GM Metro/Sprint 1985-1993 Repair Guide

Component Replacement

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IGNITION COIL REPLACEMENT



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the coil wire from the coil by gripping the boot firmly. Turn the boot 1 / 2 turn while removing the coil wire.
  4.  
  5. Remove the coil cap by turning clockwise and pushing forward. Remove the coil electrical connector.
  6.  
  7. Remove the the coil by loosening the clamp screw.
  8.  

To install:
  1. Install the coil into the clamp and tighten the clamp screw securely.
  2.  
  3. Install the coil electrical connector.
  4.  
  5. Install the coil wire by pressing the boot on firmly.
  6.  
  7. Connect the negative battery cable.
  8.  

DISTRIBUTOR REPLACEMENT



See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the wiring harness at the distributor and the vacuum line at the distributor vacuum advance unit.
  4.  
  5. Remove the distributor cap.
  6.  

Mark the distributor body in reference to where the rotor is pointing. Mark the distributor hold-down bracket and cylinder head for a reinstallation location point.

  1. Remove the hold-down bolt and the distributor from the cylinder head. Do not rotate the engine after the distributor has been removed.
  2.  

To install:


Click image to see an enlarged view

Fig. Fig. 1: Correctly aligning the distributor shaft during installation.

  1. If the engine was not rotated proceed as follows:
    1. Align the reference marks on the distributor housing to the distributor hold-down bracket.
    2.  
    3. Install the distributor into the offset slot in the camshaft, then the hold-down bolt.
    4.  
    5. Connect vacuum hoses and electrical connectors to the distributor.
    6.  
    7. Install the distributor cap, then connect the battery negative cable. Check and/or adjust the ignition timing.
    8.  

  2.  
  3. If the engine was rotated while the distributor was removed, place the engine on TDC of the compression stroke to obtain the proper ignition timing.
    1. Remove the No. 1 spark plug.
    2.  
    3. Place thumb over the spark plug hole. Crank the engine slowly until compression is felt. It will be easier to have someone rotate the engine by hand, using a wrench on the crankshaft pulley.
    4.  
    5. Align the timing mark on the crankshaft pulley with the 0 degrees mark on the timing scale attached to the front of the engine. This places the engine at TDC of the compression stroke.
    6.  
    7. Turn the distributor shaft until the rotor points to the No. 1 spark plug tower on the cap.
    8.  
    9. Install the distributor into the engine. Be sure to align the distributor-to-engine block mark made earlier.
    10.  
    11. Install the No. 1 spark plug. Connect all vacuum hoses and electrical connectors to the distributor.
    12.  
    13. Install distributor cap, then connect the battery negative cable.
    14.  
    15. Check and/or adjust ignition timing.
    16.  

  4.  

PICK-UP COIL REPLACEMENT



See Figures 2, 3 and 4



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Fig. Fig. 2: Conventional spark control distributor - exploded view



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Fig. Fig. 3: Electronic ignition with knock control distributor - exploded view



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Fig. Fig. 4: Electronic spark advance distributor - exploded view

Except Electronic Ignition With Knock Control
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the distributor and place it in a suitable holding device.
  4.  
  5. Remove the distributor cap if not already removed.
  6.  
  7. Remove the rotor by pulling upward with a twist.
  8.  
  9. Remove the pick-up coil and module dust covers.
  10.  
  11. Disconnect the wires from the pick-up coil.
  12.  
  13. Remove the pick-up coil attaching screws.
  14.  
  15. Remove the pick-up coil.
  16.  

To install:
  1. Install the pick-up coil. Adjust the pole piece air gap to specification and tighten the attaching screws to 44 inch lbs. (5 Nm).
  2.  
  3. Connect the pick-up coil wires.
  4.  
  5. Install the dust covers.
  6.  
  7. Install the rotor
  8.  
  9. Install the distributor cap.
  10.  
  11. Install the distributor.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and adjust the ignition timing to specification.
  16.  

Electronic Ignition With Knock Control
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the distributor and place it in a suitable holding device.
  4.  
  5. Remove the distributor cap if not already removed.
  6.  
  7. Remove the rotor by pulling upward with a twist.
  8.  
  9. Remove the dust cover.
  10.  
  11. Using a puller remove the pole piece.
  12.  
  13. Disconnect the wires from the pick-up coil.
  14.  
  15. Remove the pick-up coil attaching screws.
  16.  
  17. Remove the pick-up coil and frame as an assembly.
  18.  
  19. Pry the pick-up coil and frame assembly apart.
  20.  

To install:
  1. Joint the pick-up coil and frame assemblies and install.
  2.  
  3. Install the pick-up coil. Adjust the pole piece air gap and tighten the pick-up coil attaching screws to 44 inch lbs. (5 Nm).
  4.  
  5. Connect the pick-up coil wires.
  6.  
  7. Install the pole piece using an appropriate driver.
  8.  
  9. Install the dust cover. Install the rotor
  10.  
  11. Install the distributor cap.
  12.  
  13. Install the distributor.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the engine and adjust the ignition timing to specification.
  18.  

CAP AND ROTOR REPLACEMENT



See Figures 5 through 9



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Fig. Fig. 5: Loosening the distributor cap attaching screws



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Fig. Fig. 6: Carefully remove the distributor cap taking care not to stretch the ignition wires or damage the rotor

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 7: After the distributor cap is removed the rotor is in plain sight



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Fig. Fig. 8: The rotor is removed by pulling with a slight twist

  1. Disconnect the ignition coil high tension wire at the coil.
  2.  
  3. Loosen and remove the 2 distributor cap attaching screws.
  4.  
  5. Carefully remove the distributor cap. Take care not to stretch the high tension spark plug cables or damage the rotor.
  6.  
  7. Remove the rotor by pulling with a slight twist.
  8.  

To install:
  1. Inspect the condition of the distributor cap. If the cap shows signs of cracks, broken pieces, carbon tracking, charred or eroded terminals, or a worn or damaged rotor button, replace it.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Distributor cap inspection

  1. Inspect the condition of the distributor rotor. If the rotor shows signs of cracks, broken pieces, a charred or eroded tip, physical contact of the tip with the cap or insufficient spring tension, replace it.
  2.  
  3. Apply a light coating of dielectric grease to the distributor cap terminals and rotor tip.
  4.  
  5. Install the rotor by aligning the flat on the rotor and shaft. Push the rotor until it bottoms on the shaft.
  6.  
  7. Check the condition of the distributor cap gasket and replace as necessary.
  8.  
  9. Install the distributor cap and tighten the attaching screws securely.
  10.  
  11. Reinstall the coil high tension wire at the coil.
  12.  

IGNITION MODULE REPLACEMENT



Conventional Spark Control Ignition
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the distributor and place it in a suitable holding device.
  4.  
  5. Remove the distributor cap if not already removed.
  6.  
  7. Remove the rotor by pulling upward with a twist.
  8.  
  9. Remove the pick-up coil and module dust covers.
  10.  
  11. Disconnect the wires from the ignition module.
  12.  
  13. Remove the module attaching screws from the outside of the distributor housing.
  14.  
  15. Remove the ignition module.
  16.  

To install:
  1. Install the ignition module. As necessary, adjust the pole piece air gap to specification and tighten the attaching screws to 44 inch lbs. (5 Nm).
  2.  
  3. Connect the ignition module wires.
  4.  
  5. Install the dust covers.
  6.  
  7. Install the rotor
  8.  
  9. Install the distributor cap.
  10.  
  11. Install the distributor.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and adjust the ignition timing to specification.
  16.  

 
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