PONTIAC 1977 Grand Prix, Bonneville, Catalina, Le Mans, Grand Le Mans Comprehensive Workshop Service Manual| PDF Download
PONTIAC 1977 Grand Prix, Bonneville, Catalina, Le Mans, Grand Le Mans Workshop Manual | PDF Download
PONTIAC 1977 Grand Prix, Bonneville, Catalina, Le Mans, Grand Le Mans Workshop Manual | PDF Download
Easy to follow step by step instructions for the home workshop mechanic or professional technician.
This Pontiac Workshop Manual is for the following Pontiac models manufactured in 1977:
- Pontiac Grand Prix
- Pontiac Bonneville
- Pontiac Catalina
- Pontiac Le Mans
- Pontiac Grand Le Mans
- Pontiac Safari
Engines covered:
- 140 CU. IN. 2.2 LITRE INLINE 4 CYLINDER
- 151 CU. IN. 2.5 LITRE INLINE 4 CYLINDER
- 231 CU.IN. 3.8 LITRE V6 CODE C
- 350 CU.IN 5.7 LITRE AND 403 CU. IN. 6.6 LITRE V8 Codes R and K
- 301 CU.IN. 5.0 LITRE - 350 CU.IN. 5.7 LITRE - 400 CU.IN. 6.6 LITRE V8 Codes Y-P-Z
- 305 CU. IN. 5.0 LITRE - 350 CU. IN. 5.7 LITRE V8 Codes U and L
Transmissions Covered:
- Turbo Hydra-Matic 200 Automatic Transmission
- Turbo Hydra-Matic 250 Automatic Transmission
- Turbo Hydra-Matic 350 Automatic Transmission
- Turbo Hydra-Matic 400 Automatic Transmission
- 3-Speed 76mm Muncie Manual Transmission
- 4-Speed 76mm Muncie Manual Transmission
- 4-Speed 82mm Borg-Warner Manual Transmission
- 5-Speed 77mm Borg-Warner Manual Transmission
Below is a very detailed list of topics covered in this Pontiac Manual:
- GENERAL INFORMATION
- General Information
- Lubrication and Maintenance
- Description
- Engine Families
- Maintenance Schedule
- Maintenance Service Specifications
- Fluids and Lubricants
- Engine Oil and Filter
- Lift Points
- Lubrication Chart
- HEATING AND AIR CONDITIONING
- Heating
- General Description
- Heater Control Functional Test
- Diagnosis
- Heater Wiring Diagram
- Heater Trouble Diagnosis
- On-Car Service Procedures
- Available Heater Control Cable Adjustments
- Air Conditioning
- General Description
- Illustrated A/C Controls. Wiring & Vacuum Diagrams. Air & Refrigerant Flows. Refrigerant- 12 Data
- A/C Refrigerant System Diagnosis
- Insufficient Cooling "Quick-Check" Procedure
- Thermostatic Switch Diagnosis
- A/C Diagnostic Connector
- Air Conditioning Electrical Diagnosis
- On-Car Service Procedures
- Precautionary Service Measures
- Discharging. Adding Oil. Evacuating and Charging Procedures for C.C.O.T.
