Pontiac tempest 1968 User manual

1968PONTIAC
GENERAL
This manualappliesto1968Pontiac,
Tempestand Firebird models andcontains
informationonall components ofthecar
withtheexceptionofthebodywhichis
coveredina separatemanual.TheNew
Vehicle Warrantyandotherinformation
pertainingtoPontiac models iscontained
in theOwner'sManualwhichaccompanies
eachvehicleandtheOwnerProtection
Plan bookletwhichisissueddirectlyto
theOwnershortlyaftertakingdeliveryof
hiscar.
CONTENTS
The arrangementofmaterialinthemanual
isshownbythetableof contents onthe
rightsideofthis page. Black tabsonthe
first page ofeachsectionregisterwith
thistabletoassistinreadilylocatingin-
formationdesired.A detailedtableof
contents appearsatthebeginningofeach
sectionandanalphabeticalindexisin-
cludedinthebackofthemanual.
PONTIACMOTOR DIVISION
GENERAL MOTORSCORPORATION
PONTIAC, MICHIGAN48053
S-6804September 1967 Litho in U.S.A.
©General Motors Corporation 1 967
TABLE OF CONTENTS
TITLE SECTION
GENERAL INFORMATION
0
HEATING AND VENTILATION SERVICE
I
CUSTOM AIR CONDITIONER 1A
AUTOMATIC TEMPERATURE CONTROL IB
FRAME AND BODY MOUNTINGS 2
FRONT SUSPENSION 3
REAR SUSPENSION 4
STANDARD DIFFERENTIAL
4A
SAFE-T-TRACK DIFFERENTIAL 4B
PROPELLER SHAFT 4C
STANDARD BRAKES
5
DELCO MORAINE POWER BRAKE
5A
BENDIX POWER BRAKE
SB
HEAVY DUTY POWER BRAKE 5C
DISC BRAKES
SD
ENGINE MECHANICAL
6
ENGINE COOLING AND LUBRICATION 6A
ENGINE FUEL
6B
ENGINE TUNE-UP 6C
EMISSION CONTROL SYSTEMS
60
ENGINE ELECTRICAL
6E
CLUTCH, MANUAL TRANS.
7
THREE SPEED DEARBORN MANUAL TRANS.
7A
THREE SPEED SAGINAW MANUAL TRANS.
7B
FOUR SPEED SAGINAW MANUAL TRANS.
7C
FOUR SPEED MUNCIE MANUAL TRANS.
70
TURBO HYDRA-MATIC TRANS.
7E
TWO SPEED AUTOMATIC TRANS. 7F
FUEL TANK AND EXHAUST SYSTEM
8
STEERING
9
WHEELS AND TIRES
10
CHASSIS SHEET METAL 11
CHASSIS ELECTRICAL SERVICE
12
RADIATOR SUPPORT AND MOUNTING PARTS 13
FRONT AND REAR BUMPERS 14
ACCESSORIES
15
ALPHABETICAL INDEX

0-1
GENERAL INFORMATION
CONTENTS OF THIS SECTION
SUBJECT PAGE
Identification. 0 0-1
Vehicle 0-1
Body0-1
Engine 0-1
Transmission „ 0-2
SUBJECT PAGE
Lifting andTowing0-3
Lock Coding.. 0-4
Basic Dimensions.0-5
Rocker PanelHeights0-6
Lubrication . . 0-8
GENERAL INFORMATION
Only generalinformationandspecificationsappear
in thissection.Detailedspecificationsonmajor
unitsaregivenattheendofeachrespectivesection
ofthismanual.
CAR MODEL IDENTIFICATION
Certain publications carry "series"numbersto
identify models andothers carry salesdepart-
mentnames.Figure0-4 shows both methods of
identification.
VEHICLE IDENTIFICATION PLATE
Serial number,assemblyplant code andmodel
year identificationcanbedeterminedfromtheManu-
facturer's MotorVehicleIdentificationNumberPlate.
This plateisfastenedtotheupper left instrument
panelarea,visiblethroughthewindshield.The
platehas embossed numeralsasshowninFig. 0-1.
BODY IDENTIFICATION PLATE
Informationasto body style,trimnumber, body
numberandpaint code maybefoundstampedonthe
BodyIdentificationPlate(Fig. 0-2). This plateis
attachedtothe left sideofthecowlassemblyjust
below the rear edge ofthehood.
