1977 Pontiac Service Manual – PDF DOWNLOAD
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1977 Pontiac Service Manual – PDF DOWNLOAD
Language : English
Pages : 1443
Downloadable : Yes
File Type : PDF
Size: 75.6 MB
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1977 Pontiac Service Manual – PDF DOWNLOAD
This manual applies to all 1977 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.
- All information, illustrations and specifications contained in this Manual 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. Any reference to brand names in this manual is intended merely as an example of the types of lubricants, tools, materials, etc. recommended for use in servicing the 1977 Pontiac Models. In all cases, an equivalent may be used.
TABLE OF CONTENTS:
1977 Pontiac Service Manual – PDF DOWNLOAD
1977 Pontiac Service Manual…………………………………………. 1
Table of Contents………………………………………………. 3
0A – General Information………………………………………… 4
0B – Maintenance and Lubrication…………………………………. 12
Description………………………………………………… 12
Engine Families…………………………………………….. 15
Maintenance Schedule………………………………………… 15
Maintenance Service Specifications……………………………. 19
Fluids and Lubricants……………………………………….. 20
Engine Oil and Filter……………………………………….. 20
Lift Points………………………………………………… 23
Lubrication Chart…………………………………………… 25
1A – Heating and Ventilation…………………………………….. 26
General Description…………………………………………. 27
Diagnosis………………………………………………….. 34
On-Car Service……………………………………………… 36
1B – Custom Air Conditioning…………………………………….. 52
General Description…………………………………………. 53
Diagnosis………………………………………………….. 68
On-Car Service……………………………………………… 77
Minor Repair Procedures for the A-6 Compressor…………………. 82
Minor repair Procedures for the R-4 Compressor…………………. 105
1977 C60 Tempurature Cable Adjustment…………………………. 121
Illustrated Component Service………………………………… 124
Special Tools………………………………………………. 168
1C – Automatic Temperature Control……………………………….. 169
General Description…………………………………………. 169
Diagnosis………………………………………………….. 169
On-Car Service……………………………………………… 170
2A – Frame and Body Mounts………………………………………. 175
General Description…………………………………………. 175
On-Car Service……………………………………………… 176
2B – Front and Rear Bumpers……………………………………… 184
General Description…………………………………………. 184
Bumper Energy Absorbing Units………………………………… 184
Care of Aluminum Bumpers…………………………………….. 186
Illustrated Sercive Procedures……………………………….. 186
2C – Chassis Metal, Plastics, Paint and Repair…………………….. 200
General Description…………………………………………. 200
Painting and Repairing Non-Metal Exterior Parts………………… 202
Identifying and Painting Plastic Interior Trim…………………. 204
Illustrated Service Procedures……………………………….. 206
3 – Steering, Suspension, Wheels and Tires………………………… 230
General Diagnosis…………………………………………… 230
Linkage Diagnosis…………………………………………… 232
Manual Steering Gear Diagnosis……………………………….. 232
Power Steering Pump Diagnosis………………………………… 232
Steering Column Diagnosis……………………………………. 234
Lock System Diagnosis……………………………………….. 234
Signal Switch Diagnosis……………………………………… 235
Ignition Switch Diagnosis……………………………………. 236
Key Buzzer Diagnosis………………………………………… 236
Dimmer Switch Diagnosis……………………………………… 238
Power Steering Leak Diagnosis………………………………… 238
Power Steering System Test Procedure………………………….. 239
Wheel Bearing Diagnosis……………………………………… 242
Shock Absorber Diagnosis…………………………………….. 239
Tire Diagnosis……………………………………………… 241
Wear Diagnosis……………………………………………… 241
Radial Tire Waddle………………………………………….. 241
Radial Tire Lead Diagnosis…………………………………… 244
3A – Front End Alignment………………………………………… 251
General Description…………………………………………. 251
Maintenance and Adjustments………………………………….. 251
Trim Heights……………………………………………….. 260
Specifications……………………………………………… 262
3B1 – Steering Linkage………………………………………….. 263
Description and Operation……………………………………. 263
Suspension and Steering Linkage Check…………………………. 263
Tie Rods…………………………………………………… 263
Intermediate Rod……………………………………………. 265
Tie Rod Adjuster Tube……………………………………….. 267
Idler Arm………………………………………………….. 267
Shock Absorber (Intermediate Rod)…………………………….. 268
Pitman Arm…………………………………………………. 268
Torque Specifications……………………………………….. 269
3B2 – Manual Steering Gear………………………………………. 270
General Description…………………………………………. 270
Service Procedures………………………………………….. 270
Specifications……………………………………………… 276
3B3 – Power Steering Gear and Pump……………………………….. 277