- AUTOMATIC TEMPERATURE CONTROL
- General Description
- Diagnosis
- C65 Functional Test
- On-Car Service Procedures
- C65 Programmer Temperature Cable Adjustment
- C65 Programmer "Removal-Replacement-Adjustment" Procedure
- BODY, FRAME AND BUMPERS
- Frame and Body Mounts
- General Description
- Frame
- Identification
- On Car Service
- Frame Inspection
- Underbody Inspection
- Frame Repair
- Frame Alignment
- Tramming Sequence
- Frame Dimensions
- Body Mounts
- Frame Braces
- Bumpers
- General Description
- Bumper Energy Absorbing Units
- Care of Aluminum Bumpers
- Illustrated Service Procedures
- Body and Chassis Sheet Metal
- General Description
- Hood-Adjust
- Hood Hinge/Spring
- Hood Latch-Adjust
- Hood Release Cable/Rod
- Front Fender-Align
- Painting and Repairing Non-Metal Exterior Parts
- Fiberglass ABS Panel Repair
- Painting Fiberglass ABS Plastics
- Endura Paint Refinishing
- 1977 Non-Metal Exterior Painted Parts
- 1977 Pontiac Exterior Colors
- Identifying and Painting Plastic Interior Trim
- Test Procedure
- Painting Procedure
- Illustrated Service Procedures
- STEERING, SUSPENSION, WHEELS AND TIRES
- DIAGNOSIS
- General Diagnosis
- Linkage Diagnosis
- Manual Steering Gear Diagnosis
- Power Steering Pump and Gear Diagnosis
- Steering Column Diagnosis
- Steering Column Lock System Diagnosis
- Steering Column Signal Switch Diagnosis
- Ignition Switch Diagnosis
- Key Buzzer Diagnosis
- Dimmer Switch Diagnosis
- Power Steering Leak Diagnosis
- Power Steering System Test Procedure
- Wheel Bearing Diagnosis
- Shock Absorber Diagnosis
- Tire Diagnosis
- Irregular and/or Premature Wear Diagnosis
- Radial Tire Waddle
- Radial Tire Lead Diagnosis
- FRONT END ALIGNMENT
- General Description
- Maintenance and Adjustments
- Preliminary Checks
- Alignment Requirements
- Adjustments (Except H Series)
- Correction Charts
- Adjustments (H Series)
- Trim Heights
- Specifications
- STEERING LINKAGE
- Description and Operation
- Suspension and Steering Linkage Checks
- Tie Rods
- Intermediate Rod
- Tie Rod Adjuster Tube
- Idler Arm
- Shock Absorber (Intermediate Rod)
- Pitman Arm
- Torque Specifications
- MANUAL STEERING GEAR
- General Description
- Service Procedures
- Manual Gear
- Wormshaft Seal
- Disassembly of Gear
- Pitman Shaft Bushing
- Side Cover Bushing
- Wormshaft Bearing Race
- Adjuster Plug Race
- Ball Nut Servicing
- Specifications
- POWER STEERING GEAR AND PUMP
- General Description
- Power Steering Gear
- Power Steering Pump
- Service Procedures
- Pitman Shaft Seals
- Steering Gear
- Adjuster Plug Assembly
- Valve and Stub Shaft Assembly
- Pitman Shaft and Side Cover
- Rack-Piston
- Steering Gear Hose Connector
- Poppet Check Valve
- Pitman Shaft Needle Bearing and Seals Adjustment
- Power Steering Gear Ball Plug
- Pump Belt
- Flow Control Valve
- Pump Shaft Oil Seal
- Power Steering Pump
- Bleeding Power Steering System
- 605 Power Steering Gear
- Specifications
- STEERING WHEELS & COLUMNS
- General Description
- Function Locking Columns
- Steering Column With Dimmer Switch
- Key Release Column
- Mechanical Neutral Start
- Service Procedures
- Steering Column
- Tilt-Away Column and Key Release
- In-Car Procedures
- Tilt-Away Column With Dimmer Switch
- Out-of-Car Procedures
- Regular Column and Key Release
- In-Car Procedures
- Regular Column With Dimmer Switch
- Intermediate Shaft and/or Stone Shield
- Intermediate Shaft and Coupling
- Ignition Lock Assembly
- Steering Wheel
- Checking Steering Column for Damage
- Torque Specifications
- FRONT SUSPENSION
- General Description
-
Maintenance & Adjustments
- Service Procedures
-
Specifications.
- REAR SUSPENSION
- General Description
-
Shock Absorber
- Rear Suspension Service Operations
- Shock Absorbers - Removal and Installation
- Upper Control Arms
- Torque Arm H-Series
- Track Rod H-Series
- Lower Control Arms
- Bushings
- Coil Springs
- Leaf Springs
- Axle Housing
- Rubber Bumper
- Axle Housing Alignment
- Rear Stabilizer Shaft
- Superlift Shock Absorbers..
- Automatic Level Control
- WHEELS AND TIRES
- General Description
- Replacement Tires
- Replacement Wheels.
