex: 244040 KMTR VR Fax: 313-578-7375 General Motors dealers can purchase TECH 1 scan tools and accessories through Kent-Moore at the above address and phone number. Non General Motors dealer repair facilities can purchase TECH 1 scan tools and accessories from Kent-Moore at the above address or: Sun Electric Corporation One Sun Parkway Crystal Lake, IL 60014 1-800-CALLSUN (225-5786) 6:45 a.m. through 7:00 p.m. CST. BODY IDENTIFICATION A body identification tag is attached to the vehicle on the center of the radiator tie. The tag gives a schedule number and the last four digits of the vehicle identification number (VIN) sequence number. Refer to "Vehicle Identification Number" in this section Paint codes, trim numbers, seat option codes and other body information are included on the Service Parts Identification Label. Refer to "Service Parts Identifica- tion Label" in this section. FEDERAL VEHICLE THEFT PREVENTION STANDARD Federal law requires General Motors to place a vehicle identification number (VIN) label on certain parts of selected vehicles. The purpose of the standard is to reduce motor vehicle thefts by making parts removed from stolen vehicles easier to trace and recover. The label is permanently attached to an interior sur- face of the part and displays the complete VIN. The label on a replacement part contains the letter "R," the manufacturer's logo and the symbol "DOT." 1993 FIREBIRD NOTICE CONTENTS SENSITIVE TO STATIC ELECTRICITY MC0007-0A-B-RP Figure 1 - ESD Sensitive Parts Label [I] Important • THESE LABELS ARE NOT TO BE DEFACED, REMOVED OR COVERED. The labels must be shielded from paint, rustproofing and undercoating (dealer preparation included). Th~ theft deterrent labels are found on the front side door windows. VEHICLE IDENTIFICATION NUMBER Figures 2 through 4 The vehicle identification number (VIN) legally identifies the vehicle. A VIN plate is attached to the upper left of the instrument panel and can,be seen from outside the vehicle. Each sequential unit number is prefixed by letters and numbers that are explained in Figure 2. The VIN also appears on the Vehicle Certificate of Title and Registration. A derivative of the VIN is stamped on the engine and transmission. The code gives the model year, plant of manufacture and a sequence number that also indicates the car division. A VIN number is also stamped on the frame. A bar code VIN is also on the vehicle identification plate.

1993 FIREBIRD GENERAL INFORMATION OA-3 Vehicle Identification Number 1G2 FS 2 2 s 9 p 2 200001 y-- ------------ ~ PLANT SEQUENCE NUMBER VIN POSITIONS #12 THROUGH #17 G.M. MAKE IDENTIFIERS VIN POSITIONS #1, 2, 3 G.M. PLANT CODES VIN POSITION #11 MAKE USA CANADA CODE CODE A LAKEWOOD PONTIAC 1G2 2G2 ~ D DORAVILLE E LINDEN MODEL YEAR CODES VIN POSITION #10 L VAN NUYS CODE YEAR T TARRYTOWN / N 1992 p 1993 y WILMINGTON 1 OSHAWA#2 SERIES AND MODEL TABLE VIN POSITIONS #4 AND #5 2 ST.THERESE #4 #5 DIVISION 5 BOWLING GREEN CAR SERIES PONTIAC ~ CHECK 6 OKLAHOMA LINE DIGIT CITY VIN F s FIRE BIRD ~ POSITION #9 9 OSHAWA#1 F v FORMULNTRANS AM ENGINE CODES VIN POSITION #8 VIN RPO ENG. CARBURETION DISPL. MFT. CODE CODE TYPE (LITERS) DIVISION s L32 V6 MFI 3.4 CPC BODY TYPES p LT1 V8 MFI 5.7 CPC VIN POSITION #6 ~ CODE DESCRIPTION I~ 1 TWO DOOR COUPE/SEDAN RESTRAINT CODES VIN POSITION #7 2 TWO DOOR HATCHBACK CODE DESCRIPTION 3 TWO DOOR CONVERTIBLE 1 MANUAL BELTS 2 MANUAL BELTS WITH DRIVER AND PASSENGER INFLATABLE RESTRAINT SYSTEM 3 MANUAL BELTS WITH DRIVER INFLATABLE RESTRAINT SYSTEM 4 AUTOMATIC BELTS 5 AUTOMATIC BELTS WTH DRIVER INFLATABLE RESTRAINT SYSTEM PC2001-0A-F-RP Figure 2 -VIN Codes