U\J2\69 \SW\ IQOOQf
DIVISION
SERIES""
PLANT
YEAR
BODY STYLE CODE NO.
EXAMPLE OF PLATE SHOWS THE FIRST 1968
CATALINA (52) SERIES 4-DOOR SEDAN (69)
STYLE BUILT AT PONTIAC PLANT (P).
TIMEBUILT
CODE"
MODEL-
YEAR
DIVISION SERIES
-BODY Vi PE
OOP I
468-000&0
OOOA
BODY BY FISHER
ASSEMBLY PLANT
r-UNIT NUMBER
TRIM
NUMBER
SEAT TYPEJ
APL 123456 BODY
AA PAINT
MOTORSCORPORATION CERTIFIE
THATTHIS VEHICLE CONFORMS "0
(FECFML MOTOR VEHICLE SAFETY STANDARDS!
LICABLE AT TIMEOFMANUFACTURE ) >
TO THE
LOWER BODY COLOR
UPPER BODY COLOR,
OR FOLDINGTOP
OR ROOF COVER
ML 1
Fig. 0-2 BodyIdentificationPlate
Plant
Code
Pontiac Tempest
F
Pontiac (P)
X X
Arlington
(R)
X
Baltimore
(B)
X
Fremont
(Z) X
Kansas City, Ks.
(X) X
Kansas City, Mo.
(K)
X
Linden
(E)
X
Southgate
(C)
X
Lordstown
(U)
X
Framingham
(G)
X
Fig. 0-3 AssemblyPlants
ENGINE IDENTIFICATION
8-CYL.
Fig. 0-1 VehicleIdentificationPlate The8-cyl.
engine code islocatedbeneaththepro-
duction engine numberona machinedpadontheright

0-2
1968 PONTIAC SERVICE MANUAL
Series Model StyleNumber
Catalina
4-DoorSedan 25269
25200
HardtopCoupe
25287
4-DoorHardtop 25239
Convertible 25267
2 - SeatStationWagon
25235
3-SeatStationWagon 25245
Executive
HardtopCoupe
25687
25600 4-DoorSedan 25669
4-DoorHardtop
25639
2-SeatStation Wagon 25635
3-SeatStationWagon
25645
Bonneville HardtopCoupe
26287
4-DoorHardtop 26239
Convertible
26267
Station Wagon
26245
Grand Prix
HardtopCoupe 26657
26600
Tempest SportsCoupe 23327
23300
4-DoorSedan 23369
TempestCustom SportsCoupe
23527
23500 HardtopCoupe 23537
4-DoorHardtop 23539
4-DoorSedan 23569
Convertible
23567
Station Wagon
23535
LeMans
SportsCoupe
23527
23700 HardtopCoupe 23537
4-DoorSedan 23739
Convertible
23767
Tempest Safari 2-SeatStationWagon
23935
23935
G.T.O. HardtopCoupe
24237
24200
Convertible 24267
Firebird
Coupe
22337
Convertible
22367
Fig. 0-4Car Model Identification
hand bankofthe engine block(Fig.0-5)andshouldbe
usedwheneverreferringtoa specific enginee Fora
complete listingofthevarious codes and engine
options refertosection6 ofthismanual.SeeSec.
6fortheV.I.numberderivative,whichidentifies
the engine withthecar.
6-CYL.
The 6 cylinder engine code isstampedonthe cyl-
inderheadtoblockcontactsurfacebehindoilfiller
pipe(Fig.0-6).SeeSec.6 forthe V.I. number
derivative,whichidentifiesthe engine withthecar.
TRANSMISSION SERIAL NUMBER
TURBOHYDRA-MATIC
The Turbo Hydra-Matic transmissionidentifica-
tionplateislocatedontherightsideofthetrans-
missioncase(Fig.0-7).The serial number begins
withtheletterP meaningPontiac,followedbythe
letter code A,B,C,G,J,Q,T orX designating
engine usage. Thenumerical code 68,followingthe
two-letter codes representsthemodelyear.For
moredetailsandlocationofV.I.numberderivative
seesection7Eofthismanual.

