TEMPEST SHOP MANUAL 1961 PONTIAC 3 SUSPENSION 3-1 3A WHEELS AND TIRES 3A-1 5 BRAKES ENGINE MECHANICAL 6-i. 6B ENGINE FUEL 6B-i

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2 1961 PONTIAC TEMPEST SHOP MANUAL GENERAL This shop manual applies to 1961 Pontiac Tempest models. It contains information on all components of the car with the exception of the air conditioning system which will be covered in a separate manual. This manual was prepared prior to the initial Tempest pro duction and includes all pertinent information available at time of preparation. A second edition will be released as soon as possible after the start of production. CONTENTS Arrangement of the material is shown by the table of contents on the right-hand side of this page. Black tabs on the first page of each section can be seen on the edge of the book below the section title. More detailed table of contents precedes each section, and an index is included in the back of the manual. AIR CONDITIONING CAUTION It is extremely important that proper methods and precautions be observed when disconnecting any refrigerant lines or units. Check information published concerning air conditioning prior to performing operations of this nature. Failure to observe this caution may result in injury to personnet or cause extensive damage to the air conditioning system. PONTIAC MOTOR DIVISION GENERAL MOTORS CORPORATION PONTIAC 11, MICHIGAN S-6104 TP SEPTEMBER 1960 Litho in U. S. A. Table of Contents SEC TION TITLE PAGE GENERAL INFORMATION 2 GENERAL LUBRICATION 3 SUSPENSION 3-1 3A WHEELS AND TIRES 3A-1 A REAR AXLE AND PROPELLER SHAFF 5 BRAKES ENGINE MECHANICAL 6-i LA Wi ENGINE COOLING AND LUBRICATION 6B ENGINE FUEL 6B-i 6C ENGINE TUNE-UP 6C-1 6D ENGINE CLUTCH 6D-i 7 STANDARD TRANSMISSION 7-1 7A AUTOMATIC TRANSMISSION 7A-i 8 FUEL TANK AND EXHAUST STANDARD STEERING 9-1 9A POWER STEERING 9A-i 10 CHASSIS SHEET METAL OA BODY 1OA-i ELECTRICAL AND 1 INSTRUMENTS 11 i 12 ACCESSORIES 12-i 13 INDEX 13-1 A September 1960 Pontiac Motor Division, General Motors Corp.

3 PONrIAC TEMPEST SHOP MANUAL GENERAL INFORMATION CONTENTS OF THIS SECTION SUBJECT Vehicle Identification Plate Body ldenhhclltion Plate PAGE SUBJECT I-fl Misccllancuus Data I-fl General Specifications PAGE I-i 1-2 GENERAL INFORMATION General information and cncral spccificafions ap prar in this section. Detailed specifications are given on major units at the end of each section of this manual. VFHICEE IDFNTJFJCATION PiMP Serial, assembly plant and model year identifica ban can be made from thc Manufacturer s Motor Vchiclc ldcnfihcation Number Plate. This plati is a mc tel strip we ci is fastened to the left front hinc pillar post, visible when the left front door i open. The plate has cmbosscd numcrals as showti in Fig. 11. SCOY IDINrIFICAflON PLATE Identification as to body style, body number, trio, and paint is eerricd on a plete Fig. 1-3 attached to the left ride of the cowl just under thc rcar tdge of the hood. SEP IES DENTPFICA11ON NUMSERS - I 21 AtL NUMEERS START WITh I 1001 FOR each PReFIX COMBINA7IOH // I 0p o NT AC/i] 0 /0 It P 1001 / MODEt YEAR ASSRMSLY PIANI P ONTIAC SSDUTH GATe MODeL 21 }75E0 PO=PONILAC YEAS 2l35sTA11OM wkgon S&sOEJrH GATE JoNTIACIDIv. GENERAL MOTORSsCORP. ItONTIAC, MIcHdGM7 STYL 6lO BODY P0-000 TRIM 000 PAINT 00 ACC THIS CAR FINISHED WITH *_ 2r-2a-. ACTYEJC LACQUER body BY FIShER rig. I-i Vehicle IdeMificohion Plole Fiç. 1-2 ody Idenliflcation Plate Pontioc Tenipset Station Wagon, Series 2135

4 GENERAL INFORMATION I Pontiac Tempest Sedan. Series 2119 RELATION OF CAR SPEED TO ENGINE RPM CAR SPEED MPH. REAR WHEEL R.P.M. ENGINE R.P.M. FOR AXLE RATIOS AND GIVEN TIRES 3.3! c S S SO *51 380! j ! AXLE RATIO 6.OOxlS RATIO* TIRE SIZE 6.SOxIS 3.3! SI., = Eogine R.P.M. V = Car Spttd MPH.