OA-4 GENERAL INFORMATION VIN NUMBER PLATE LOCATION KC1002-0A·F-RP Figure 3 - VIN Plate Location Vehicle Identification Number 1 G 2 F S 2 2 S 9 P 2 200001 Dilon MieT Year ______ .....,-I Plant of Manufacture I Sequence Number I -- - -- --- 2 P 2 200001 VIN Derivative PC2002-0A-F-RP A V6 B V8 Figure 4 - VIN Derivative A C VIN DERIVATIVE (PRIMARY) D VIN DERIVATIVE (OPTIONAL) E ENGINE ID NUMBER VERIFICATION LABEL LOCATED ON OIL PAN ASSEMBLY c 1993 FIREBIRD MODEL IDENTIFICATION Models (series) and body styles for the current year are listed in Figure 2. ENGINE IDENTIFICATION Figures 2 and 4 through 6 The VIN code (Figure 2) provides detailed engine information by the engine code letter located on the vehicle identification plate. Stick-on-labels attached to the engine indicate the engine unit number and code. These labels also contain bar codes for in-plant identification. Engines are stamped with an engine identification number which identifies the assembly plant, the month produced, the day produced and the engine type code. All engines and transmissions are stamped with a VIN derivative, created from the complete VIN. Refer to "Vehicle Identification Number" in this section. The stamping contains nine positions. Position 1 is the GM car division identifier. Position 2 is the model year code. Posi- tion 3 is the car assembly plant code. Positions 4 through 9 contain the assembly plant sequential number of the vehicle (Figure 4). If the engine in the vehicle is the original engine, information can be derived from the eighth VIN position letter or number (Figure 2). To determine if the engine is original, compare the VIN and the VIN derivative. The VIN derivative should be the same as positions 3 and 10 through 17 of the VIN. B c PC0005-0A·F-RP Figure 5 - Engine Identification Locations (Typical)

1993 FIREBIRD TRANSMISSION USAGE Figure 7 Transmission usage affects axle usage. The transmission usage chart lists each engine with the axles and transmissions used for each. TRANSMISSION IDENTIFICATION Figures 8 and 9 The transmission has two identifying stampings: the transmission identification and the VIN derivative. The GENERAL INFORMATION OA·S transmission identification number gives the transmission model and when it was made. On the automatic transmission, the transmission identification number is located on the plate on the automatic transmission case. On the manual transmission, the transmission identification number is located either on the transmission case or the bell housing. The VIN derivative is created from the complete VIN and is stamped in either of 2 places (Figure 8). Refer to "Vehicle Identification Number" in this section. For more information on rear axle differential ratio codes, refer to SECTION 4B. Engine Identification Number 0 00 00 000 Source Code F-Flint Motor V-Flint Engine T-Tonawanda $-Saginaw Parts K-GM of Canada LTD. M-GM of Mexico H-Hydra-Matic Engine 3.4L, V6 (VIN S) 5.7L, VS (VIN P) Month Produced 01 January 02 February 12 December Figure 6 - Engine Identification Number TRANSMISSION USAGE Axle (RPO-Ratio) GUS 3.23 GU2-2.73 or GUS-3.23 Figure 7 - Transmission Usage Chart A PRIMARY LOCATION B SECONDARY LOCATION HYDRA-MATIC 4L60 Type Code . Day Produced LC0003-0A-B-RP Transmission M49-Borg-Warner Manual 5-speed MDS-Hydra-Matic 4L60 M49-Borg-Warner Manual 5-Speed M28-Borg-Warner Manual 6-Speed M29-Borg-Warner Manual 6-Speed MDS-Hydra-Matic 4L60 PC0001-0A-F-RP JULIAN DATE (OR DAY OF THE YEAR) CALENDAR YEAR SOME MODELS (3 = 1993) SHIFT BUILT A & B = FIRST SHIFT C & H = SECOND SHIFT PC0002-0A-F-RP Figure 8 - Automatic Transmission Identification

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1993 Pontiac Firebird Service & Repair Manual Software

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