PONTIAC 1977 Sunbird, Astre, Ventura Workshop Manual | PDF Download

PONTIAC 1977 Sunbird, Astre, Ventura Workshop Manual | PDF Download

Easy 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 Sunbird
• Pontiac Astre
• Pontiac Ventura

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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