Pontiac Trans am 1977 User manual

Released By: www.78ta.com

Serial Number: 77SER-001-1008

IMPORTANTSAFETY NOTICE

Proper service and repair

important to the safe, reliable operation of all motor vehicles. The

service procedures recommended by Pontiac and described in this service manual are effective

methods of performingservice operations. Some of these service operations require the use of

tools specially designed for the purpose. The special tools should

used when and as

recommended.

important to note that this manual contains various Warnings, and Cautionswhich should

be carefully read in order to minimizethe risk of personal injury to service personnel or the

possibility that improper service methods will

followed which may damage the vehicle or

render

unsafe.

also

important to understandthat these Warnings and Cautions are not

exhaustive. Pontiac could not possibly know, evaluate and advise the service trade of

all

conceivable ways in which service might

done or of the possible hazardous consequencesof

each way. Consequently, Pontiac has not undertaken any such broad evaluation. Accordingly,

anyone who uses a service procedure or tool which

not recommended by Pontiac must first

satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the

service methodhe selects.

CAUTION

1977

vehicles contain parts dimensioned in the metric system. Many fasteners are metric and

some are very close in dimension to familiar customary measurements inthe inchsystem.

important to notethat, duringany vehicle maintenance procedures, replacement fasteners must

have the same measurements as those removed, whether metric or customary. Mismatched or

incorrect fasteners can result in vehicle damage or malfunction, or possibly personal injury.

Therefore, fasteners removed from the vehicle should

saved for re-use whenever possible.

Where the fasteners are not satisfactoryfor re-use, care should

taken toselect

replacement

that matches the original.

Additional information concerning the identification of metric fasteners

contained in

Section OA of this Manual.

TABLE OF CONTENTS

PONTIAC

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.

PONTlAC MOTOR DIVISION

GENERAL MOTORS CORPORATION

PONTIAC, MICHIGAN48053

S-7704F January, 1977 Litho in U.S.A.

General Motors Corporation 1977

SECTION NAME

GENERAL INFORMATION

General Information

B. Lubrication and Maintenance

SECT.

HEATING AND AIR CONDITIONING

A. Heating

B. Madual Air Conditioning

C. Automatic Air Conditioning

BODY, FRAME AND BUMPERS

A. Frame and Body Mounts

B. Bumpers

C. Body and Chassis Sheet Metal

STEERING, SUSPENSION, WHEELS

AND TIRES

A. Front End Alignment

B. Steering

C. Front Suspension

Rear Suspension

E. Wheels and Tires

REAR AXLE AND PROP SHAFT

A. Prop Shaft

B. Rear Axle

BRAKES

ENGINE

A. Mechanical

B. Cooling

C. Fuel (carburetor, fuel pump, tank,

cannister)

Electrical (cranking, charging, ignition,

battery)

E. Emission Controls

F. Exhaust

TRANSMISSION

A. Automatic

B. Syncromesh

C. Clutch

CHASSIS AND BODY ELECTRICAL

ACCESSOR

ALPHABETICAL INDEX

GENERAL INFORMATION OA-1

SECTION

GENERAL INFORMATION

CONTENTS OF THlS SECTION

General Information

.................................................................................................

OA-1

Ignition, Door and Trunk Locks

.............................................................................

OA-1

Metric Fasteners

.......................................................................................................

OA-4

Capacities

.................................................................................................................

OA-7

GENERAL INFORMATION

Only general specifications and information appear in

this section. Detailed specifications on major units are given

at the end of each respective section of this manual.

BODY IDENTIFICATION PLATE

Information as to body style, trim number, body number

and paint code may be found stamped on the Body

Identification Plate (Fig. OA-1). This plate is attached to the

upper horizontal surface of the dash panel (shroud) in the

engine compartment. The plate is located on the right hand

side on B Series and on the left hand side on all other models.

