Table Of Content

28800 m m s Covers all U.S. and Canadian mode*» ol Chovrolot Spectrum and Geo Storm xoaoc umr 3.1* torrents.ru expert22 ana http://rutracker.oro (8425) 28800 flFNM il MOTORS S T O R M /S P E C T R U M U b f iC n M L m V I v n w 1935-93 r e p a ir m a n u a l Covers all U.S. and Canadian m odels of Chevrolet Spectrum and Geo Storm expert22 fl/ia http://rutracker.org / 4 m S t f * ? 2 S 28800 1985-93 REPAIR MANUAL *7 & e *p ni a t S te fc *)e t T R .e fa z v i V > $ <$■ ffllBUUMOW Covers all U.S. and Canadian models of Chevrolet Spectrum and Geo Storm by Kevin M. G. Maher, a s.e. i t f j g f A u to /n o t/v e 1 # I V B o o k s PUBLISHED BY HAYNES NORTH AMERICA. Inc. ACXIsSSCKIIiS MFMRFP /VSSCCUTION MtMbtK Manufactured in USA © 1993 Haynes North America, Inc. ISBN 0-8019-8425-4 Library of Congress Catalog Card No. 92-054900 0123456789 9876543210 Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park 1 California 91320 USA 0F1 Chilton is a registered trademark of W.G. Nichols, Inc., and has been licensed to Haynes North America, Inc. expert22 /yia http://rutracker.org Contents 1-6 MODEL IDENTIFICATION 1-11 ROUTINE MAINTENANCE 1-6 SERIAL NUMBER 1-30 FLUIDS AND LUBRICANTS ROUTINE MAINTENANCE IDENTIFICATION 1-38 TRAILER TOWING 1-9 SPECIFICATIONS CHARTS 1-38 JACKING 2-2 2-14 TUNE-UP PROCEDURES IGNITION TIMING 2-2 2-16 ENGINE PERFORMANCE SPECIFICATIONS CHARTS VALVE LASH 2-6 2-20 FIRING ORDERS IDLE SPEED AND AND TUNE-UP 2-7 MIXTURE ADJUSTMENT ELECTRONIC IGNITION 3-2 ENGINE ELECTRICAL 3-21 ENGINE AND ENGINE ENGINE MECHANICAL 3-24 SPECIFICATIONS CHARTS REBUILDING 3-83 EXHAUST SYSTEM 4-3 EXHAUST EMISSIONS 4-23 SELF-DIAGNOSTICS 4-6 EMISSION CONTROLS 4-24 TROUBLE CODES EMISSION CONTROLS 4-14 ELECTRONIC ENGINE 4-25 DIAGNOSTIC CHARTS CONTROLS 4-198 VACUUM DIAGRAMS 5-2 CARBURETED FUEL SYSTEM 5-17 FUEL SYSTEM MULTI-PORT FUEL INJECTION SYSTEM 5-23 FUEL TANK 6-10 AIR BAG SYSTEM 6-25 WIPERS AND WASHERS 6-14 HEATER 6-27 INSTRUMENTS CHASSIS ELECTRICAL 6-17 AIR CONDITIONER 6-31 LIGHTING 6-22 CRUISE CONTROL 6-38 WIRING DIAGRAMS Contents 7-2 MANUAL TRANSAXLE 7-16 CLUTCH 7-17 DRIVE TRAIN AUTOMATIC TRANSAXLE 8-2 8-16 WHEELS STEERING 8-2 FRONT SUSPENSION SUSPENSION AND 8-9 SPECIFICATIONS CHARTS STEERING 8-10 REAR SUSPENSION 9-2 9-18 BRAKE OPERATING PARKING BRAKE SYSTEM 9.20 SPECIFICATIONS CHAFITS 9-9 FRONT DISC BRAKES BRAKES 9-13 REAR DRUM BRAKES 10-2 10 EXTERIOR 10-9 INTERIOR BODY AND TRIM 10-18 GLOSSARY GLOSSARY 10-23 MASTER INDEX MASTER INDEX SAFETY NOTICE Proper service and repair procedures are vital to the sate, reliable operation ol all motor vehicles, as well as the personal satety of those per forming repairs. This manual outlines procedures for servicing and repairing vehicles using safe, effective methods. The procedures contain many NOTES, CAUTIONS and WARNINGS which should be followed, along with standard procedures to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety. It is important to note that repair procedures and techniques, tools and parts for servicing motor vehicles, as well as the skill and experience of the individual performing the work vary widely. It is not possible to anticipate all of the conceivable ways or conditions under which vehicles may be serviced, or to provide cautions as to all possible hazards that may result. Standard and accepted safety precautions and equipment should be used when handling toxic or flammable fluids, and safety goggles or other protection should be used during