Service Procedure

NOTE: The "Check Oil" reminder label and/or glove box supplements for Campaign 84-C-15B and/or 87-C-11 should be taken care of at this time if they are still open.

To reduce the effects of fluid leaks which may lead to engine compartment fires, Pontiac dealers will do the following at no charge:

1. INSTALL EXHAUST MANIFOLD SHIELD

a. Remove right side grille panel & disconnect negative battery cable.

ILLUSTRATION D (Deck Lid):

b. Remove rear engine compartment lid (on 1984 models also remove center grille from engine compartment lid). Remove rubber dust seal and retaining clips (rivets) from leading edge (front) of decklid assembly (and leave off). On 1984 vehicles, remove plastic deflector from underside of decklid grille opening (and leave off); reinstall center grille. (See Illustration D for component identification.)

c. Remove air cleaner assembly.

d. Remove dipstick tube.

e. Disconnect 02 sensor wire.

f. Raise vehicle.

g. Remove and discard convertor splash shields (only on 1984-85).

h. Remove convertor pipe to exhaust manifold bolts.

i. Remove A/C mount bracket bolt and install new stud-headed bolt (# 3) in block above oil pan rail at A/C bracket. Spacer (1984-86: # 4 - WITHOUT A/C or NO Spacer WITH A/C; 1987 & 88: # 4 - WITHOUT A/C or # 26
- WITH A/C) to be installed on stud.
j. Lower vehicle.

k. Remove exhaust manifold and gasket.

l. Clean gasket surface on cylinder head and exhaust manifold if a new manifold is not installed.

ILLUSTRATION E (Harness Taping):

m. Install protective tape wrap (provided in kit) on engine wiring harness starting at themostat housing and ending at bulkhead connector on 1984 vehicles (Illustration E).

ILLUSTRATION A - 1984-86 MODELS:

ILLUSTRATION B - 1987 MODELS:

ILLUSTRATION C - 1988 MODELS:

n. Install new cylinder head bolts (1984-86 vehicles only) provided in kits. New cylinder head bolts should be installed using torque values described in Illustration A & B. HEAD BOLTS SHOULD BE REPLACED ONE AT A TIME. If a broken head bolt is encountered, refer to Dealer Service Bulletin 87-6(GAS)-94 for the proper procedure.

o. Install new 02 sensor (# 21, 1984-86) in exhaust manifold.

p. Install deflector (# 2), gasket (# 23), and exhaust manifold (# 7) (new manifold provided for 84-86 vehicles). Shield is not gasketed against cylinder head. Note that shield leg/bracket has different spacers (# 4 or # 26) or no spacer depending upon model year and equipment.

q. Manifold bolts should be installed using torque values described in Illustration A, B & C. Lock tabs (# 6, 1984-88) should be installed on outboard manifold runner bolts.

r. Install dipstick tube.

s. Install new exhaust pipe seal. Loosely install one (1) convertor pipe to exhaust manifold bolt (# 12).

t. Raise vehicle.

u. Install remaining manifold to convertor pipe bolt (# 12) and tighten using torque values described in Illustration A & B.

v. Install shield leg nut (# 5) and washer (# 19) and tighten using torque values described in Illustration A, B & C.

w. Lower vehicle.
x. Remove starter motor heat shield and clamps (may already be removed) from exhaust manifold to convertor exhaust pipe.

y. Install new heat stove (# 20 & 25, 1984-86 only) as shown in Illustration A with band clamps (# 20) on front pipes.

z. Install air cleaner assembly. aa. Connect negative battery cable and install right side grille panel.


NOTE: THE REMAINING STEPS BELOW ARE INSPECTION ITEMS. IT IS IMPERATIVE THAT CARE BE EXERCISED IN INSPECTION. THE PARTICULAR ITEMS HAVE BEEN CHOSEN DUE TO THEIR POTENTIAL ASSOCIATION WITH UNDERHOOD FIRE. SEE THE NOTES ON EACH STEP FOR THE TYPES OF REPAIRS AUTHORIZED.

* PRIOR TO PERFORMING THESE INSPECTIONS, THE TRAINING MOVIE "WINNERS DO IT RIGHT" (MAILED SEPT. 1989) SHOULD BE VIEWED.