OPTION DESIGNATION

SERIES

(

for

plant

use

BODY STYLE

DlV~S~~~-~

rASSEMBLY PLANT

TIME

BUILT

CODE-

UPPER

BODY

COLOR

TRIM COMBINATION

NUMBER CONV. TOP COLOR

MODULAR

SEAT

CODE-

LOWER

B~DY

COLOR

3407

Fig.

OA-1

Vehicle Body Style Identification Plate

VEHICLE IDENTIFICATION PLATE

Serial number, assembly plant code, engine, carburetor,

style, series and model year identification can be determined

from the Manufacturer's Motor Vehicle Identification

Number Plate. This plate is fastened to the upper left

instrument panel area, visible through the windshield. The

plate has embossed numerals as shown in Fig. OA-2.

GOVERNMENT CERTIFICATION LABEL

All models have a label on the left door end panel stating

that the car conforms to all government requirements.

NOTE:

This label must not be removed.

CAR MODEL IDENTIFICATION

Thevarious Pontiac models areidentified both by names

and by "series" letters. Fig. OA-2 shows both methods of

identification.

The third letter code in the vehicle identification number

shows the plant where a given car was built (Fig. OA-2).

ENGINE IDENTIFICATION

Theengine letter code appears as the second letter in the

vehicle identification number as shown in Fig. OA-2.

For identification of specific engines refer to engine

section in this manual.

IGNITION, DOOR AND TRUNK

LOCKS

Two separate keys (Fig. OA-3) are used; type

"E"

(square) for ignition switch only and type

"H"

(oval) for all

doors, glove box, tailgate, hatchback and deck lid locks.

IGNITION LOCK

Removal

1. Remove lock assembly from steering column. See

Section 3B4 in this manual.

2. Production lock is not serviceable and should be

discarded.

NOTE:

In the event that the old tumblers are to be

re-used, the following procedure may be used to

disassemble the lock cylinder.

a. Pry off gate adapter stop ring (Fig. OA-4).

b. With key inserted in lock, turn counterclockwise to

stop (accessory position).

c. Using suitable pick, depress brass pin in slot on side

of cylinder as shown in Fig. OA-5.

PLANT

SEQUENTIAL

NUMBER

DIVISION CODE (PONTIAC)

