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.

0-8 1968
PONTIAC SERVICE MANUAL
WEIGHTS AND MEASURES
LINEAR MEASURE
1/12 foot (ft.)1 inch(in.)
12inches. 1 foot
3 feet 1 yard (1yd.)
AREAMEASURE
1/144square foot (sq.ft.).1 squareinch(sq.in.)
144squareinches ........ 1 square foot
9square feet 1 square yard (sq.yd.)
LIQUIDMEASURE
1/16pint(pt.)1 ounce(oz.)
1pint16 ounces
2pints. ........ 1 quart(qt.)32 ounces
4quarts1 gallon(gal.)
31-1/2 gallons1 barrel (bbl.)
DRYMEASURE
1/2quart(qt.)1 pint(pt.)
2pints1 quart(qt.)
8quarts1 peck(pk.)
4pecks1 bushel(bu.)
105quarts1 barrel
CUBICMEASURE
1,728cubicinches1 cubic foot
27cubic feet ........... 1 cubic yard
COMMON WEIGHT
16 ounces 1 pound
100pounds1 hundredweight(cwt.)
2000 pounds1 ton
COMMON U.S.A. EQUIVALENTS
LENGTH
1inch 25.4001 millimeters
1millimeter 0.03937 inches
1 foot . 0.304801 meters
1meter 3.28083 feet
1 yard 0.914402 meters
1meter 1.093611 yards
1mile 1.609347 kilometers
1kilometer 0.621370 miles
LIQUIDCAPACITY
1quart 0.94633 liters
1liter 1.05671 quarts
1gallon 3.78533 liters
1liter 0.26418 gallons
DRYCAPACITY
1quart 1.1012 liters
1liter 0.9081 quarts
1peck3.071liters
1liter 32562 pecks
LUBRICATION
ITEMS REQUIRING LUBRICATION OR SERVICE AT4 MONTHS OR
6,000-MILE INTERVALS, WHICHEVER OCCURSFIRST
Engine Oil. . . Change
Atmospheric
Temperatures
Expected
Recommended
SAE Viscosity
Number Alternate
AboveFreezing
(32 °F. andabove) 20W 10W-30
BelowFreezing
(0°to 32°F.)
low 10W-30
BelowZero 5W
5W-20
NOTE: All engines are equipped with specially
engineered pistons rings, These rings allow oil to
flow freely on the cylinder walls during break-in
period. Therefore, oil consumption may be higher
during break-in period than it will be afterward.
Oil whichaccordingtothelabeloncanisintended
forserviceMSandconformstoGMStandard6041M
shouldbeused.

GENERAL INFORMATION
0-9
ITEMS REQUIRING LUBRICATION OR SERVICE AT4 MONTHS OR
6,000-MILE INTERVALS, WHICHEVER OCCURS FIRST (Continued)
Oil Filter , . Changeatfirstoilchange;everyotheroilchange
thereafter.
Manifold HeatControlValveObserveforfreedomofmovement.Lubricatewith
heatvalvelubricant.
Sta. Wag. Tail GateHingeandLinkageEngineoileverysixmonths,more often ifrequired.
ITEMS REQUIRING LUBRICATION OR
SERVICE AT4 MONTHS OR 6,000-MILE INTERVALS,
WHICHEVER OCCURS FIRST
Chassis LubrictaionLubricateallnormallygreasedsuspensionparts
includingballjoints.
PowerSteeringSystemandPumpReservoir....MaintainlubricantlevelwithGMpowersteering
fluid, part 1050017. Ifthislubricantisnotavailable,
use DEXRON automatictransmissionfluid.
Standard DifferentialCheckforleaks,maintainlubricantlevelwith SAE-80
oil whereavailableor SAE-90 Multi-Purposegear
lubricant meetingrequirementsof MIL-L-2105B.
Change lubricantonlywhennecessarytodis-
assemble.
Saf-T-Track DifferentialCheckforleaks. Refill withpart 1050081 lubricant
only.Changelubricantonlywhennecessarytodis-
assemble.
Manual Transmission0 . Checkforleaks.Maintainlubricantlevelwith SAE-
80whereavailableor SAE-90 Multi-Purposegear
lubricant meetingrequirementsof MIL-L-2105B.
Change lubricantonlywhennecessaryto
disassemble.
Clutch Linkage— ManualTransmissionChecklashandadjustasrequired.Lubricatewith
chassisgreaseatpushrodtoclutchforkjointand
atcross-shaft.
Manual Transmission. Engineoilatalljoints below steeringcolumnshift
Shift Linkage,ColumnShiftlevers.Chassisgreaseatcrossshaftbearingpoints.
Manual TransmissionShiftLinkage,FloorShift. . Engineoilatalljointsunder body (lubricateshifter
mechanismliberally).
Brake SystemandMasterCylinderChecksystemforadequatebrakepedalreserveand
forevidenceofleaking,correct.Useonly SAE-70R3
fluid suchasDelcoSupremeII.
Hood Latch Engineoilonpivotsandspringanchor points,and
lightgreaseonreleasepawl,everysixmonthsoras
required.
HoodHingesEngineoilonhingepinsandspringanchorpoints,
everysixmonthsorasrequired.
Accelerator LinkageEngineoilatallpivotpoints.Donotlubricatethe
linkagewhichisa partofthecarburetorassembly.
Tempestand Firebird cablemustnotbelubricated.