GENERAL INFORMATION
0-3
PRODUCTION
ENGINE NUMBER
ENGINE
CODE
TRANSMISSION
IDENTIFICATION
PLATE
Fig. 0-5 8-Cylinder Engine Serial Number Location
Fig. 0-7 Turbo Hydra-Matic Serial Number Location
TEMPEST AUTOMATIC
The transmissionidentificationnumberlocatedon
thelowerservocover (Fig„ 0-8),rightsideofthe
transmission, containsmodelandassemblydate
code. Formore complete informationandlocation
of V.I. numberderivativeseesection7F.
LIFTING AND TOWING
Pontiac, Tempestand Firebird maybeliftedonthe
frame rails asshowninSec.2.Theycanalsobe
liftedatfrontcrossmemberorateitherfrontor
rear lowercontrol arms. Whenliftingonlowercon-
trol arms, avoidcontactinglowershockabsorber
brackets.
Under nocircumstancesshouldliftadaptersbe
usedonthebumpers,propellershaft,transmission,
rear axleor engine.
£•••
The propellershaftandexhaustsystemarelower
than theside rails. Lift adaptersmustprovide
adequateclearanceheightfor these parts.
TOWING PRECAUTIONS
Always placea rubbermatorothersuitablema-
terial between thebumperandthetowchainsor
cables.Forfrontendlifting,placechainsorcables
around the ends oftheframeside rails atbothsides.
All models canbe towed withoutdisconnectingthe
propellershaft except incaseswherethetransmis-
sionorpropellershafthaspossibly been subjectto
failure ordamage.Insuchcases,thepropellershaft
mustbedisconnectedfromthedifferentialandwired
to tail pipeorcarmustbe towed with rear wheelsoff
theground.Ifthepropellershaftisdisconnectedand
the"\J" jointbearingretainingstrapisbroken,
wrap tapearoundthebearingcapstopreventloss.
When towingwiththe rear wheelsofftheground,the
steeringwheelmustbecenteredandheldinposition
bya steeringwheelholdingclamporbytyingitto
^^^^^^^^^^^
I PRODUCTION
MODEL j DAY BUILT
YEAR
Fig. 0-6 6-Cylinder Engine Serial Number Location Fig. 0-8 Tempest Automatic Transmission Serial Number

0-4
1968 PONTIAC SERVICE MANUAL
the window division channel. Tire togroundclear-
ance shouldnotexceed6 inches while towing thecar
and speeds shouldnotexceed35mphfor distances
upto50miles.
CAUTION; Power steering-equipped cars should
be towed with caution, since there is no power
assist with the engine off.
CODING SIDE BAR LOCK
All 1968Pontiacs,TempestsandFirebirds will
havenewtype lock cylindersandkeys(Fig.0-9).
Two separate keysareused;type"Cn(hexagonal)
for ignition switch,doorlocksandtailgateandtype
"D" (round)forthetrunkandglovecompartment.
Thekeys will notbeinterchangeable with each other
or with those used prior to1968 because ofnew
keyway designandanincreasednumberof biting
depths.
stampedonitsside.Beforethe lock cylindermay
becoded,thecorrectcodemustbedetermined.If
thenumberedblankinthekeyheadhasnotbeen
removed,determinethecodebyconsultingthe lock
manufacturer'scodebook.Shouldtheblankbemiss-
ing, proceedas follows;
1. Place thekeyonthesilhouetteinFig.0-10,
aligning thekey with theoutlineasaccuratelyas
possible.
2.Startingatthe base ofthekeyblade,determine
thelowest level visibleinpositionNo.1.
3. Determinethelowestvisible level forthere-
maining five positions.As each tumbler level is
determined, write thatnumberintheblank space
abovethepositionnumbers.
After thekeycodehasbeendetermined,thecor-
recttumblersshouldbeinstalledas follows:
Locks areavailable without tumblers,springsor
retainers.Uncodedsidebarlocksmaybecodedto
matchthekeysusedonthecarbyorderingtheabove
partsseparately.Fivetypesoftumblersareusedto
composethevariouscombinationsand each iscoded
according toa number,one(1)through five (5),
1.Beginning with slotnexttoheadofcylinder
(numberoneposition) install tumblersinslotsin
sequence determined from keycode.
2.Insertspringin each roundcavityof each
tumbler lock betweenslots.
NOTE: Do not pull springs apart; unscrew them.
C KEY
FOR IGNITIONAND DOOR
LOCKS, USE CODE SERIES 0N00
TO 9N99AND0P00TO 9P99.