IYIL

MODE^

YEAR

1977

C&E

BODY TYPE

SPORT COUPE

HATCHBACKCOUPE

ENGINE

OPTION

CODE

ENGINE

VIN

NAME

SERIE! ENGINE

DESCRIPTION

140C.I.D. 2-BBL.-L4

151C.I.D. 2-BBL.-L4

231C.I.D. 2-BBL.-V6

140C.I.D. 2-BBL.-L4

I151C.I.D. 2-BBL.-L4

ASTRE HC

ASTRE SAFARI

ASTRE

COUPE

2 SEAT WAGON

2 DR. HARDTOP

2 DR. HARDTOP 87

FIREBIRD

231C.I.D. 2-BBL.-V6

301C.I.D. 2-BBL.-V8

305 C.I.D. 2-BBL.-V8

350

C.I.D. 4-B6L.-V8

350

C.I.D. 4-BBL.-V8

400 C.I.D. 4-BBL.-V8

403 C.I.D. 4-BBL.-V8

151C.I.D. 2-BBL.-L4

231C.I.D. 2-BBL.-V6

301C.I.D. 2-BBL.-V8

305 C.1 D. I-BBL.-V8

350 C.I.D. 4-BBL.-V8

FlREBlRDESPRIT

FlREBlRDFORMULA

FlREBlRDTRANS AM

VENTURA

HATCHBACKCOUPE 17

2 DRXOUPE

4 DR. SEDAN

HATCHBACK COUPE

VENTURA

VENTURA SJ

2 DR. COUPE 27

4 DR. SEDAN 69

LE MANS

LE MANSSAFARI

LE MANS

4 DR. SEDAN

STATIONWAGON

2 DR. COUPE 231C.I.D. 2-BBL.-V6

301 C.I.D. 2-BBL.-V8

350 C.I.D. 4-BBL.-V8

350

C.I.D. 4-BBL.-V8

400

C.I.D. 4-BBL.-V8

403 C.I.D. 4-BBL.-V8

LE MANS

GRAND LEMANS

GRAND LE MANS

GRANDPRlX

GRANDPRlX SJ

GRANDPRlX LJ

STATIONWAGON

HARDTOPCOUPE

HARDTOPCOUPE 301 C.I.D. 2-BBL.-V8 L27 Y

350 C.I.D. 4-BBL.-V8 L76 P

350 C.I.D. 4-BBL.-V8 L34 R

400 C.I.D. 4-BBL.-V8 L78

403C.I.D. 4-BBL.-V8 L80 K

231 C.I.D. 2-BBL.-V6 LD7 C

301 C.I.D. 2-BBL.-V8 L27 Y

350 C.I.D. 4-BBL.-V8 L76 P

350 C.I.D. 4-BBL.-V8 L34 R

400

C.I.D. 4-BBL.-V8 L78

403 C.I.D. 4-BBL.-V8 L80 K

CATALlNA

CATALINA

GRANDSAFARI

BONNEVILLE

BONNEVILLE BROUGHAM

BONNEVILLEBROUGHAM

STATIONWAGON 35

2 DR. COUPE

4 DR. SEDAN 69

STATIONWAGON

DR.

COUPE

---

4 DR. SEDAN

6!3

...

-~-

2 DR. COUPE

4 DR. SEDAN

GENERAL INFORMATION OA-3

A KEY

FOR IGNITION LOCK ONLY

B KEY

FOR REAR COMPARTMENT,

DOOR, TAILGATE, HATCHBACK

AND GLOVE COMPARTMENT LOCKS,

2878

Fig. OA-3 Key Blanks

LOCK

ANCHOR

WASHER

ADAPTOR

STOP

WASHER

ASSEMBLY

4252

Fig. OA-4 Exploded View of Lock Cylinder

Fig. OA-5 Depressing Lock Cylinder Retaining Pin

d. It will be necessary to fashion a pick and insert this

behind the cylinder wall to depress the brass pin.

e. While holding pin depressed, turn key and lock

slightly and pull lock assembly out of cylinder approximately

1/8".

f. Pull key out of lock assembly approximately two (2)

teeth and, using suitable pick, slide or shake plastic retainer

in end of lock toward pin side of cylinder.

g. Pull key and lock assembly out of cylinder.

h. Pry off tumbler retainer, unscrew springsand remove

tumblers.

i. Retain tumblers and discard lock cylinder.

Coding Side

Bar

Lock

NOTE:

The glove compartment lock uses a snap-in

tumbler cylinder. With this design, the cylinder (less

tumbler and springs) along with precoded tumblers and

springs are serviced. The tumblers may be snapped out

and in again, however, it is recommended that after two

or three times the cylinder should be replaced with new

tumblers since the retention is lessened each time. The

OLD and NEW style cylinders are completely

interchangeable.

Lock kits are available without tumblers, springs or

retainers. Uncoded side bar locks may be coded to match the

keys used on the car by ordering the above parts separately.

Five types of tumblers are used to make the various

combinations and each is coded according to a number, one

(1) through five

(5),

stamped on its side. Before the lock

cylinder may be coded, the correct code must be determined.

If the numbered blank in the key head has not been removed,

determine the code by consulting the lock manufacturer's

code book. Should the blank be missing, proceed as follows:

Place the key on the silhouette in Fig. OA-6, aligning

the key with the outline as accurately as possible.

4998 POSITION LEVELS

Fig. OA-6 Key Coding Diagram

2. Starting at the base of the key blade, determine the

lowest level visible in position No. 1.

Determine the lowest visible level for the remaining

five positions. As each tumbler level is determined, write that

number in the blank space above the position numbers.

After the key code has been determined, the correct

tumblers should be installed as follows:

Beginning with slot next to head of cylinder (number

one position) install tumblers in slots in sequence determined

from key code.

2. Insert spring in each round cavity of each tumbler lock

between slots (Figs. OA-7 and OA-8).