0-10 1968
PONTIAC SERVICE MANUAL
ITEMS REQUIRING LUBRICATION OR
SERVICE AT4 MONTHS OR 6,000-MILE INTERVALS,
WHICHEVER OCCURS FIRST (Continued)
AutomaticTransmissionShiftLinkage
Lubricate withchassisgreaseatcrossshaftpivot
points.Consolecontrolcablemustnotbelubricated.
ITEMS REQUIRING LUBRICATION Oi
SERVICE AT12 MONTHS OR 12,000 MILE INTERVALS,
WHICHEVER OCCURS FIRST
PositiveCrankcaseVentilation
Check hose between valvecoverandaircleaner,for
clear passages;replaceif clogged. Clean andre-oil
ventilationfilterinaircleaner.Replacevalve.
NOTE: This filter should be cleaned and re-oiled
after each occasion of driving under severe dust
conditions*
Carburetor Fuel Filter - Integral Removeandcleanbronzefilterandfiltercavity,
replacepaperelement.
Air CleanerElement(Paper)
Standard onAll 2Bbl. and 4Bbl. V-8andall
6-cylinder1 BM.and4 Bbl. engines.
Replace.
NOTE: Clean and re-oil after each occasion of
driving under severe dust conditions. Allow excess
oil to drain out of filter prior to installation.
ITEMS REQUIRING LUBRICATION
OR SERVICE EVERY 24 MONTHS OR24,000 MILES,
WHICHEVER OCCURS FIRST
AutomaticTransmission Replacetransmissionfluid.Alsoreplaceoilfilter
in sumpofTurbo Hydra-Matic. Refill with DEXRON
automatictransmissionfluid.Underheavy-dutyop-
eratingconditionsorexcessive stop-and-go driving,
replaceoil(andfilteronTurboHydra-Matic)at
12,000-mileintervals.
ITEMS REQUIRING LUBRICATION OR SERVICE
AT SPECIAL INTERVALS
Tires
Rotatetiresevery 6,000 milesandrebalancetireand
wheelassembliesasrequired.
Parking Brake Cables
Front WheelBearings
Clean andlubricateduringmajorbrakeservice,
lightwater-resistantgrease. Use
Lubricate attimeofmajorbrakeservice.Usehigh
melting-point,water-resistantgrease,andonly
enough tothoroughlycoattherollers.Donot fill
thewheelhubcavity.Wipeanygreaseoff exposed
surfaceofhubandseal.

