1972 Pontiac Series Service Manual S-7204 – PDF DOWNLOAD
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1972 Pontiac Series Service Manual S-7204 – PDF DOWNLOAD
Language : English
Pages : 1509
Downloadable : Yes
File Type : PDF
Size: 71.4 MB
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1972 Pontiac Series Service Manual S-7204 – PDF DOWNLOAD
This manual applies to all 1972 Pontiac Series and Models. It contains service information on all components of the car except the body. Body information is contained in a separate Body Manual. Other information pertaining to the operation of the car is contained in the Owner’s Manual which accompanies each vehicle.
- The arrangement of material in this manual is indicated by the table of contents at the right. Black tabs on the first page of each section register with this table to assist in readily locating information desired.
- A detailed table of contents appears at the beginning of each section and an alphabetic index is included at the back of the manual.
TABLE OF CONTENTS:
1972 Pontiac Series Service Manual S-7204 – PDF DOWNLOAD
1972 Pontiac Service Manual…………………………… 1
Table of Contents………………………………… 2
00 – General Information………………………….. 3
Identification……………………………….. 3
Vehicle……………………………………… 3
Body………………………………………… 3
Engine………………………………………. 5
Transmission…………………………………. 6
Towing………………………………………. 6
Ignition Lock………………………………… 7
Nut and Bolt Markings…………………………. 9
Basic Dimensions……………………………… 11
Lubrication………………………………….. 15
01 – Heating and Ventilation………………………. 22
Diagnosis……………………………………. 22
General Description…………………………… 25
Service Procedures……………………………. 30
01A – Custom Air Conditioning……………………… 60
Diagnosis……………………………………. 60
Principles of Refrigeration……………………. 79
General Description…………………………… 82
Service Procedures……………………………. 106
01B – Automatic Tempurature Control………………… 188
B Series Diagnosis……………………………. 188
G Series Diagnosis……………………………. 199
General Description…………………………… 210
B Series Description………………………….. 212
G Series Description………………………….. 227
Service Procedures……………………………. 230
02 – Frame and Body Mountings……………………… 246
Frame Identification………………………….. 251
Frame Lift Points…………………………….. 247
Frame Alignment………………………………. 249
Body Bolts…………………………………… 250
03 – Front Suspension…………………………….. 252
Trouble Diagnosis and Testing………………….. 253
General Description…………………………… 262
Shock Absorbers………………………………. 263
Suspension Alignment………………………….. 264
Ball and Joint Inspection……………………… 266
General Information…………………………… 267
Adjustment Procedures…………………………. 267
Minor Service………………………………… 272
Major Service………………………………… 276
Torque Specifications…………………………. 284
Alignment Specifications………………………. 285
Special Tools………………………………… 286
04 – Rear Suspension……………………………… 287
Trouble Diagnosis and Testing………………….. 288
General Description…………………………… 293
General Information…………………………… 299
Adjustment Procedures…………………………. 299
Major Service………………………………… 299
04A – Non Type C Differential……………………… 325
Trouble Diagnosis and Testing………………….. 325
Gear Tooth Nomenclature……………………….. 329
Red Lead Test………………………………… 329
Adjustments Affecting Tooth Contact…………….. 329
General Description…………………………… 331
Design………………………………………. 332
Operation……………………………………. 332
Axle Ratios………………………………….. 333
Periodic Service……………………………… 335
Minor Service………………………………… 335
Major Service………………………………… 340
04B – Non Type C Safe T Track Differential………….. 357
Trouble Diagnosis and Testing………………….. 357
General Description…………………………… 357
Major Repairs………………………………… 360
04C – Type C Standard Differential…………………. 369
Trouble Diagnosis and Testing………………….. 369
Description………………………………….. 369
Operation……………………………………. 370
Useage of C Differential………………………. 371
Gear Ratios………………………………….. 371
Axle Shaft and Bearing Seal……………………. 371
Differntial Removal Case and Assembly…………… 372
Drive Pinion…………………………………. 373