* PLEASE NOTIFY YOUR CUSTOMER OF ANY ISSUES NOT FIXED IN YOUR INSPECTION WHICH WILL BE HIS/HER RESPONSIBILITY.

* ANY ISSUES NOT SPECIFICALLY AUTHORIZED IN THIS BULLETIN MAY BE DISCUSSED WITH YOUR APPROPRIATE ZONE CONTACT PERSON WITH SERVICE RESPONSIBILITY


2. INSPECT COOLING SYSTEM

a. Visual check of coolant level. Adding needed coolant to specified level and/or diagnostic procedure will be authorized if coolant loss is determined to be a chronic problem.

NOTE: With engine cold, perform a pressurized leak test as described in 1986 Fiero Service Manual Section 6B-14, 15.

b. Visually inspect for significant leaks. Repairs are authorized for external coolant leaks from any engine compartment area, specifically thermostat housing, water pump, coolant hoses and connectors in engine compartment.

C. Visually inspect for signs of coolant hose wear or aging. Replacement of damaged hoses is authorized.

d. Perform a function check of cooling fan. Replacement of relay, coolant switch, wiring or fan is authorized to make functional.

ILLUSTRATION F - 1984-88 MODELS (Heat Shields):

ILLUSTRATION G - 1984-86 MODELS (Heat Shields):

3. INSPECT EXHAUST SYSTEM

a. Observe for any significant leaks (vehicle running). Repairs are authorized for any leaks forward of the catalytic convertor. Also repairs should be made if any irregularity in manifold or front pipe prevents proper installation of the new shield.

b. Visually inspect for presence of appropriate heat shields. Repair or replacement will be authorized for starter shield, convertor shield, muffler shield, or bulkhead shields. See Illustrations F and G for correct configurations.
4. INSPECT LUBRICATION SYSTEM

a. Visually inspect for indications of significant oil leakage. Repairs for seepage will not be authorized, only areas with significant leakage. Specifically, rocker cover gasket repair or PCV breather are authorized. Oil pan or filter leaks are not nomally covered.

b. Visually verify update to 4 quart system. Vehicles should all be equipped with the larger oil filter APF51 style). Replacement of the filter is authorized if vehicle was not previously retrofit.

c. Check oil level. Make-up oil authorized for vehicles 1 quart or more low.
5. INSPECT FUEL SYSTEM

a. Visually inspect for signs of leakage inside engine compartment. Repairs are authorized for retorque, new fitting, or hose replacement.

b. Visually inspect evaporative emission system for integrity of harness connections. Reinstallation of harness authorized if necessary. Tampered systems to be replaced only if vapor lines were left open (presenting some fire risk). All emission discrepancies should be noted in writing to the owner and noted on the repair order.


6. INSPECT TRANSMISSION OIL COOLER

a. Visually inspect for signs of oil cooler hose leakage near transmission. Repairs are authorized for hose degradation or fitting tighten/replace.


7. INSPECT IGNITION SYSTEM

a. Visually inspect for proper spark plug wire routing. Rerouting authorized if required and replacement of spark plug wire retainer clips only.


8. INSPECT ENGINE COMPARTMENT WIRING

a. Visually inspect for correct routing of engine wiring harness in vicinity of exhaust manifold. Reroute and clip as necessary.

b. Visually inspect for correct battery cable routing. Reroute and clip if required.

c. Visually inspect for any obvious chafing/wear on starting/charging circuit wiring. Wire, conduit or retainer replacement authorized if necessary.


9. VISUALLY INSPECT FOR ANY COMBUSTIBLE MATERIALS HANGING LOOSE IN FRONT OF ENGINE COMPARTMENT. (e.g. conduit, insulation) Remove as required.


10. Install rear engine compartment lid and left side grille panel.
NOTE THAT COMPONENTS ON THE BULKHEAD WILL NOW BE BARELY VISIBLE FROM OUTSIDE THE VEHICLE WITH THE ENGINE COMPARTMENT LID CLOSED. THIS CHANGE INCREASES AIR FLOW THROUGH THE ENGINE COMPARTMENT. SHOULD YOUR CUSTOMER WISH, THE VISIBLE BULKHEAD COMPONENTS MAY BE SPRAYED FLAT BLACK.


11. Install campaign identification label.