D KEY
FOR REAR COMPARTMENT
AND GLOVE COMPARTMENT
LOCKS, USE CODE SERIES 0R00
TO 9R99 AND0T00TO 9T99.
3. Install springretaineroversprings with ends
insertedinslots,and hold inplace.
4.Checkbyinsertingcutkey.Sidebar will drop
in placewhenkeyisinsertedifcorrecttumblers
havebeeninstalled.
5.Stakespringretainerinplaceusingsmall
punchand light hammer.
POSITION
123456
LEVEL
23 4 5
Fig.0-9KeyBlanks Fig.0-10Key
Coding Diagram

GENERAL INFORMATION
0-5
PONTIAC
SERIES
K
E
Y
252 256 262 266
STYLE
K
E
Y
35
39
45 67
69 87
35 39
45
69 87 39
45 67
87 57
OVER-ALL LENGTH A
218.4 215.6 218.4 215.6 215.6 215.6 218.4
222.6
218.6
222.6 222.6 222.6
218.4
222.6 222.6
215.6
WIDTH
B 79.4
HEIGHT (Unloaded)
C
55.3 55.3 55.3 55.3 55.3 55.3 55.3 55.3 55.3 55.3 55.3 54.3 54.3 54.3 54.3 53.9
WHEELBASE D 121 121 121 121 121 121 121 124 121 124 124 124 121 124 124 121
TREADFRONT E
63
TREADREAR
F
64
OVERHANGFRONT G 38.6 38.5
OVERHANGREAR
H 59.2 56.4 59.2 56.4 56.4 56.4 60.5 60.5 59.2 60.5 60.5 60.5 59.2 60.5 60.5 56.4
TEMPEST
SERIES
K
E
Y
233 235 237 239 242
STYLE
K
E
Y
27 69 27 37
35
39 67 69 27 37 39 67
35
37
67
OVER-ALL LENGTH A 206.6 206.6 206.6 206.6
203.4
206.6 206.6 206.6 206.6 206.6 206.6 206.6
203.4
206.6 206.6
WIDTH
B
74.4
HEIGHT (Unloaded) C
54.41 54.4 54.4 54.41 54.4 54.4 54.4 54.4 54.9 54.9 54.9 54.9 55.4 54.2 54.2
WHEELBASE
D 115
TREADFRONT
E
58
TREADREAR
F
59
OVERHANGFRONT G
35.8
OVERHANGREAR H 55.7 55.7 55.7 55.7 52.6 55.7 55.7 55.7 55.7 55.7 55.7 55.7 52.6 55.7 55.7
Fig. 0-11 Basic Dimensions
ROCKER PANEL
HEIGHT
SECTION A-A
37.QQ-25.80
FOR121W.B.
"28.70 FOR124W.B.
-ROCKER PANEL HEIGHT
CURB ROCKER
PANEL HEIGHT
^(NOMINAL)
MODEL
FRONT
REAR
9.30 9.00 521
1, 5269,5239,5267 & 5287
5639,5669,5687,6239,6267,6287EXC. H.D. SPRINGS
9.13 8.70 6657
9.80 9.80 5235,5245,5635,5645,6245
9.80 9.80
ALL H.D. SPRINGS
FOR REFERENCE ONLY-CURB LOADCONDITION.
(FULL FUEL TANK, SPECIFIED TIRE PRESSURE, STD. EQUIP. SPRINGS)
Fig. 0-12 RockerPanelHeights—Pontiac

0-6 1968PONTIAC
SERVICE MANUAL
ROCKERPANEL
HEIGHT
32.00—
.ROCKER PANEL HEIGHT
.23.00L.W.B.
19.00S.W.B.
TO GROUND
SECTION A - A
CURB ROCKER
PANEL HEIGHT
^(NOMINAL) MODEL
FRONT
REAR
MODEL
9.50 9.00 3327,3527,3727,3537,3737,3567,3767,
3539,3739,4237,4267EXC.H.D. SPRINGS
9.60 9.20 3369,3569
10.25 10.00 3535,3935INC.H.D.
SPRINGS
10.50 10.50
ALL H.D. SPRINGS EXC.3535& 3935
TANK,SPECIFIED TIRE PRESSURE.)