GENERAL INFORMATION
0-11
ITEMS REQUIRINGLUBRICATION OR SERVICE
AT SPECIAL INTERVALS (Continued)
Brake Assemblies
Manual Steering Gear
BodyDoor Locks and Strikers . . .
DoorHingeHold-Opens.
BodyDoorHingePins. . . .
Station WagonFoldingSeat
Fuel DoorHinge. . . . .
Rear CompartmentLidHinges. . . . . .
Convertible Front Door-to-LockWedgePlates. . .
Windshield WasherSolvent
Air ConditioningCondenser Core
Battery . . . .
Clean andlubricate shoe pads,anchorpins, shoe
hold-downspringpins(atcontact area withbacking
plate)andadjustingscrewattimeofmajorbrake
service.Useonlya highmeltingpointlubricantand
applysparingly.
CAUTION: Grease must be kept off brake linings;
remove by sanding.
Add lubricantasnecessary.Changelubricantonly
whennecessarytodisassemble.Usewaterresistant
EP greasetolevelofcentersidecoverbolthole.
Stick-typelubricant- usesparinglyasrequired.
Light greaseonfrictionsurface.Usesparinglyas
required.
Engine oilasrequired.
Engine oilonpivotsasrequired.Usesparingly.
Engine oilonhingepinandspringanchorpointsas
required.
Engine oilasrequired.
Stick-typelubricant,usesparinglyasrequired.
UsePontiacsolvent,part 1050418, orequivalentand
follow instructionsonlabeltoensureproperopera-
tionofwasher,andtopreventpaintdamagefrom
excessivelystrongsolutions.
Clean offleavesand bugs andflush outside ofcon-
densorandradiatorcoretoremove dirt annualy
eachspring.
CAUTION: Do not use steam.
Add distilledwaterevery30days.Mayrequire
morefrequentadditionsduringhighambienttem-
peraturesand/or extended tripoperation. Clean
terminalsyearlyandapplypetroleum.
ITEMS NOT NORMALLYREQUIRING SERVICE
STARTING MOTOR
Nolubricationrequired except onoverhaul.When
overhaulingstartingmotoradda fewdropsofen-
gine oiltothebronzebushingsinbothendframes.
ball bearinganda rollerbearing.Bothbearingshave
a greasesupplywhicheliminatestheneedfor
periodiclubrication.Thealternatorbrushesare
extra longandundernormaloperatingconditions
will provide extended service.
ALTERNATOR
CONVERTIBLE HYDROELECTRIC PUMP MOTOR
The alternatorisdesignedandconstructedto give
longperiodsoftrouble-freeservicewitha limitedThehydroelectricpumpmotor does notrequire
amountofmaintenance.Therotorismountedona periodicservice,

0-12 1968
PONTIAC SERVICE MANUAL
CLUTCH RELEASE BEARING
The clutchreleasebearingrequiresnoperiodic
lubrication. Itisa ballbearing,lubricatedand
sealedforlife.
SPEEDOMETER CABLE
Periodic lubricationisnotrequired.Wheninstall-
inga newdrivecable,applya lightcoatof speedom-
etercablegreasewipingoffall excess thefulllength
ofthecable.
CAUTION: Excessive amounts of lubricant can
cause speedometer head failure. Lubricate new
drive cables only.