CAUTI0N:

Do not pull springs apart; unscrew

them.

Install springretainer over springs, with ends inserted

in slots, and hold in place.

Check by inserting cut key. Sidebar will dropin place

when key is inserted and correct tumblers have been installed.

OA-4

1977

PONTIAC SERVICE MANUAL

PRE-CUT

TUMBLERS

Fig. OA-7 Pre-Cut Tumblers

CYLINDER

4256

Fig. OA-8 Installing Tumblers

5. Install spring retainer using vise. Stake as shown in

Fig. OA-9.

HERE

4257

Fig. OA-9 Staking Tumbler Spring Retainer

Installation

1. With key inserted in lock part way, assemble wave

washer and special lock washer over lock as shown in Fig.

OA-4.

Align tang of washer over side bar of lock and insert

assembly into cylinder so that tang on washer enters slot in

cylinder.

3. Be sure plastic lock in cylinder does not interfere with

assembly.

4. When lock is fully seated in cylinder, rotate lock

cylinder to lock position and remove key.

Install stop adapter over tail of cylinder and rotate

clockwise until adapter contacts stop pin located in sleeve.

Stake as shown in Fig. OA-10.

Fig.OA-10 Staking Adapter Stop

5. Assemble lock and cylinder assembly into steering

column. See Section 3B4 of this manual.

METRIC FASTENERS

All 1977 Pontiacs have some metric threaded fasteners

and some customary or inch-system fasteners. Catalina,

Bonneville and Bonneville Brougham are about 50% metric,

50% customary. Most of the other cars have a small metric

fastener content. It is most important that replacement

fastenersbe of the correct nominal diameter, thread pitch and

strength.

Original equipment metric fasteners (except "beauty"

bolts, such as exposed bumper bolts, and cross recess head

screws) are identified by a number marking indicating the

strength of the material in the fastener as outlined below.

Metric cross recess screws are identified by a Posidriv or

Type 1A cross recess as shown in Figure OA-11. Either a

Phillips head orType 1Acorssrecess screwdrivercan be used

in Posidriv recess screw heads, but Type 1A cross recess

screwdrivers will perform better.

NOTE:

Most metric fasteners have a blue color coating.

However, this should not be used as a positive way of

identifying assomemetric fasteners are not color coated.

General MotorsEngineering Stardards,along with other

North American Industries, have adopted a portion of the

standard metric fastener sizes defined by IS0(International

Stardards Organization). Thiswas doneto reduce the number

of fastener sizes used and yet retain the optimum strength

characteristics in each thread size. For example, the

customary 1/4-20 and 1/4-28 screws are replaced by the

metric M6.3

1 screw which has nearly the same diameter

GENERAL INFORMATION OA-5

POSlDRlV

SCREW HEAD

IDENTIFICATION MARKS

(4)

Fig.

OA-1 1

Cross Recess Screw

and 25.4 threads per inch. The thread pitch is in between the

customary coarse and fine thread pitches.

Metric and customary thread notation differ slightly.

The difference is illustrated in Fig. OA-12.

FASTENER STRENGTH

IDENTIFICATION

Most commonly used metric fastener strength property

classes are 9.8 and 10.9with the class identification embossed

on the head of each bolt. Customary (inch) strength classes

range from grade 2 to 8 with radial line identification

embossed on each bolt head. Markings correspond to two

lines less than the actual grade (i.e., grade

bolt will exhibit

5 embossed radial lines on the bolt head). Some metric nuts

will be marked with single digit strength identification

numbers on the nut face. Fig. OA-13 illustrates the different

strength markings.

When replacing metric fasteners, be carful to use bolts

and nuts of the same strength or greater than the original

fasteners (the same number marking or higher). It is likewise

important to select replacement fasteners of the correct size.

Correct replacement bolts and nuts are available through

General Motors Parts Division. Many metric fasteners

available in the after-market parts channels were designed to

metric standards of countries other than the United States,

and may be of a lower strength, may not have the numbered

head marking system, and may be of a different thread pitch.

