GM Metro/Sprint 1985-1993 Repair Guide



Repair information for 1985-93 Chevrolet Sprint and Geo Metro is intended to help you learn more about the inner working of your vehicle and save you money in it's upkeep and operation.

The first two segments will be the most used, since they contain maintenance and tune-up information and procedures. Studies have shown that a properly tuned and maintained vehicle can get at least 10% better gas mileage than an out-of-tune vehicle. Other information deals with the more complex systems of your vehicle. Operating systems from engine through brakes are covered to the extent that the average do-it-yourselfer becomes mechanically involved. This guide will give you detailed instructions to help you perform minor to major repairs on your vehicle that in turn will save you money, give you personal satisfaction and help you avoid expensive repair bills.

A secondary purpose of this guide is a reference for owners who want to understand their vehicle and/or their mechanics better. In this case, no tools at all are required.

Before removing any bolts, read through the entire procedure. This will give you the overall view of what tools and supplies will be required. There is nothing more frustrating than having to walk to the bus stop on Monday morning because you were short one bolt on Sunday afternoon. So read ahead and plan ahead. Each operation should be approached logically and all procedures thoroughly understood before attempting any work.

All information contains adjustments, maintenance, removal/installation and repair or overhaul procedures. When repair is not considered practical, we tell you how to remove the part and then how to install the new or rebuilt replacement. In this way, you at least save the labor costs. Backyard repair of some components is just not practical.

Two basic mechanic's rules should be mentioned: One, the left-side of the vehicle or engine is the driver's side. Conversely, the right-side of the vehicle means the passenger's side. Secondly, most screws and bolts are removed by turning them counterclockwise and tightened by turning them clockwise.

Safety is always the most important rule. Constantly be aware of the dangers involved in working on a vehicle and take the proper precautions. (See the information, Servicing Your Vehicle Safely and the SAFETY NOTICE on the acknowledgment page). Pay attention to the instructions provided.

There are 3 common mistakes in mechanical work:

  1. Incorrect order of assembly, disassembly or adjustment: When taking something apart or putting it together, doing things in the wrong order usually costs extra time, however, it CAN break something. Read the entire procedure before beginning disassembly. Do everything in the order in which the instructions say you should do it, even if you can't immediately see a reason for it. When you're taking something apart that is very intricate (for example, a carburetor), you might want to draw (or take) a picture of how it looks when assembled at one point, in order to make sure you get everything back in its proper position. (We will supply exploded views whenever possible). When making adjustments, especially tune-up adjustments, do them in order. Often, one adjustment affects another and you cannot expect satisfactory results unless each adjustment is made only when it cannot be changed by any other.
  3. Overtorquing (or undertorquing): While it is more common for overtorquing to cause damage, undertorquing can cause a fastener to vibrate loose causing serious damage. Especially, when dealing with aluminum parts, pay attention to torque specifications and utilize a torque wrench during assembly. If a torque figure is not available, remember that by using the right tool for the job, you will probably not have to strain yourself to get a fastener tight enough. The pitch of most threads is so slight that the tension you put on the wrench will be multiplied many times (in actual force) on the fastener you are tightening. A good example of how critical torque is can be seen in the case of spark plug installation, especially where you are putting the plug into an aluminum cylinder head. Too little torque can fail to crush the gasket, causing leakage of combustion gases and consequent overheating of the plug and engine parts. Too much torque can damage the threads or distort the plug, which changes the spark gap.

There are many commercial products available for ensuring that fasteners won't come loose, even if they are not torqued just right (a very common brand is Loctite®). If you're worried about getting something together tight enough to hold but loose enough to avoid mechanical damage during assembly, one of these products might offer substantial insurance. Read the label on the package and make sure the product is compatible with the components involved before choosing one.

  1. Crossthreading: Crossthreading occurs when a part such as a bolt is screwed into a nut or casting at the wrong angle. It is more likely to occur if access is difficult. To help prevent crossthreading, clean and lubricate the fasteners, then start threading with the part to be installed going straight in. Start the bolt or spark plug with your fingers. If you encounter resistance, unscrew the part and start over again at a different angle until it can be inserted and turned several turns without much effort. Keep in mind that many parts, especially spark plugs, use tapered threads so that gentle turning will automatically bring the part you're threading to the proper angle if you don't force it or resist a change in angle. Don't put a wrench on the part until it's been turned a couple of turns by hand. If you suddenly encounter resistance, and the part has not been fully seated, don't force it. Pull it back out and make sure it's clean and threading properly.

Always take your time and be patient. Once you have some experience working on your vehicle, it will become an enjoyable hobby.