Setting Pinion Depth………………………….. 373
Differential Case Install……………………… 377
Side Bearing Shims……………………………. 377
04D – Type C Safe T Track Differential……………… 382
Trouble Diagnosis and Testing………………….. 382
Description………………………………….. 382
Operation……………………………………. 383
Specifications and Adjustments…………………. 386
Lubrication………………………………….. 386
Service Procedures……………………………. 386
Assembly Clutch Pack………………………….. 387
Checking Pinion to Side Gear Clearance………….. 388
Flushing…………………………………….. 390
04E – Propeller Shaft…………………………….. 393
Trouble Diagnosis and Testing………………….. 393
General Description…………………………… 395
Inspection…………………………………… 397
Minor Service………………………………… 397
Major Service………………………………… 397
Install Propeller Shaft Assembly……………….. 402
05 – Brakes General………………………………. 404
Trouble Diagnosis and Testing………………….. 404
Brake Noises…………………………………. 408
Brake Cautions……………………………….. 410
General Description…………………………… 410
Operation……………………………………. 412
Service Operations……………………………. 414
Hydraulic Systems…………………………….. 425
05A – Delco Moraine Power Brake……………………. 437
Trouble Diagnosis and Testing………………….. 437
General Description…………………………… 438
Design………………………………………. 439
Principles of Operation……………………….. 439
Vacuum Failure……………………………….. 440
Checks and Adjustments………………………… 440
Minor Repairs………………………………… 441
Overhaul Power Unit…………………………… 442
Master Cylinder Remove………………………… 441
Front Housing Remove………………………….. 441
Power Piston Disassemble………………………. 442
Power Piston Install………………………….. 446
Front Housing Replace…………………………. 446
05B – Bendix Power Brake………………………….. 448
General Description…………………………… 450
Design………………………………………. 450
Principles of Operation……………………….. 452
Checks and Adjustments………………………… 454
Minor Repairs………………………………… 454
Overhaul Unit………………………………… 454
05C – Bendix Power Brake………………………….. 461
Trouble Diagnosis and Testing………………….. 461
System Test………………………………….. 461
Vacuum Leak in Released Position……………….. 461
Unit Operation……………………………….. 461
Vacuum Leak in Holding Position………………… 462
Hydraulic Leak……………………………….. 462
Description of Operation………………………. 463
Principles of Operation……………………….. 465
Checks and Adjustments………………………… 467
Bleeding Systems……………………………… 468
Stop Lamp Switch……………………………… 468
Master Cylinder and Power Unti Remove…………… 469
Master Cylinder Remove………………………… 469
Valve Assembly Remove…………………………. 469
Power Section Disassemble……………………… 470
Master Cylinder Disassemble……………………. 472
Master Cylinder Assemble………………………. 473
Power Unit Assemble…………………………… 473
Push Rod Adjustment…………………………… 475
Power Brake Assembly Install…………………… 475
05D – Delco Moraine Power Brake……………………. 478
Trouble Diagnosis and Testing………………….. 478
General Description…………………………… 479
Operation……………………………………. 481
Checks and Adjustments………………………… 483
Major Repairs………………………………… 484
05E – Disc Brakes………………………………… 496
Trouble Diagnosis and Testing………………….. 496
Testing Proportioning Valve……………………. 496
General Diagnosis…………………………….. 496
General Description…………………………… 498
Operation……………………………………. 499
Combination Valve…………………………….. 500
Lining Inspection…………………………….. 501
Lining Replacement……………………………. 502
Caliper Overhaul……………………………… 506
Install Caliper………………………………. 507
Bleeding Disc Brakes………………………….. 507
Rotor Measurments…………………………….. 511
Rotor Service………………………………… 508
Specifications……………………………….. 511
06 – Engine Mechanical……………………………. 513
General Description…………………………… 519
Six Cylinder Engine…………………………… 521
V-8 Engine…………………………………… 559
06A – Engine Cooling and Lubrication……………….. 621
Trouble Diagnosis…………………………….. 622
Fan Clutch Diagnostic Procedure………………… 621
General Description…………………………… 625
Engine Lubrication System……………………… 638
Accessory Drive Installation…………………… 644
Drive Belt Chart……………………………… 645
Fan Type Useage………………………………. 651
Radiator Useage………………………………. 652
Torque Specifications…………………………. 653
Special Tools………………………………… 653