- Maintenance and Minor Adjustments
- Wheel Maintenance
- Wheel Attaching Studs
- Inflation of Tires
- Tire Rotation
- Cast Aluminum Wheel
- Stowaway Spare
- Service Procedures
- Wheel and Tire Assembly
- Balancing Wheels
- Vibration
- Styled Wheel Hub Cap
- Recharging C02 Inflator Canister
- Specifications
- REAR AXLE AND PROP SHAFT
- Prop Shaft
- General Description
- Diagnosis
- Maintenance and Adjustments
- Unit Repair
- Specifications
- Special Tools
- Rear Axle
- General Description
- Standard Differential
- Positive Traction Differential
- Diagnosis
- On Car Service
- Unit Repair
- Specifications
- Special Tools
- BRAKES
- General Description
- Diagnosis
- Pedal Travel
- Brake Pedal Mounting
- Stop Light Switch
- Bleeding Brakes
- Brake Pipes
- Brake Hoses
- Parking Brake Cables
- Parking Brake Adjustment
- Master Cylinder Overhaul
- Disc Brakes
- Lining Inspection
- Caliper Overhaul
- Rotor Servicing
- Drum Brakes
- Drum Brake Lining Replacement
- Inspection and Reconditioning Brake Drums
- Wheel Cylinder Overhaul
- Unit Repair
- Power Brake Units
- Specifications
- ENGINE
-
140 CU. IN. 2.2 LITRE INLINE 4 CYLINDER
- General Description
- Engine Lubrication
- On Car Service
- Engine Front Cover
- Accessory Drive Pulley
- Timing Belt and Water Pump
- Checking Timing Belt Tension
- Camshaft Timing Sprocket
- Timing Belt Cover Upper (Camshaft)
- Timing Belt Lower (Crankshaft)
- Crankshaft Timing Sprocket
- Oil Pump (Crankcase Front Cover) Seal
- Oil Pan and Baffle
- Oil Pump Screen and Pick-up Tube
- Oil Seal (Rear Main)
- Oil Pump (Crankcase Front Cover)
- Camshaft Cover
- Camshaft
- Valve Stem Oil Seal and/or Valve Spring
- Intake Manifold
- Exhaust Manifold
- Cylinder Head Assembly
- Flywheel
- Engine Mounts
- Cylinder Block
- Oil Filter Bypass Valve
- Connecting Rod and Piston Assemblies
- Connecting Rod Bearings
- Main Bearings
- Crankshaft
- 151 CU. IN. 2.5 LITRE INLINE 4 CYLINDER
- General Description
- On-Car Service
- Engine Insulators
- Intake and Exhaust Manifolds
- Rocker Arm Cover
- Rocker Arm, Pushrod and/or Stud
- Valve Springs, Shields and Seals
- Pushrod Cover or Gasket
- Hydraulic Valve Lifters
- Cylinder Head Gasket
- Cylinder Head Disassemble
- Valves and Seats
- Harmonic Balancer and/or Seal
- Timing Cover
- Camshaft
- Oil Pan
- Oil Pump
- Connecting Rod Bearings
- Rear Main Bearing Oil Seal
- Main Bearings
- Piston and Rod Assembly
- Piston Rings
- Piston Pins
- Cylinder Bores
- Engine Assembly
- Crankshaft
- Bolt Torque Specifications
- Engine Specifications
- Special Tools
- 231 CU.IN. 3.8 LITRE V6 CODE C
- Engine Construction
- Lubrication System
- Removal and Installation of Engine Mounts
- Removal and Installation of Engine Intake Manifold or Gasket
- Removal and Installation of Exhaust Manifold
- Removal and Installation of Cylinder Head
- Reconditioning Valves and Guides
- Removal and Installation of Timing Chain Cover
- Front Crankshaft Oil Seal Replacement
- Removal and Installation of Timing Chain and Sprocket
- Camshaft Bearing Remove and Install
- Removal and Installation of Oil Pan
- Removal and Inspection of Oil Pump Pipe and Screen Assembly
- Testing Oil Pressure
- Removal, Inspection and Installation of Oil Pump Cover and Gears
- Connecting Rod Bearings
