Service Procedure
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 DEFLECTOR
a. Remove outboard grille panels, and disconnect BOTH positive and negative battery cables (remove the battery on vehicles equipped with air conditioning).
ILLUSTRATION C - DECK LID:
b. Remove rear encine compartment lid. Remove rubber dust seal and retaining clips from leading edge (front) of decklid assembly (and leave off) (ILLUSTRATION C).
ILLUSTRATION D - AIR INTAKE DUCT SYSTEM 1985-86:
ILLUSTRATION E - AIR INTAKE DUCT SYSTEM 1987-88:
c. Remove air intake duct assembly (ILLUSTRATION D & E). Remove foam rubber seal on air cleaner housing neck (85-86 only). Remove PCV vent tube elbow(s), clamps and hoses at engine and air cleaner. DO NOT remove PCV vent tube mounted on forward engine compartment wall.
d. Apply penetrating oil to all bolts and studs of the forward exhaust manifold. THIS STEP IS VERY IMPORTANT TO AVOID STUD BREAKAGE LATER ON.
e. Remove exhaust manifold to crossover bolts.
Disconnect upper engine strut.
g. Raise vehicle.
h. Remove convertor down pipe to crossover bolts.
i. Remove convertor heat shield.
j. Perform the following steps on air conditioned vehicles:
1. Remove air conditioning compressor shield.
2. Disconnect A/C belt and wires from compressor.
3. Remove A/C compressor mount bolts and lower A/C adjusting bracket.
4. Lower vehicle.
5. Remove upper A/C compressor mount bracket.
6. Raise vehicle.
k. Install jack stands under rear of vehicle to allow cradle to be lowered slightly.
l. Install jack stand under cradle and remove forward cradle bolts and nuts; lower cradle slowly approximately SIX (6) inches below mountings (for better access to front exhaust manifold). Do not lower more than SIX (6) inches.
m. Remove outer exhaust manifold heat shield.
n. Remove forward manifold bolts and studs. Best results will be obtained by:
^ Applying penetrating oil early (step c) and reapply now.
^ In the event of bolt breakage, a service tool for piloting easyouts (WITHOUT removing the cylinder head) has been provided. Kent-Moore Tool J-38782 has been provided to all involved dealers.
o. Clean exhaust manifold gasket surfaces. Inspect 1987-88 exhaust manifold for any evidence of cracking or significant warpage. The 1985-86 vehicles will have a new (slotted flange) manifold installed if not already equipped.
p. Cut wire harness bracket off engine coolant pipe to avoid interference with new shield.
ILLUSTRATION A - 1985-86 KIT:
ILLUSTRATION B - 1987-88 KIT:
q . Stack manifold deflector, gasket and manifold over new bolts and
install (position on head using top bolts) using torque values described in ILLUSTRATION A & B.
ILLUSTRATION F - MANIFOLD HEAT SHIELD:
r. Modify (ILLUSTRATION F) and install outer manifold heat shield (dimensions for modification on illustration).
s. Reattach cradle and torque cradle bolts according to the applicable Fiero Service Manual procedure. Remove jack stands. Lower vehicle.
ILLUSTRATION A - 1985-86 KIT:
ILLUSTRATION B - 1987-88 KIT:
t. Install crossover to manifold bolts using torque values described in ILLUSTRATION A & B.
u. Install upper A/C compressor mount bracket.
v. Install side heat shield (A/C equipped vehicles), and install battery (to be connected later).
w. Raise vehicle.
x. Install A/C compressor, attach wires, lower adjusting bracket and belt (do adjustment at this time).
y. Install convertor down pipe to crossover bolts (installing new seal provided in the kit).
z. Install A/C compressor heat shield (A/C equipped vehicles), convertor heat shield.
NOTE: THE 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 VIDEO "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. aa. Conduct inspection underneath the vehicle for:
^ Any indication of transmission oil cooler hose leakage.
^ Interference between right hand wheelhouse splash shield and coolant hose. IF CAMPAIGN 86-C-13 HAS NOT BEEN PERFORMED, DO IT NOW.
ILLUSTRATION G - HEAT SHIELD ARTWORK:
^ Any missing heat shield for this application (ILLUSTRATION G).
ILLUSTRATION H - PLUG WIRE CLIP:
bb. Lower vehicle. Remove plug wire clip, slide conduit up, and rein-
stall clip, connect wires to spark plugs (ILLUSTRATION H). The clip
is no longer seated on the bracket and should be repositioned above
the edge of the rocker cover. Bracket should be removed.
cc. Loosen shift cable bracket bolt (already installed on manual trans-
mission equipped vehicles; bolt supplied in kit for automatic trans-
mission equipped vehicles).
ILLUSTRATION I - AIR INLET (85-86):
ILLUSTRATION J - AIR INLET (87-88):
dd. Install new PCV grommet in the forward rocker cover, new air intake
duct (w/clamps) and vent tube/bracket assembly. Orient grommet with
flat side facing forward (ILLUSTRATION I & J). Position tube/bracket
assembly under shift cable bracket bolt (manual transmissions) or
install bolt supplied in kit (automatic transmissions). For 1987-88
vehicles, install rubber cap with clamp on air cleaner housing.
ee. Connect engine strut and torque according to the applicable Fiero
Service Manual procedure.
ff. Install new oil filler cap on rear rocker cover.
gg. Inspect battery cable and routing for any signs of chafing or wear.
Replace or reroute as necessary.
hh. Connect battery and install engine compartment side outer grill.
ii. Install J34730-1 (Fuel Pressure Gauge).
jj. Pressurize fuel system to approximately 40 psi by running fuel pump
with key on. Using pressure gage on schrader valve, monitor to check
if system holds pressure. Observe coldstart and port injector
connections at fuel rail as well as coupled fuel hose fittings for
any sign of leakage. Repair as necessary.
kk. Pressurize HOT coolant system to 15 psi. using a hand pump. Observe
throttle body-heater pipes at connection to throttle body for any signs of leakage. Repair any coolant leakage observed here or elsewhere within the engine compartment.
NOTE: STEP 2 IS AN INSPECTION ITEM. 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.
* 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. INSPECTION
Conduct general inspection of vehicle for any other potential fire related issues, specifically:
Rocker cover leakage from either gasket surface or PCV valve grommet leakage should be repaired if significant. SEEPAGE IS NOT SIGNIFICANT.
Improper wiring harness, coolant hose, or fuel line routings which are resulting in chafing of a serious nature should be rerouted (and repaired if necessary).
Inspect cooling fan operation (on 1985-87 the engine compartment blower fan also should be inspected). Replacement of relay, coolant switch, wiring or fan is authorized to make functional.
3. Install engine compartment lid.
4. Install campaign identification label.