Fig. 0-13RockerPanelHeights—Tempest
CURB ROCKER
PANELHEIGHT
(NOMINAL)
MODELS
FRONT
REAR
MODELS
8.40 8.10
ALL
SECTIONA - A
CURB ROCKER
PANEL.HEIGHT
FOR REFERENCE ONLY- CURBLOAD CONDITION
FULL FUEL TANK. SPECIFIEDTIRE PRESSURE.
STANDARDEQUIPMENTSPRINGS-
TO GROUND
Fig. 0-14RockerPanelHeights—Firebird

GENERAL INFORMATION
0-7
DRILL SIZES
Letter
Sizes
Drill
Wire
Drill Wire
Drill
Wire
Drill
Letter
Sizes
Diameter Gage Diameter Gage Diameter Gage Diameter
Letter
Sizes
Inches
Sizes
Inches Sizes Inches Sizes Inches
Z
0.413 1
0.2280
28 0.1405 55
0.0520
Y
0.404
2 0.2210
29 0.1360
56 0.0465
X
0.397
3
0.2130
30 0.1285 57
0.0430
w
0.386
4
0.2090
31 0.1200
58
0.0420
V
0.377
5
0.2055 32
0.1160
59 0.0410
U
0.368
6
0.2040
33
0.1130
60 0.0400
T
0.358
7
0.2010
34
0.1110
61
0.0390
S
0.348
8 0.1990
35 0.1100
62 0.0380
R
0.339
9 0.1960
36 0.1065 63
0.0370
Q
0.332
10 0.1935 37
0.1040
64
0.0360
P
0.323
11
0.1910
38 0.1015 65
0.0350
o 0.316 12
0.1890
39 0.0995 66
0.0330
N
0.302 13 0.1850
40
0.0980
67 0.0320
M
0.295
14
0.1820
41
0.0960
68
0.0310
L
0.290
15
0.1800
42 0.0935 69
0.0292
K
0.281 16
0.1770
43
0.0890
70
0.0280
J
0.277 17
0.1730
44
0.0860
71
0.0260
I
0.272
18 0.1695 45
0.0820
72 0.0250
H
0.266
19 0.1660
46 0.0810
73 0.0240
G
0.261 20
0.1610
47 0.0785 74 0.0225
F
0.257 21
0.1590
48 0.0760
75 0.0210
E
0.250
22 0.1570
49 0.0730
76 0.0200
D
0.246
23
0.1540
50
0.0700
77 0.0180
C
0.242
24
0.1520
51 0.0670
78
0.0160
B
0.238
25 0.1495 52 0.0635 79 0.0145
A
0.234
26
27
0.1470
0.1440
53
54 0.0595
0.0550
80 0.0135
DECIMAL EQUIVALENTS
1/64. . . .015625 17/64. .
. . .265625 33/64. . .
. .515625 49/64. . . .765625
1/32. . . .03125 9/32. .
. . .28125 17/32. . .
. .53125 25/32. . .
. .78125
3/64. . . .046875 19/64. .
. . .296875 35/64. . .
. .546875 51/64. . . .796875
1/16. . . .0625 5/16. .
. . .3125 9/16. . .
. .5625 13/16. . . .8125
5/64. . .
. .078125 21/64. .
. . .328125 37/64. . . .578125 53/64. . . .828125
3/32. . . .09375 11/32. .
. . .34375 19/32. . . .59375 27/32. . .
. .84375
7/64. . .
. .109375 23/64. .
. . .359375 39/64. . . .609375 55/64. . . .859375
1/8...
. .125 3/8. .
. . .375 5/8... Q625 7/8. . .
. .875
9/64. . . .140625 25/64. .
. . .390625 41/64. . .
. .640625 57/64. . . .890625
5/32. . . .15625 13/32. .
. . .40625 21/32. . . .65625 29/32. . . .90625
11/64, . . .171875 27/64. .
. . .421875 43/64. . . .671875 59/64. . . .921875
3/16. . .
. .1875 7/16. .
. . .4375 11/16. . . .6875 15/16. . .
. .9375
13/64. . . .203125 29/64. .
. . .453125 45/64. . .
. .703125 61/64. . . .953125
7/32. . .
. .21875 15/32. .
. . .46875 23/32. . . .71875 31/32. . . .96875
15/64. . . .234375 31/64. .
. . .484375 47/64. . . .734375 63/64. . . .984375
1/4...
. .25 1/2. .
. . .5 3/4...
. .75 1. . . . 1.