1-1
HEATING AND VENTILATION
SERVICE
CONTENTS OF THIS SECTION
SUBJECTPAGE
Cable Adjustments
Service Procedures(Remove
and Replace)1-1
Heater ControlPanel1-1
SelectSwitch1-2
Pontiac1-2
Fan SpeedSwitch1-3
Resistor 1-4
Wiring Harness(includes
Circuit diagram)1-4
Temperature ControlCable1-4
Air ControlCable1-5
Tempest1-5
Firebird 1-5
DefrosterCable1-6
SERVICE AND ADJUSTMENTS
Service andadjustmentproceduresforPontiac,
Tempestand Firebird HeatingandVentilationSys-
tems arecoveredinthefollowingsection.Forcom-
ponentdescription,theoryofoperation,testingand
diagnosisinformationseetheDiagnosisManual.
TEMPERATURE CABLE ADJUSTMENT
PONTIAC
1.Insurethatcableissecuredatcontrolandat
heater,androutedsmoothlyandfreeofsharpkinks
or bends,
2. Rotatetemperatureswitchcounterclockwiseto
full coldposition(noredbarsexposedincontrol
panel window).
3. Adjustturnbuckleuntilcamroller bottoms at
endofheatercamslot(Fig.1-1).
4.Rotateknobclockwisetomaximumheat(all
red barsexposedincontrolpanelwindow)andback
againtofullcoldposition;controlshouldremain
with noredbarsexposedandcamrollershouldbe
tightagainstendofcamslot.
5.Ifanyoffirstredbarsareexposed,repeat
steps 3 and4 untilcableisproperlyadjusted.
TEMPEST
1.Makesurecableissecureatbothends.
SUBJECTPAGE
Tempest.. 1-6
Firebird. i_6
Defroster — Diaphragm andHose1-6
Pontiac1-6
Air InletDiaphragmandHose1-6
Pontiac1-6
Vacuum SupplyHose1-6
Pontiac1-6
Blower MotorandImpeller
Air InletDuct.. 1-6
Pontiac1-6
Tempest1-6
Heater Core andCasei-8
Heater Hose- All. l-ii
DefrosterDuctl-ii
2. Holdleverontopofheatercaseinfullcold
position(fullleftorclockwisewhenviewedfrom
above).
3. Adjustcableturnbucklesothattemperature
controllever will springback1/16"to1/8"when
pushedtotheOFFposition.
AIRCONTROL CABLE ADJUST
TEMPEST AIR CONTROL CABLE ADJUST
1.PlaceaircontrolleverinOFFposition.
2. Holdairdoor crank onheatercaseina closed
position(crankrotatedfullclockwisewhenviewed
from above).
3. Whileholdingaircontroldoorinclosedposi-
tion,adjustturnbuckletomoveleveragainst bottom
ofslotincontrolpanel,thenturnturnbucklein
opposite directiontomovecontrollever1/16"to
1/8"awayfromendofslot.
4.Moveleverto DE-ICE position,thenbackto
OFF.
5. Lever musthaveslightspringbackfromendof
slot,nottoexceed1/8".
HEATER CONTROLPANEL
REMOVAL AND INSTALLATION
PONT/AC
1. Pull offcontrolknobsfrompanelandremove
bezelsfromleftandrightswitches(Fig.1-1).

1-2 1968
PONTIAC SERVICE MANUAL
ROUTE VACUUM HOSEBETWEEN
DEFROSTER NOZZEL AND DASH MAT
CONNECTVACUUMHOSEWITHGREEN
STRIPE TOAIR INLET DIA.
CONNECTVACUUMHOSEWITHBLUE
STRIPE TO DEFROSTERDIAPHRAGM DIAPHRAGM
CABLE ASS'Y MUST LAY BETWEEN-
DIAPHRAGM ANDTABON MOUNTING
BRACKET AS SHOWN
Fig. 1-1 Passenger CompartmentDetails—Pontiac
Reach behindinstrumentpanelandremovecontrol
panel.
2.Removetemperaturecontrolcableatheater
controlswitch.
3. Detachheaterwireharnessfromtemperature
switchand select switch.
4.Removevacuum hoses from select switch.
5.Removecontrolpanellamp.
6. Install byreversingtheabove.
7.Adjusttemperaturecontrolcable.
FIREBIRD
1.Removeinstrumentpanel trim plate(Fig.1-3).
2.Removecontrolpanelretainingscrews.
3. Movepanel rearward.
4.Removefanswitchconnector,lightandcables.
5.Removepanel.
6.Toinstall,reverseremovalprocedure.
SELECT AND VACUUM VALVE
SWITCH REPLACEMENT (Fig. 1-4)
TEMPEST
1.Removescrewsretainingheatercontrolpanel
toinstrumentpanelandbrace(Fig.1-2).
2.Removeblower speed switchconnectorandlight
connector.
3. Droppanelfromdashareaandremove3
screwsand2 clipsretainingcontrolcables.
4.Toreplace,reverseprocedure,makingsure
thatLP.wireharnessretainerclipissecuredunder
upperattachingscrew.
PONTIAC
1.Removetwo1/4"hexscrewsfromtheswitch
mountingbracket.
2.Aroundonestrandofthe dial cord,placea
paperclip between theswitchmountingbracketand
theback-plateoftheescutcheon.
CAUTION: Dial cord is spring-loaded and cord
will vanish into the escutcheon if paper clip is not
used.
3. Remove dial cordfrompulleyonswitchshaft
and removeswitch.
5. Check operationandadjustmentofcables. 4.Reassemblyisthereverseofdisassembly.