General Description…………………………………………. 277
Service Procedures………………………………………….. 279
Specifications……………………………………………… 315
3B4 – Steering Wheels and Columns………………………………… 317
General Description…………………………………………. 317
Service Procedures………………………………………….. 319
Torque Specifications……………………………………….. 370
3C – Front Suspension…………………………………………… 371
General Description…………………………………………. 371
Maintenance and Adjustments………………………………….. 373
Service Procedures………………………………………….. 373
Except H Series…………………………………………….. 373
Specifications……………………………………………… 391
3D – Rear Suspension……………………………………………. 392
General Description…………………………………………. 392
Rear Suspension Service Operations……………………………. 394
3E – Wheels and Tires…………………………………………… 426
General Description…………………………………………. 426
Maintenance and Minor Adjustments…………………………….. 427
Service Procedures………………………………………….. 428
Specifications……………………………………………… 433
4A – Propeller Shaft……………………………………………. 434
General Description…………………………………………. 434
Diagnosis………………………………………………….. 435
Maintenance and Adjustments………………………………….. 437
Unit Repair………………………………………………… 442
Specifications……………………………………………… 446
Special Tools………………………………………………. 446
4B – Differential………………………………………………. 447
General Description…………………………………………. 447
Diagnosis………………………………………………….. 450
On-Car Service……………………………………………… 454
Unit Repair………………………………………………… 455
Specifications……………………………………………… 467
Special Tools………………………………………………. 470
5 – Brakes…………………………………………………….. 471
General Description…………………………………………. 471
Diagnosis………………………………………………….. 472
On-Car Service……………………………………………… 477
Master Cylinder…………………………………………….. 489
Disc Brakes………………………………………………… 492
Drum Brakes………………………………………………… 508
Unit Repair………………………………………………… 511
Specifications……………………………………………… 530
6 – Engine…………………………………………………….. 531
Engine Identification……………………………………….. 531
Engine Performance Diagnosis…………………………………. 532
6A – Engine Mechanical………………………………………….. 546
General Information…………………………………………. 546
Mechanical Diagnosis………………………………………… 547
6A1 – 2.2 Litre Engine………………………………………….. 550
General Description…………………………………………. 550
Engine Lubrication………………………………………….. 552
On-Car Service……………………………………………… 553
Engine Front Cover………………………………………….. 553
Accessory Drive Pulley………………………………………. 553
Timing Belt and Water Pump…………………………………… 554
Checking Timing Belt Tension…………………………………. 554
Camshaft Timing Sprocket…………………………………….. 554
Timing Belt Cover Upper……………………………………… 555
Timing Belt Lower…………………………………………… 555
Crankshaft Timing Sprocket…………………………………… 556
Oil Pump Seal………………………………………………. 556
Oil Pan and Baffle………………………………………….. 556
Oil Pump Screen and Pick-up Tube……………………………… 557
Oil Seal…………………………………………………… 557
Oil Pump…………………………………………………… 558
Camshaft Cover……………………………………………… 560
Camshaft…………………………………………………… 560
Valve Stem Oil Seal and/or Valve Spring……………………….. 562
Intake Manifold…………………………………………….. 564
Exhaust Manifold……………………………………………. 564
Cylinder Head Assembly………………………………………. 565
Flywheel…………………………………………………… 568
Engine Mounts………………………………………………. 568
Cylinder Block……………………………………………… 576
Oil Filter Bypass Valve……………………………………… 576
Connecting Rod and Piston Assemblies………………………….. 569
Connecting Rod Bearings……………………………………… 573
Main Bearings………………………………………………. 574
Crankshaft…………………………………………………. 575
6A2 – 2.5 Litre Engine………………………………………….. 581
General Description…………………………………………. 581
On-Car Service……………………………………………… 586
6A3 – 3.8 Litre Engine………………………………………….. 607
Engine Construction…………………………………………. 607
Lubrication System………………………………………….. 608
Removal and Installation of Engine Mounts……………………… 609
Removal and Installation of Intake Manifold or Gasket…………… 610
Removal and Installation of Exhaust Manifold…………………… 610
Removal and Installation of Cylinder Head……………………… 611
Reconditioning of Valves and Guides…………………………… 612
Removal and Installation of Timing Chain Cover…………………. 613
Front Crankshaft Oil Seal Replacement…………………………. 614
Removal and Installation of Timing Chain and Sprocket…………… 614
Camshaft Bearing Removal and Install………………………….. 615
Removal and Installation of Oil Pan…………………………… 616
Removal and Inspection of Oil Pump Pipe and Screen Assembly……… 616
Testing Oil Pressure………………………………………… 617
Removal, Inspection and Installation of Oil Pump Cover and Gears…. 617
Connecting Rod Bearing………………………………………. 618
Crankshaft Bearings and Seals………………………………… 620