- Camshaft Bearings and Seals
- Installation of Rear Bearing Oil Seals
- Pistons, Rings and Connecting Rods
- Reboring Cylinder and Fitting New Pistons
- Removal and Installation of Engine
- Removal and Installation of Automatic Transmission Flywheel
- Automatic Transmission Flywheel Balance
- Harmonic Balancer
- Bolt Torque Specifications
- General Specifications
- 350 CU.IN 5.7 LITRE AND 403 CU. IN. 6.6 LITRE V8 Codes R and K
- Description
- Engine Lubrication System
- Engine Mountings
- Intake Manifolds
- Exhaust Manifolds
- Valve Cover
- Rocker Arm Assemblies
- Valve Lifters
- Cylinder Head and Gasket
- Valves and Springs With Head Removed
- Crankshaft Pulley
- Harmonic Balancer
- Front Cover
- Oil Seal
- Timing Chain and Gears (With Front Cover Removed)
- Checking Valve Timing Without Removing Front Cover
- Camshaft
- Camshaft Bearings
- Camshaft and Oil Galley Plugs
- Oil Pan
- Oil Pump
- Connecting Rod and Piston Assembly
- Rod Bearings
- Main Bearings
- Rear Main Bearing Upper Oil Seal
- Rod Assembly
- Checking Cylinder Bore
- Piston Rings
- Piston Pins
- Engine Assembly
- Crankshaft
- Flywheel
- Torque Specifications
- Engine Specifications
- Special Tools
- 301 CU.IN. 5.0 LITRE - 350 CU.IN. 5.7 LITRE - 400 CU.IN. 6.6 LITRE V8 Codes Y-P-Z
- General Description
- Engine Mountings
- Exhaust Manifolds
- Intake Manifolds
- Push rod Cover
- Rocker Arm Cover
- Valve Springs, Shields or Seals
- Rocker Arm Studs
- Valve Lifter Remove
- Hydraulic Valve Lifters, Recondition
- Cylinder Head or Gasket
- Cylinder Head and Valves Recondition
- Harmonic Balancer
- Timing Chain Cover Seal
- Timing Chain Cover
- Timing Chain and Sprockets
- Camshaft and Bearings
- Oil Pan and/or Gasket
- Oil Pump
- Connecting Rod Bearings
- Main Bearings
- Main Bearing Rear Oil Seal
- Connecting Rod and Piston
- Piston Pin
- Cylinder Bores
- Piston Fit and Replace
- Piston Rings
- Engine Assy. Remove
- Crankshaft Replace
- Torque Specifications
- Engine Specifications
- Special Tools
- 305 CU. IN. 5.0 LITRE - 350 CU. IN. 5.7 LITRE V8 Codes U and L
- General Description
- Service Procedures
- Engine Mounts
- Intake Manifold
- Exhaust Manifold
- Rocker Arm Cover
- Valve Mechanism
- Valve Springs and Seals
- Valve Lifters
- Cylinder Head
- Rocker Arm Studs
- Valve Guide Bores
- Valve Seats
- Valves
- Torsional Damper
- Crankcase Front Cover
- Oil Seal (Front Cover)
- Camshaft
- Camshaft Bearings
- Oil Pan
- Oil Pump
- Connecting Rod Bearings
- Main Bearings
- Oil Seal (Rear Main
- Piston and Rod Assembly
- Piston Pins
- Piston Rings
- Engine Assembly Remove and Replace
- Crankshaft Replace
- Engine Torques
- Engine Specifications
- Special Tools
-
COOLING
- General Description
- Diagnosis
- Service Operations
- Thermostat Remove and Replace
- Water Pump Remove and Replace
- Water Pump Overhaul (Where Used)
- Radiator and/or Shroud Remove and Replace
- Coolant Reservoir Remove and Replace
- Illustrations of Radiator, Shroud and Related Items
- Belt Diagrams and Specifications
- Radiator Usage Chart
- Capacities and Specifications
- FUEL, CARBURETOR, FUEL PUMP, TANK, CANNISTER
- GENERAL DESCRIPTION
- Fuel System
- DIAGNOSIS
- Fuel System Diagnosis
- CARBURETION
- 5210
- M2MC 200
- 2GC/2GE
- M4MC
- FUEL SUPPLY
- General Description
- On-Car Service