5 C PONTIAC TEMPEST SHOP MANUAL GENERAL SPECIFICATIONS DIMENSION KEY 2119 SEDAN 2135 STATION WAGON Over-all length F 189.3" 189.3" Width A 72.2" 72.2" Height with Passengers C 53.5" 54.3" Wheelbase D 112" 112" Tread Front B 56.5" 56.5" Rear G 56.5" 56.5" Turning Circle Curb to Curb Road Clearance 6.0" 6.0" Overhang rear E 45.7" 45.7" Tire Size 6.00 x x 15 Ramp Angle I I I t:._5...i::i:ii:iiiijl LU a U G -ii1-j7

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7 GENERAL LUBRICATION CONTENTS OF THIS SECTION SUBJECT PAGE SUBJECT PAGE Chassis and Body Lubrication Engine Crankcase Engine Electrical Starting Motor Distributor Engine Fuel Carburetor Air Cleaner Manifold Heat Valve Transmission Automatic Synchromesh Clutch Release Bearing Clutch Linkage Gear Shift Controls Speedometer Drive Cable Generator Universal Joints Front Suspension Wheel Bearings Ball Joints Shock Absorbers Rear Suspension Differential Shock Absorbers Wheel Bearings Steering Steering Gear Power Steering Brakes Master Cylinder Cables Battery Body CHASSIS AND BODY LUBRICATION Pontiac Tempest cars should be lubricated period ically see Figures 2-1 and 2-2 to retain all the builtin value. Experience has shown that the need for this vital service varies according to the conditions under which the car is driven. WHEN TO LUBRICATE For normal driving conditions, lubrication is recom mended every 2,000 miles. This applies to all models with the exception of those driven under the condi tions described below. DRIVING OVER ROUGH AND DUSTY ROADS When the car is driven over rough or dusty roads, more frequent lubrication might be necessary. Fig. 2-2 Power Steering Lubrication Points DRIVING IN SLUSH, WATER OR MUDDY ROADS Cars driven through slush, water or muddy roads should be lubricated at more frequent intervals, due to the washing effect of the water on the lubricant in front suspension parts and the clutch and brake pedal shafts. LOW MILEAGE DRIVING Some cars are driven very little and accumulate mileage slowly. It is good practice to lubricate these cars every 1,000 miles. HIGHMILEAGE DRIVING Cars operated over 500 miles per week under favor able conditions should be lubricated once a month. ENGINE CRANKCASE The terms "For Service ML", "For Service MM"