HEATING AND VENTILATION
1-3
NOTE; CABLES MUSTBEROUTED
SMOOTHLY & FREE FROM
BENDS & KINKS.
Fig. 1-2 ControlPanel and CableRouting—Tempest
BLOWER SPEED SWITCH
REMOVE AND REPLACE
PONTIAC
NOTE: When replacing this switch, note the posi-
tion of the defective switch and mount the new
switch in the same position. If the blower does not
function properly, use the procedure below.
1. Turn controlknobcounterclockwisetothestop.
2.Removetwo1/4"hexscrewsandremove
switch.
3. Attachnewswitchleavingscrews loose enough,
sothattheswitchcanberotatedinitsslots.
4.Makesurethatthecontrolknobisalltheway
counterclockwise,bendthewire link untilnored
bars canbeseen.
5.Attachtheelectricalconnectortothenew
switch.
6.Rotatethecontrolknobuntilfourredbarsare
seen.
7.Rotatetheswitchinthe slots untiltheblower
just passesintothe MED-2 operatingspeed(there
are fourspeeds: LO,MED-1,MED-2, & HI).
8.Becarefulthattheswitch does notrotate;
tightenscrews.
9. Check toseethattheblowerpassesfrom
MED-1 to MED-2 whenfourredbarsareshowing
onthefrontofthecontrolheadtoinsureproper
bloweroperation.
TEMPEST
1.Disconnectbattery.
2.Disconnectwiresfromblowerswitch(Fig.1-2).
3. Removeplasticknobfromlever.
4.Removeswitchfrompanel.
5.Replacebyreversingtheaboveprocedure.
FIREBIRD
1.Removeinstrumentpanel trim plate.
2.Removecontrolassembly-to-instrumentpanel
reinforcementattachingscrewsandpushthecontrol
toward thefrontofthevehicleanddown.
3. Removethetwoswitchattachingscrewsand
electrical connector.
4. Install switch,screws,andelectricalconnector.

1-4
1968 PONTIAC SERVICE MANUAL
Fig. 1-3 ControlPanel Cables Attached—Firebird
5.Place control inInstrumentpaneland secure
with attachingscrews.
6. Replace trim plate.
BLOWER MOTOR RESISTOR—ALL
REMOVE AND REPLACE (Fig. 1-1) TYPICAL
1.Removeglovecompartment.
2. Removeresistorconnector.
3.Removeresistor.
4. Replacebyreversingremovalprocedure.
5. Checkforoperation.
HEATER WIRING HARNESS—ALL
REMOVE AND REPLACE (Fig. 1-5)
1.Removeconnectorat blower motorandfeed
through dash.
2. Remove blower switch connector.
3. Removeconnectorat accessory feed.
4.Removeresistorconnector.
5. Toreplace,reverseremovalprocedure.
6.Checkforoperation.
TEMPERATURECONTROLCABLE
REMOVE AND REPLACE
PONTIAC
1.Disconnecttemperature control cableattopof
heater (Fig.1-1).
2. Disconnecttemperature control cableatthe
heater control switch (Fig.1-4).
3. Removecable, taking care nottobendor kink
same.
TEMPEST
1.Removeglovebox(Fig.1-2).
2. Removetemperature control bowdencable from
heater coreand case assembly.
3. Removetemperature control bowdencable from
control assembly.
4.Replacebyreversingtheaboveprocedure.
5. Adjust thetemperature control bowdencable.
6.Replaceglovebox.
FIREBIRD
1.Removeglovecompartment(Fig.1-3).

HEATING AND VENTILATION
1-5
Fig. 1-4 ControlPanelConnection—Pontiac
2. Removecableand heater case.
3.Remove trim plateand control panelretaining
screws.
4. Pushpanelrearwardandremovecable.
5.Replacebyreversingabove.
6. Checkforoperation.
AIRCONTROLCABLE—REPLACEMENT
TEMPEST
1.Removeglovecompartment.
2. Removeair control bowdencable from heater
coreand case assembly(Fig.1-2).
3.Removeair control bowdencable from control
assembly.
4. Replaceair control bowdencable.
5. Adjust air control bowdencable.
6.Replaceglovecompartment.
FIREBIRD
1.Removeglovecompartment.
POWER FEED
CONNECTOR
Fig. 1-5 HeaterHarness—Typical