Installation of Rear Bearing Oil Seals………………………… 621
Pistons, Rings and Connecting Rods……………………………. 623
Reboring Cylinder and Fitting New Pistons……………………… 624
Removal and Installation of Engine……………………………. 628
Removal and Installation of Transmission Flywheel………………. 628
Automatic Transmission Flywheel Balance……………………….. 629
Harmonic Balancer…………………………………………… 629
Bolt Torque Specifications…………………………………… 630
General Specifications………………………………………. 630
6A4 – 5.7 Litre and 6.6 Litre Engine……………………………… 633
Description………………………………………………… 633
Engine Lubrication System……………………………………. 634
Engine Mountings……………………………………………. 636
Intake Manifolds……………………………………………. 636
Exhaust Manifolds…………………………………………… 638
Valve Cover………………………………………………… 638
Rocker Arm Assemblies……………………………………….. 638
Valve Lifters………………………………………………. 640
Cylinder Head and Gasket…………………………………….. 643
Valves and Spring with Head Removed…………………………… 643
Crankshaft Pulley…………………………………………… 646
Harmonic Balancer…………………………………………… 646
Front Cover………………………………………………… 647
Oil Seal…………………………………………………… 648
Timing Chain and Gears………………………………………. 648
Check Valve Timing………………………………………….. 649
Camshaft…………………………………………………… 650
Camshaft Bearings…………………………………………… 651
Camshaft and Oil Galley Plugs………………………………… 652
Oil Pan……………………………………………………. 652
Oil Pump…………………………………………………… 653
Connecting Rod and Piston Assembly……………………………. 654
Rod Bearings……………………………………………….. 654
Main Bearings………………………………………………. 655
Rear Main Bearing Upper Oil Seal……………………………… 656
Rod Assembly……………………………………………….. 657
Checking Cylinder Bore………………………………………. 658
Piston Rings……………………………………………….. 658
Piston Pins………………………………………………… 660
Engine Assembly…………………………………………….. 661
Crankshaft…………………………………………………. 662
Flywheel…………………………………………………… 663
Torque Specifications……………………………………….. 664
Engine Specifications……………………………………….. 665
Special Tools………………………………………………. 669
6A5 – 5.0 Litre and 6.6 Litre Engines…………………………….. 670
General Description…………………………………………. 670
Engine Mountings……………………………………………. 673
Exhaust Manifolds…………………………………………… 674
Intake Manifold…………………………………………….. 675
Pushrod Cover………………………………………………. 676
Rocker Arm Cover……………………………………………. 676
Valve Springs, Shield or Seal………………………………… 676
Rocker Arm Studs……………………………………………. 676
Valve Lifter Remove…………………………………………. 677
Hydraulic Valve Lifters Recondition…………………………… 677
Cylinder Head or Gasket……………………………………… 678
Cylinder Heads and Valve Recondition………………………….. 679
Harmonic Balncer……………………………………………. 681
Timing Chain Cover Seal……………………………………… 681
Timing Chain Cover………………………………………….. 681
Timing Chain and Sprockets…………………………………… 682
Camshaft and Bearings……………………………………….. 682
Oil Pan and/or Gasket……………………………………….. 684
Oil Pump…………………………………………………… 685
Connecting Rod Bearings……………………………………… 686
Main Bearings………………………………………………. 686
Main Bearing Rear Oil Seal…………………………………… 687
Connecting Rod and Piston……………………………………. 688
Piston Pin…………………………………………………. 690
Cylinder Bores……………………………………………… 690
Piston Fit and Replace………………………………………. 691
Piston Rings……………………………………………….. 691
Engine Assembly Remove………………………………………. 692
Crankshaft Replace………………………………………….. 692
Torque Specifications……………………………………….. 693
Engine Specifications……………………………………….. 693
Special Tools………………………………………………. 696
6A6 – 5.0 Litre and 5.7 Litre Engine……………………………… 697
General Description…………………………………………. 698
Service Procedures………………………………………….. 699
Engine Torques……………………………………………… 724
Engine Specifications……………………………………….. 725
Special Tools………………………………………………. 726
6B – Engine Cooling…………………………………………….. 727
General Description…………………………………………. 727
Diagnosis………………………………………………….. 732
Service Operations………………………………………….. 736
Thermostat Remove and Replace………………………………… 738
Water Pump Remove and Replace………………………………… 738
Water Pump Overhaul…………………………………………. 739
Radiator Remove and Replace………………………………….. 739
Coolant Reservoir Remove and Replace………………………….. 739
Illustrations of Radiator……………………………………. 740
Belt Diagrams and Specifications……………………………… 744
Radiator Useage Chart……………………………………….. 748
Capacities and Specifications………………………………… 749
6C – Fuel System……………………………………………….. 751
General Description…………………………………………. 751
Diagnosis………………………………………………….. 752
Carburetion………………………………………………… 758
Model 5210……………………………………………… 758
Model M2Mc 200………………………………………….. 787
Model 2GC/2GE…………………………………………… 771
Model M4MC……………………………………………… 800