The metric fasteners used on these products are designed to

new, international standards that may not yet be

manufactured by some non-domestic bolt and nut suppliers.

In general, except for special applications, the common sizes

and pitches are:

CUSTOMARY METRIC

M6.3

THREAD MWOR NUMBER OF THREADS THREAD MAJOR DIAMETER DISTANCE BETWEEN

DIAMETER ININCHES PER INCH INMlLLlMETRES THREADS INMlLLlMETRES

4997

Fig.

OA-12

Thread Notation

OA-6

1977

PONTIAC SERVICE MANUAL

NUT STRENGTH

GRADE 2 GRADE

GRADE

IDENTIFICATION

(GM 260-MI (GM 280-MI (GM 290-MI (GM 300-MI

CUSTOMARY (INCH) BOLTS-IDENTIFICATION MARKS CORRESPOND TO BOLT

STRENGTH-INCREASING NUMBERS REPRESENT INCREASING STRENGTH.

METRIC BOLTS-IDENTI FlCATlON CLASS NUMBERS CORRESPOND TO BOLT

STRENGTH-INCREASING NUMBERS REPRESENT INCREASING STRENGTH.

Fig.

OA-13

Bolt Strength Markings

GENERAL INFORMATION

OA-7

Fractions

1/64

.....

1/32

.....

3/64

.....

1/16

.....

5/64

.....

3/32

.....

7/64

.....

118

.....

9/64

.....

5/32

.....

11/64

.....

3/16

.....

13/64

.....

7/32

.....

15/64

.....

114

.....

17/64

.....

9/32

.....

19/64

.....

5/16

.....

21/64

.....

11/32

.....

23/64

.....

318

.....

25/64

.....

13/32

.....

27/64

.....

7/16

.....

29/64

.....

15/32

.....

31/64

.....

112

r.....

DECIMAL AND METRIC EQUIVALENTS

Decimal

015625

....

03125

....

.046875

....

0625

.....

078125

....

09375

....

109375

....

125

......

140625

....

15625

....

171875

....

1875

.....

203125

....

21875

....

234375

....

250

......

265625

....

28125

....

296875

....

3125

.....

328125

....

3375

....

359375

....

375

......

390625

....

40625

....

421875

....

4375

.....

453125

....

A6875

....

A84375

....

500

......

Metric

3688

79375

1.19062

1.58750

1.98437

2.38125

2.77812

3.1750

3.57187

3.96875

4.36562

4.76250

5.15937

5.55625

95312

6.35000

6.74687

7.14375

7.54062

7.93750

8.33437

8.73125

9.12812

9.52500

9.92187

10.31875

10.71562

11.11250

11.50937

1190625

12.30312

l2.7OOOO

Fractions

33/64

.....

17/32

.....

35/64

.....

9/16

.....

37/64

.....

19/32

.....

39/64

.....

518

.....

41/64

.....

21/32

.....

43/64

.....

11/16

.....

45/64

.....

23/32

.....

47/64

.....

314

.....

49/64

.....

25/32

.....

51/64

.....

13/16

.....

53/64

.....

27/32

.....

55/64

.....

718.

.....

57/64

.....

29/32

.....

59/64

.....

15/16

.....

61/64

.....

31/32

.....

63/64

.....

Decimal

515625

...

53125

....

546875

...

5625

....

578125

...

59375

....

609375

...

625

.....

A40625

...

65625

....

671875

...

5875

....

703125

...

71875

....

734375

...

750

.....

...

766625

78125

....

796875

...

8125

....

828125

...

Metric

13.09687

13.49375

13.89062

14.28750

14.68437

15.08125

15.47812

15.87500

16.27187

16.66875

17.06562

17A6250

17.85937

18.25625

18.65312

19.05000

19.44687

19.84375

20.24062

20.63750

21.03437

21A3125

21.82812

22.22500

22.62187

23.01875

23.41562

23.81250

24.20937

24.60625

25.00312

25.40000

0838

Fig

.OA-14

Conversion Chart

Customary and Metric

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