- ACCELERATOR CONTROLS
- SPECIFICATIONS
- ELECTRICAL - CRANKING, CHARGING, IGNITION, BATTERY
- Diagnostic Connector
- General Electrical System Diagnosis
- Battery Charging System
- Ignition System
- Cranking System
- Specifications
- Emission Controls
- General Description
- Vacuum Hose Schematics
- Early Fuel Evaporation System (EFE)
- Exhaust Gas Recirculation System (EGR)
- Positive Crankcase Ventilation (PCV)
- Thermostatic Air Cleaner (TAC)
- Air Injection Reaction System (AIR)
- Engine Performance Specifications
- Exhaust
- General Description
- Exhaust Pipe
- Muffler
- Resonator
- Hanger
- Clamp
- Catalytic Converter
- On-Car Service
- Catalyst
- Bottom Cover
- TRANSMISSION
- TURBO HYDRA-MATIC 200 AUTOMATIC TRANSMISSION
- General Description
- Diagnosis
- On Car Service
- Governor
- Intermediate Servo
- Pressure Regulator
- Control Valve Assembly
- Oil Cooler Pipes
- T.V. Cable
- Column Shift Controls
- Console Shift Controls
- Unit Repair
- Transmission Removal
- Transmission Disassembly
- External Parts
- Front Unit Parts
- Front Gear Parts
- Rear Gear Parts
- Manual Shaft & Parking Pawl Parts
- Inspection of Case
- Low and Reverse Clutch
- Oil Pump
- Pressure Regulator
- Pump Body
- Pump Cover
- Intermediate Servo Piston
- Bushing Service
- Specifications
- Special Tools
- TURBO HYDRA-MATIC 250 AUTOMATIC TRANSMISSION
- General Description
- Diagnosis
- Maintenance and Adjustments
- On-Car Service
- Unit Repair
- Governor
- Intermediate Servo
- Pressure Regulator
- Control Valve Assembly
- Oil Cooler Pipes
- T.V. Cable
- Column Shift Controls
- Console Shift Controls
- Unit Repair
- Transmission Removal
- Transmission Disassembly
- External Parts
- Front Unit Parts
- Front Gear Parts
- Rear Gear Parts
- Manual Shaft & Parking Pawl Parts
- Inspection of Case
- Low and Reverse Clutch
- Oil Pump
- Pressure Regulator
- Pump Body
- Pump Cover
- Intermediate Servo Piston
- Bushing Service
- Specifications
- Special Tools
- TURBO HYDRA-MATIC 350 AUTOMATIC TRANSMISSION
- General Description
- Diagnosis
- Maintenance and Adjustments
- On-Car Service
- Unit Repair
- Governor
- Intermediate Servo
- Pressure Regulator
- Control Valve Assembly
- Oil Cooler Pipes
- T.V. Cable
- Column Shift Controls
- Console Shift Controls
- Unit Repair
- Transmission Removal
- Transmission Disassembly
- External Parts
- Front Unit Parts
- Front Gear Parts
- Rear Gear Parts
- Manual Shaft & Parking Pawl Parts
- Inspection of Case
- Low and Reverse Clutch
- Oil Pump
- Pressure Regulator
- Pump Body
- Pump Cover
- Intermediate Servo Piston
-
Bushing Service
- Specifications
- Special Tools
- TURBO HYDRA-MATIC 400 AUTOMATIC TRANSMISSION
- General Description
- Planetary Gear Train
- Preliminary Checking Procedure
- Specific Transmission Malfunctions
- Causes of Transmission Malfunctions
- Periodic Service Recommendations
- Towing
- Transmission Fluid
- On Car Service
- Column Shift Controls
- Console Shift Controls
- Downshift Control Switch
- Neutralizer Switch
- Transmission Fluid
- Pressure Regulator Valve
- Units or Parts Readily Removeable From Transmission
- Units or Parts Readily Removeable After Oil Pan Removal
- Unit Repair
- Remove Transmission
- Converter and Modulator
- Governor. Speedometer Driven
- Gear. Pan.