06B – Engine Fuel………………………………… 655
General Trouble Diagnosis and Testing…………… 655
Carburetor Air Cleaner and Silencer…………….. 657
Heat Control Valve……………………………. 657
Intake Systems Ram Air………………………… 658
Idle Stop Solenoid……………………………. 659
Accelerator Linkage and Adjustments…………….. 659
Hot Idle Compensator………………………….. 659
Fuel Pump……………………………………. 660
MV Monojet Carburetor…………………………. 664
WGD Carburetor……………………………….. 681
2GV Carburetor……………………………….. 690
4MV Quadrajet Carburetor………………………. 709
Carburetor Service Specifications………………. 736
06C – Engine Tune Up……………………………… 737
Spark Plug Removal……………………………. 737
Compression Test……………………………… 737
Spark Plug Clean Test and Install………………. 738
Ignition System Service and Repairs…………….. 739
Battery and Battery Cables Clean and Test……….. 740
Generator……………………………………. 740
Fan Belt Inspect and Adjust……………………. 740
Manifold Heat Valve…………………………… 740
Intake Manifold………………………………. 740
Air Cleaner Service…………………………… 741
Fuel Lines and Filter…………………………. 741
Cooling System……………………………….. 741
Lubrication System……………………………. 741
Choke Adjustment……………………………… 741
Idle Stop Solenoid……………………………. 741
Tune Up Equipment…………………………….. 741
Positive Crankcase Ventilation…………………. 742
Road Test……………………………………. 742
06D – Emission control Systems…………………….. 744
Introduction…………………………………. 744
Closed Positive Crankcase ZVentillation System…… 744
Auto-Therm Air Cleaner………………………… 746
Controlled Combustion System…………………… 748
Ignition and Curb Idle Settings………………… 753
Evaporation Control System…………………….. 754
Dwell and Ignition Timing……………………… 752
Idle Speed Chart……………………………… 753
Air Injection Reactor System…………………… 757
06E – Engine Electrical…………………………… 763
Cranking Circuit……………………………… 763
Charging Circuit……………………………… 774
Ignition Circuit……………………………… 792
Unit Distributor……………………………… 806
Ignition and Starting Switch…………………… 807
07 – Clutch Manual Transmissions…………………… 813
Trouble Diagnosis…………………………….. 813
General Description…………………………… 814
Periodic Service Recommendations……………….. 816
On Car Adjustments……………………………. 816
Major Repairs………………………………… 817
Specifications……………………………….. 821
07A – Three Speed Saginaw Transmission……………… 823
Trouble Diagnosis…………………………….. 823
General Description…………………………… 824
Periodic Service recommendations……………….. 826
On Car Adjustments……………………………. 826
Minor Repairs………………………………… 829
Major Repairs………………………………… 831
Specifications……………………………….. 838
Special Tools………………………………… 839
07B – Three Speed Muncie Transmission………………. 840
Trouble Diagnosis…………………………….. 840
General Description…………………………… 843
Periodic Service Recommendations……………….. 845
On Car Adjustments……………………………. 846
Minor Repairs………………………………… 847
Major Repairs………………………………… 849
Specifications……………………………….. 856
Special Tools………………………………… 857
07C – Four Speed Saginaw Transmission………………. 858
Trouble Diagnosis…………………………….. 858
General Description…………………………… 858
Periodic Service Recommendations……………….. 858
On Car Adjustments……………………………. 859
Minor Repairs………………………………… 860
Major Repairs………………………………… 863
Specifications……………………………….. 869
Special Tools………………………………… 869
07D – Four Speed Muncie Transmission……………….. 870
Trouble Diagnosis…………………………….. 870
General Description…………………………… 872
Periodic Service Recommendations……………….. 875
On Car Adjustments……………………………. 875
Minor Repairs………………………………… 878
Major Repairs………………………………… 880
Specifications……………………………….. 888
Special Tools………………………………… 890
07E – Turbo Hydra-matic M40 Transmission……………. 891
Trouble Diagnosis…………………………….. 892
General Description…………………………… 901
Nuetral Range Engine Idling……………………. 912
Drive Range First Gear………………………… 915
Drive Range Second Gear……………………….. 915
Drive Range Third Gear………………………… 917
Detent Downshift……………………………… 920
Part Throttle Downshift……………………….. 920
Super Range Second Gear……………………….. 922
Lo Range First Gear…………………………… 922
Reverse Range Reverse Gear…………………….. 924