8 PONTIAC TEMPEST SHOP MANUAL Atmospheric Temperatures S.A.E. Numbei Acceptable Expected Recommended Multigrade 10 F. 110 F. 20W 1OW F. below zero to 95 above zero low 1OW F. below zero and colder 5W 5W-20 NOTE: Petroleum based oils which are identified as "For Service MS or DG" ore recommended for the Pontiac Engine. Summer- White,- with avg. with avg. Favorable daytime temp. daytime temp. Operations over 32 F.- Dusty below 32 F.- Over JO ml. Short trips Conditions Short trips avg/trip less than JOmi. avg/trip less than TOm. avg/trip Every Every Every Every 4,000 miles 2 months 1,000 miles month Fig. 2-3 Engine Oil Chart Fig. 2-4 Oil Change Intervals and "For Service MS or DG" are used by the oil industry to designate the types of engine oil supplied to meet the requirements of various service conditions Petroleum based engine oils of type MS or DG, as supplied by reputable marketers, are suitable for use in Pontiac Tempest engines. S.A.E. OIL NUMBER SYSTEM The numerical designations such as low, 20W and 20, etc., adopted by the Society of Automotive Engi neers, classify lubricating oil only according to Fluid ity viscosity. The oils with the lower numbers are lighter and flow more readily than do the oils with the higher numbers. The letter "W" after the number indicates an oil adapted for cold weather starting. Multi-viscosity type crankcase oils such as 5W-20, 1OW-20, and 10W-3D are designed to combine the easy starting characteristics of the low number with the warm weather operating characteristics of the higher number. SELECTING OIL OF THE PROPER NUMBER An oil should be used which provides safe lubrica tion, satisfactory oil economy under warm climatic conditions, and easy starting at the lowest atmospheric temperatures expected during the period the oil is to remain in the engine. Based on these considerations, the numbers of engine oil which are recommended for the Pontiac Tempest engine under various climatic conditions are shown in Fig. 2-3 above. OIL CHANGERECOMMENDATIONS After the first 1,000 miles of driving, the original SAE low heavy duty breakin oil should be drained from the engine and the crankcase refilled with oil as rec ommended in Fig. 2-3 and 2-4. Every 4,000 miles thereafter under favorable operating conditions over 10 miles average per trip, drain and refill the engine in the same manner. Adverse driving conditions, such as short trip winter driving less than 10 miles average per trip, makes it advisable to change oil every month. Similar short trips in the summer make it advisable to change oil every two months. It is always advisable to drain the crankcase only after the engine is thoroughly warmed. The benefit of draining is lost, to a large extent, if the crankcase is drained when the engine is cold as the oil will be thick and will not drain properly. The crankcase refill capacity is 4 quarts except when the oil filter cartridge is changed. The refill capacity with an oil filter cartridge change is 5 quarts. OIL FILTER DISPOSABLE TYPE A full flow oil filter is optional on Pontiac Tempest 4 cylinder engines and standard on the V-8 engines. This filter removes harmful particles of dirt, grit or other foreign materials before they can cause undue engine wear by embedding themselves in bearing sur faces or otherwise harmfully affect engine performance. The filter cartridge should be replaced once yearly or every 15,000 miles, whichever occurs first. ADDING OIL BETWEEN CHANGES Since the lubrication system in a Pontiac Tempest is a full pressure system, it is not necessary to keep oil level up to the "FULL" mark on the dipstick. It is only necessary to keep oil level above "ADD OIL" mark. It takes two quarts to bring the oil level from "ADD OIL" to "FULL" mark. Each time the gas tank is filled, the oil level should be checked. How ever, it is good economy to let the oil level approach the "ADD OIL" mark before having oil changed. CAUTION: Do not overfill. CRANKCASE VENTILATOR The crankcase breather element, built into the oil filler cap, should be cleaned at 2,000 miles intervals, oftener in dusty areas.

9 GENERAL LUBRICATION 2-3 Clean oil filler and ventilator cap filter by plunging up and du ;i several times in a can of kerosene or other suitable solvent. Re-oil element by dipping in engine nil and allowing to drain thoroughly. GENERATOR ENGINE ELECTRICAl. At eaeh lubrication perioti. fill the oil cup with engine oil CAUnON: Do nsf oil wuhi engine runnieg. STARTING MOTOR No lubrication required except on overhaul. When overhauling starting motor add few drops of engine oil to the bronze bushings in both end frames. DISTRIBLITOR-4 CYLINDER ENGINE The hinge cap oiler slcould be filled with S.A.E. 20 oct at each Iuhrication. When replacing contact points add a trace of special Cam and Ball Bearing Lubri Est to the lire a ker cam- No other lubrication is re - quired Contact points should be completely free of lubricant at all Ln,es. ENGINE CARnURETOR AIR ClEANER FUEL POLYURETHANE AIR CLEANER Vash element in kerosene. sqtteczc dry, dip In S.A.E. low-al oil, squeere dry to remove excess oil and re-install every 15,000 miles or yesrly. DO NOT WRING DRY. Clean mote often under severe dust conditions. FUEL FILTER IOISPOSA8LE TYPEI The disposable type fuel filter assembly should replaced at 10,000 mile intervals or yearly. FUEL FILTER EINTIGRAL TYPE-ONE BARflL ONEVI The integral filter, 1 c a ted in the fuel inlet of the carburetor, shou!d be cleaned twice yearly and re placed after 15,000 miles. Replace oftener if flooding UI VSPOt lock occurs. MANIFOlD HMT CONTROL VALVE-4 CYLINDER ENGINE CE cek lies L Va VC in ti h bank manifold for free dma of movement: if sticking, lubricate hushing with graphite in alcohol. TRANSMISSION AUTOMATIC TRANSMISSION Automatic Transmission Fluid Type "A" with an AQ-ATF-A number recommended for use in the automatic transmission. However, if this type of fluid is not available, it is permissible to use automatic transmission fluid Type A! th an AQ-ATF num ber. Refill capacity 5 pints. The leni may be checked through the access hole in the rear compart ment Fig be STANDARD AIR CLEANER The carburetor standard air cleaner should be serv iced in the spring and fall or every 10,000 milesunder extremely dusty conditions service eveiy miles or oftener. Followisig is the coirce t cleaning proced ore Remove filter etc men from carburetor sir clcancr. 2. Clean clement by plunging up and down in a can of gasoline or kerosene. - It e - oil ci esnesit by dipping in engine oil and a lowing excess o I to dra in off before assembly. 4. Clean dirt nut of element seat in silencer body 5551 n assemble. Fig. 7-5 Au!onloEit Transmission Access Hole