- Filter and Intake Pipe
- Pressure Switch. Control Valve
- Assembly. Governor Screen Assembly.
- Electrical Connector. Governor Pipes and Detent Spring Assembly
- Rear Servo. Valve Body
- Spacer. Gasket and Front Servo
- Rear Oil Seal and Case Extension
- Front End Play Checking Procedure
- Oil Pump
- Disassembly of Gear Unit
- Overhaul of Major Units Governor Assembly
- Front Servo
- Rear Servo
- Control Valve Assembly
- Oil Pump
- Forward Clutch
- Direct Clutch and Intermediate Roller Center Support
- Inspection of Major Units
- Reaction Carrier. Roller
- Clutch and Output Carrier Assembly
- Output Shaft
- Rear Internal Gear
- Sun Gear
- Sun Gear Shaft
- Main shaft
- Front and Rear Bands
- Case Extension
- Modulator and Valve
- Manual and Parking Linkage
- Case Assembly
- Converter
- Reassembly and Installation of Transmission
- Rear Unit
- Assembly of Units into Transmission Case
- Case Extension Assembly
- Check Balls. Control Valve
- Spacer Plate & Gasket. Detent Solenoid.
- Front Servo Assembly and Electrical
- Connector
- Rear Servo Assembly
- Control Valve Assembly
- Governor Pipes and Screen Assembly
- Filter and Intake Pipe
- Modulator Valve and Vacuum Modulator
- Governor
- Speedometer Driven Gear
- Converter Assembly
- Transmission Assembly
- Specifications
- Transmission Identification
- Torque
- Special Tools
- MANUAL TRANSMISSIONS
- General Description
- 3-Speed 76mm Muncie Manual Transmission
- 4-Speed 76mm Muncie Manual Transmission
- 4-Speed 82mm Borg-Warner Manual Transmission
- 5-Speed 77mm Borg-Warner Manual Transmission
- Diagnosis
- Maintenance and adjustments
- On Car-Service
- Dismantle and Re Assembly of Units
- 3-Speed 76mm Muncie Manual Transmission
- 4-Speed 76mm Muncie Manual Transmission
- 4-Speed 82mm Borg-Warner Manual Transmission
- 5-Speed 77mm Borg-Warner Manual Transmission
- Specifications
- Special Tools
- Clutch
- General Description
- Diagnosis
- Maintenance and Adjustments
- On-Car-Service
- Clutch Pedal Replacement
- Clutch Cross Shaft Replacement
- Clutch Cable Replacement
- Unit Repair
- Clutch Assembly Replacement
- Pilot Bearing Replacement
- Special Tools
- CHASSIS AND BODY ELECTRICAL
- Wiring Harnesses
- Engine Wire Harness
- Front End Wire Harness
- Battery Cables
- Fuse Block and Bulkhead Connector
- Instrument Panel
- Instrument Panel Pad, Cluster and Attaching Parts
- Instrument Panel (Speedo) Cluster
- Printed Circuit
- Instrument Panel Wire Harness
- Instruments
- General Description
- Diagnosis
- On-Car Service
- Speedometer Cable
- Horn
- Lamps
- Headlamps
- All Other Front Bulbs
- Rear Bulbs
- Seat Belt Warning System
- Windshield Washer and Wiper System
- ACCESSORIES
-
General Description
- Diagnosis
- On-Car Service
- Cruise Control System
- Radio
-
AM-FM Stereo
- AM or AM-FM Stereo/Tape Player
- Digital Radio
- CB Radio
- CB Antenna
- Windshield Antenna
- Radio Suppression Equipment
- Antenna Lead-In
- Power Antenna
- Rally Gage. Tachometer and Clock
- Fuel Economy Indicator
- Tachometer
- Clock
- Digital Clock
- Trip Odometer
- Console
- Engine Block Heater
- Rear Window Defogger
- Trailer Wiring Harness
- Controlled Cycle Wiper Systems
- Right Hand Remote Control Rear View Mirror
- Luggage Compartment Lamp
- Deck Lid Release
- Dash Mounted Accessory Switches
PLEASE NOTE: This manual applies to all 1977 Pontiac Series and Models.
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Language: English
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