Periodic Service Recommendations……………….. 926
Operations not Requiring Removal of Transmission…. 926
Removal and Disassembly of Transmission…………. 931
Overhaul of Major Units……………………….. 943
Inspection of Major Units……………………… 962
Transmission Reassembly……………………….. 969
Specifications……………………………….. 985
Special Tools………………………………… 986
07F – Two Speed Automatic M32 Transmission………….. 988
Trouble Diagnosis…………………………….. 988
General Description…………………………… 992
Hydraulic Unit Operation……………………….1003
Periodic Service Recommendations………………..1011
Operations not Requiring Removal of Transmission….1013
Removal and Disassembly of Transmission………….1018
Overhaul and Inspection………………………..1021
Transmission Reassembly………………………..1031
Specifications………………………………..1037
Special Tools…………………………………1038
07G – Turbo Hydramatic M38 Transmission……………..1039
Trouble Diagnosis……………………………..1039
General Description……………………………1048
Nuetral Engine Idling………………………….1057
Drive Range First gear…………………………1060
Drive Range Second Gear………………………..1060
Drive Range Thrid Gear…………………………1063
Lo Range First Gear……………………………1063
Super Range Second Gear………………………..1066
Drive Range Detent Downshift……………………1066
Reverse Engine Idling………………………….1068
Periodic Service Recommendations………………..1068
Operations not Requiring Removal of Transmission….1071
Removal and Disassembly of Transmission………….1077
Overhaul of Major Units………………………..1085
Transmission Reassembly………………………..1111
Specification…………………………………1118
Special Tools…………………………………1119
08 – Fuel Tank and Exhaust System…………………..1121
Fuel Gauge Checking Procedure…………………..1122
Fuel System…………………………………..1121
Exhaust System………………………………..1127
Minor and Major Service………………………..1146
General Specifications…………………………1153
Special Tools…………………………………1153
09 – Steering…………………………………….1154
Trouble Diagnosis and Testing…………………..1155
Energy Absorbing Steering Column………………..1161
Steering Gear Description………………………1164
Power Steering Pump Description…………………1169
General Information……………………………1175
Steering Column……………………………….1175
Flexible Coupling……………………………..1201
Universal Joint and Lower Steering Shaft…………1201
Steering Linkage………………………………1201
Steering Gear…………………………………1206
10 – Wheels and Tires……………………………..1238
Trouble Diagnosis and Testing…………………..1238
General Description……………………………1241
Tire Size and Load Range……………………….1241
Inflation of Tires…………………………….1241
Tire Rotation…………………………………1242
Wheel and Tire Balance…………………………1243
Minor Repairs…………………………………1244
Puncture Repair……………………………….1246
Balance Procedure……………………………..1246
11 – Cassis Sheet Metal……………………………1252
Hood…………………………………………1252
Hood Latch……………………………………1253
Hood Release………………………………….1257
Hood Hinge……………………………………1257
Front Fender………………………………….1257
Front Inner Fender…………………………….1260
Headlamp Filler Panels…………………………1261
12 – Chassis Electrical and Instruments……………..1271
Diagnosis…………………………………….1271
General Description……………………………1293
Service Procedures…………………………….1310
12-114 B Series…………………………………..1375
12-115 A Series…………………………………..1380
12-116 G Series…………………………………..1385
12-117 F Series…………………………………..1390
12-118 X Series…………………………………..1395
13 – Radiator…………………………………….1400
14 – Front and Rear Bumbers………………………..1401
General Description……………………………1401
Front Bumpers…………………………………1401
Rear Bumpers………………………………….1410
Polyurethane Bumper Repair……………………..1414
15 – Accessories………………………………….1416
Diagnosis…………………………………….1416
General Description……………………………1424
Service Procedures…………………………….1433
B Series Power Accessories Schematics……………1496
A and G Series Power Accessories Schematics………1498
F Series Power Accessories Schematics……………1500
B Series Electronic Accessories Schematics……….1501
A and G Series Electronic Accessories Schematics….1502
F Series Electronic Accessories Schematics……….1503
Index……………………………………………1504
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S.V