Fuel Supply………………………………………………… 816
Accelerator Controls………………………………………… 819
Specifications……………………………………………… 823
6D – Engine Electrical………………………………………….. 825
Diagnostic Connector………………………………………… 825
General Electrical System Diagnosis…………………………… 829
Battery……………………………………………………. 831
Charging System…………………………………………….. 837
Ignition System…………………………………………….. 849
Cranking System…………………………………………….. 864
Specifications……………………………………………… 871
6E – Emission Control Systems……………………………………. 873
General Description…………………………………………. 873
Vacuum Hose Schematics………………………………………. 876
Early Fuel Evaporation Systems……………………………….. 886
Exhaust Gas Recirculation Systems…………………………….. 886
Positive Crankcase Ventilation System…………………………. 888
Thermostatic Air Cleaner…………………………………….. 888
Air Injection Reaction Systems……………………………….. 890
Engine Performance Specifications…………………………….. 894
6F – Exhaust System…………………………………………….. 896
General Description…………………………………………. 896
On-Car Service……………………………………………… 897
7A1 – Turbo Hydra-Matic 200……………………………………… 901
General Description…………………………………………. 901
Diagnosis………………………………………………….. 904
On-Car Service……………………………………………… 923
Governor…………………………………………………… 923
Intermediate Servo………………………………………….. 923
Pressure Regulator………………………………………….. 923
Control Valve Assembly………………………………………. 924
Oil Cooler Pipes……………………………………………. 924
T.V. Cable…………………………………………………. 924
Column Shift Controls……………………………………….. 925
Console Shift Controls………………………………………. 925
Specifications……………………………………………… 981
Special Tools………………………………………………. 982
7A2 – Turbo Hydra-Matic 250……………………………………… 984
General Description…………………………………………. 984
Diagnosis………………………………………………….. 985
Maintenance and Adjustments………………………………….. 994
On-Car Service……………………………………………… 996
Unit Repair………………………………………………… 999
Specifications………………………………………………1032
Special Tools……………………………………………….1033
7A3 – Turbo Hydra-Matic 350………………………………………1034
General Description………………………………………….1034
Diagnosis…………………………………………………..1035
Maintenance and Adjustments…………………………………..1047
On-Car Service………………………………………………1051
Unit Repair…………………………………………………1054
Specifications………………………………………………1091
7A4 – Turbo Hydra-Matic 400………………………………………1093
General Description………………………………………….1094
Preliminary Checking Procedures……………………………….1095
Specific Transmission Malfunctions…………………………….1099
Causes of Transmission Malfunctions……………………………1099
Periodic Service Recommendations………………………………1112
On-Car Service………………………………………………1112
Unit Repair…………………………………………………1116
Overhaul of Major Units………………………………………1129
Inspection of Major Units…………………………………….1147
Reassembly and Installation of Transmission…………………….1153
Specifications………………………………………………1167
Special Tools……………………………………………….1168
7B – Manual Transmissions………………………………………..1170
General Description………………………………………….1170
Diagnosis…………………………………………………..1180
Maintenance and Adjustments…………………………………..1185
On-Car Service………………………………………………1191
Unit Repair…………………………………………………1196
Specifications………………………………………………1229
Special Tools……………………………………………….1230
7C – Clutch…………………………………………………….1232
General Description………………………………………….1232
Diagnosis…………………………………………………..1234
Maintenance and Adjustments…………………………………..1234
On-Car Service………………………………………………1237
Unit Repair…………………………………………………1239
Special Tools……………………………………………….1242
8 – Chassis Electrical…………………………………………..1243
Wiring Harness………………………………………………1243
Instrument Panel…………………………………………….1266
Horn……………………………………………………….1299
Lamps………………………………………………………1303
Seat Belt Warning System……………………………………..1312
Windshield Washer and Wiper System…………………………….1314
Electrical Wire Codes by Catagory……………………………..1315
Electricall Wire Code by Circuit Number………………………..1317
Figure 8-1 B Series……………………………………………..1319
Figure 8-2 A Series……………………………………………..1324
Figure 8-3 A and AG Series……………………………………….1329
Figure 8-4 F Series……………………………………………..1334
Figure 8-5 X Series……………………………………………..1339
Figure 8-6 H Series……………………………………………..1344
Figure 8-7 HM Series…………………………………………….1349
9 – Accessories…………………………………………………1354
Cruise Control Systems……………………………………….1355
Radio………………………………………………………1377
Power Antenna……………………………………………….1399
Rally Gauge, Tachometer and Clock……………………………..1405
Miscellaneous Accessories…………………………………….1414
Accessory Wiring Diagrams…………………………………….1433
Index………………………………………………………….1438
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