10 PONTIAC TEMPEST SHOP MANUAL SYNCHROMESH An SAE 80 or 90 "Multi-Purpose" gear lubricant must be used in the Synchromesh transmission. CAUTION: Straight Mineral Oil gear lubricants or any "active sulpher soap" lubricants must not be used. c. Then feed cable through lubricant in hand and into casing until the lubricant has been applied to the lower two-thirds of cable. Do not over lubricate and do not apply lubricant to upper third of cable, since operation of cable assures adequate lubrication of the upper third and at the same time prevents lubricant from seeping into the speedometer head. The SAE 80 or 90 viscosity grade is recommended for year around use. Refill capacity is 2.8 pints. UNIVERSAL JOINTS CLUTCH RELEASE BEARING The clutch release bearing requires no periodic lu brication. It is a ball bearing, lubricated and sealed with enough lubricant for life. The universal joints are of the roller bearing type and are packed with lubricant at the factory. Every 25,000 miles the universal joints should be disassem bled, cleaned and packed with high melting point wheel bearing grease. More frequent lubrication is not necessary and is not recommended. CLUTCH LINKAGE Use engine oil on all moving parts of the clutch linkage. Spherical joint at fork should be lubricated with wheel bearing grease. The clutch countershaft on V-8 engine cars should be lubricated with chassis lubricant. GEARSHIFT CONTROL The lower cover of the assembly housing the gearshift lever should be removed every 10,000 miles and wheel bearing grease placed in the socket which holds the lower gearshift lever ball. SPEEDOMETER DRIVE CABLE Lubricate speedometer cable when dry. In some cases the lubricant placed in the conduit at the factory may become dry causing a slight binding of the cable. A dry cable will usually be noticeable by wavering of the speedometer needle. A very dry cable, of course, will be noisy. When lubricating the speedometer cable, first remove it from the top. To insure quiet cable operation, apply suitable speedometer cable lubricant on lower two-thirds of cable and assemble in casing in the following manner: a. Wipe cable clean using lint free cloth. Flush bore of casing with oleum spirits or suitable solvent solution and blow dry with air under pressure. b. Place 1" of suitable speedometer cable lubricant in palm of the hand. FRONT WHEEL SUSPENSION BEARINGS Front wheel bearings require no periodic lubrica tion. They should be lubricated only when it is neces sary to remove wheels for other work, such as brake relining. The bearings should then be thoroughly cleaned and packed with high melting point water re sistant wheel bearing lubricant. The spindle should be coated and the I.D. of the seal. If wheel bearings are found to be discolored - turned blue or straw colored-it does not indicate that they have been over heated due to lack of lubricant. This discoloration is merely a chemical reaction of substances in the lubri cant and does not affect the serviceability of the bear ing in any manner. Wheel bearings that are not prop erly adjusted, i.e., too tight or too loose, are usually the cause of wheel bearing failure. BALL JOINTS The upper and lower control arm balls should be lubricated every 2,000 miles with chassis lubricant. SHOCK ABSORBERS Give visual inspection for leaks and jounce car at each lubrication period to see that shock absorbers are in operative condition. If inoperative or if leaks are found, the unit should be replaced.

11 GENERAL LUBRICATION 2-5 REAR SUSPENSION DIFFERENTIAL An SAE 80 or 90 "Multi-Purpose" gear lubricant must be used in the differential assembly. CAUTION: Straight Mineral Oil gear lubricants or any "active sulpher soap" lubricants must not be used. The SAE 80 or 90 viscosity grade is recommended for year around use. Refill capacity is 3 pints. WHEEL BEARINGS The rear wheel bearings require no periodic lubri cation. SHOCK ABSORBERS Give visual inspection for leaks and jounce car at each lubrication period to see that shock absorbers are in operative condition. If inoperative or if leaks are found, the unit should be replaced. STEERING STEERING GEAR Lubricant change is not necessary unless the unit is disassembled for repair. At each chassis lubrication, unit should be checked for leaks. If there is evidence of leakage from the steering gear, the leak should be corrected and steer ing gear lubricant added to bring to proper level. If unit does not leak it is only necessary to check level once yearly preferably in the fall. POWER STEERING It is not necessary to change fluid unless the unit is disassembled for repairs. However, if there are any leaks in the system they should be corrected and the fluid level checked. Add recommended Hydra-Matic fluid to bring level up to mark near top of reservoir. In an emergency, a good grade of S.A,E. low oil may be used, but should be replaced with specified fluid as soon as possible. added as needed. Otherwise fluid level should be checked at the time of brake adjustment. When adding fluid, bring level to 1" from gasket surface of filler neck as instructed in Brake Section of this manual. NOTE: Always use heavy duty brake fluid which meets the S.A.E. 70R3 specifications. CABLES Brake cables should be lubricated yearly prefer ably in the fall or when the rear wheels and drums are off to replace brake shoes and linings or to make a major adjustment. "Autolube A" Lubriplate, Delco Brake Lubricant, Bendix Brake Lubricant or equiva lent, recommended. NOTE: Chassis lubricant should be used every 2,000 miles as shown in Fig Lubricate as follows: 1. Thoroughly clean cable, from conduit to cable equalizer. 2. Remove retainer at forward end of conduits. 3. Unhook parking brake cable at equalizer Fig Unhook cable from parking brake lever assembly in drum and remove cable from backing plate. 5. Slide the conduit forward on the brake cable. 6. Clean the cable, examine for broken strands, and apply "Autolube A" Lubriplate, Bendix Brake Lubricant, Delco Brake Lubricant to the cable, or equivalent. 7. Inspect cable connections to hand brake actuat ing lever to be certain cable is seated in lever hook. 8. Slide brake cable conduit back in position and secure at forward end with retainer. BRAKES MASTER CYLINDER If there is evidence of leakage in the brake hydrau lic system, the leak should be corrected and fluid Fig. 2-6 Parking Brake Cable Equalizer

12 PONTIAC TEMPEST SHOP MANUAL 9. Install brake cable in backing plate and secure "Autolube A" Lubriplate or equivalent. to lever assembly. 10. Connect parking brake at equalizer and adjust DOOR HINGE as described in Section 5. Apply light engine oil when dry. BATTERY DOOR AND REAR DECK LOCKS Observe liquid level. If low, add distilled or "de- mineralized" water to bring level to bottom of vent Whenever it becomes difficult to insert the key into the lock, a small amount of powdered graphite should be blown into the lock cylinder. well. Inspect top of battery and retainer. If damp or corroded, clean with soda solution or diluted am- HOOD LATCH AND SAFETY HOOK monia water; dry thoroughly. Check the specific gravity of the battery. The battery should be kept at or near a full charge t all Apply light engine oil to hinge pins and "Auto lube A" Lubriplate or equivalent to latch and safety hook friction surfaces. times hydrometer reading. This is espe cially important in cold weather when the demands HOOD HINGE on the battery are high. A battery can freeze in ex treme cold if it is not in a fully charged condition. Apply light engine oil when dry. CAUTION: Battery fumes are inflammable and FUEL TANK DOOR toxic. Apply light engine oil to hinge pin. BODY REAR DECK LID LOCK BOLT DOOR LOCK AND STRIKER Spring and fall or every 10,000 miles apply "Auto Wipe lock and striker parts clean and apply a light coat of stick-type lubricant to the mating surfaces lube A" Lubriplate or equivalent to lock bolt which contacts lock striker. of the rotary lock bolt and the striker teeth of each door. Clean off excess lubricant. TAIL GATE HINGES CAUTION: Do not use oil. Apply light engine oil to rear gate hinges. slot in deck lid DOOR HINGE HOLD OPEN SPRINGS STATION WAGON FOLDING SEAT AND STRAPS Apply "Autolube A" Lubriplate or its equivalent Coat front door hinge hold open springs and fric- to the frictional area of the folding rear seat back tion surface on rear door hold open straps with support assembly. Wipe off all excess lubricant.