cutting, grinding, chiseling, prying, or any other process that can cause material removal or projectiles. Some procedures require the use of tools specially designed for a specific purpose. Before substituting another tool or procedure, you must be completely satisfied that neither your personal safety, nor the performance of the vehicle will be endangered. Although information in this manual is based on industry sources and is complete as possible at the time of publication, the possibility exists that some car manufacturers made later changes which could not be included here. While striving for total accuracy, the authors or publishers cannot assume responsibility for any errors, changes or omissions that may occur in the compilation of this data. PART NUMBERS Part numbers listed in this reference are not recommendations by Haynes North America, Inc. for any product brand name. They are refer ences that can be used with interchange manuals and aftermarket supplier catalogs to locate each brand supplier’s discrete part number. SPECIAL TOOLS Special tools are recommended by the vehicle manufacturer to perform their specific job. Use has been kept to a minimum, but where absolutely necessary, they are referred to in the text by the part number of the tool manufacturer. These tools can be purchased, under the appro priate part number, from your local dealer or regional distributor, or an equivalent tool can be purchased locally from a tool supplier or parts out let. Before substituting any tool for the one recommended, read the SAFETY NOTICE at the top of this page. ACKNOWLEDGMENTS Portions of materials contained herein have been reprinted with the permission of General Motors Corporation, Service Technology Group. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, includ ing photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or pub lishers for loss, damage or injury caused by any errors in, or omissions from, the information given. FLUIDS AND LUBRICANTS EVAPORATIVE CANISTER 1-14 AUTOMATIC TRANSAXLE 1-33 FUEL FILTER 1-13 BODY LUBRICATION AND HOSES 1-19 MAINTENANCE 1-36 PCV VALVE 1-14 CHASSIS GREASING 1-35 TIRES AND WHEELS 1-28 COOLING SYSTEM 1-33 WINDSHIELD WIPERS 1-27 ENGINE 1-30 SERIAL NUMBER IDENTIFICATION FLUID DISPOSAL 1-30 ENGINE 1-8 FUEL AND ENGINE OIL TRANSAXLE 1-8 RECOMMENDATIONS 1-30 VEHICLE 1-6 MANUAL TRANSAXLE 1-32 VEHICLE CERTIFICATION LABEL 1-6 MASTER CYLINDER 1-34 SERVICING YOUR VEHICLE SAFELY POWER STEERING PUMP 1-34 DO’S 1-5 REAR WHEEL BEARINGS 1-36 DON’TS 1-6 HOW TO USE THIS BOOK 1-2 SPECIFICATIONS CHARTS JACKING 1-38 CAPACITIES 1-43 MODEL IDENTIFICATION 1-6 ENGINE IDENTIFICATION 1-10 PUSHING AND TOWING 1-38 TRANSAXLE IDENTIFICATION 1-11 ROUTINE MAINTENANCE VEHICLE IDENTIFICATION ACCESSORY DRIVE BELT(S) 1-18 CHART 1-9 AIR CLEANER 1-11 TOOLS AND EQUIPMENT AIR CONDITIONING SYSTEM 1-21 SPECIAL TOOLS 1-3 BATTERY 1-15 TRAILER TOWING 1-38 FLUIDS AND LUBRICANTS 1-30 HOW TO USE THIS BOOK 1-2 JACKING 1-38 MODEL IDENTIFICATION 1-6 PUSHING AND TOWING 1-38 ROUTINE MAINTENANCE 1-11 SERIAL NUMBER IDENTIFICATION 1-6 SERVICING YOUR VEHICLE SAFELY 1-5 SPECIFICATIONS CHARTS 1-9 TOOLS AND EQUIPMENT 1-3 TRAILER TOWING 1-38 1-2 ROUTINE MAINTENANCE HOW TO USE THIS BOOK Chilton’s Total Car Care Manual for the Chevrolet/Geo even if you can’t immediately see a reason for it. When you’re Spectrum and Storm is intended to help you learn more about taking apart something that is very intricate, you might want to the inner workings of your vehicle and save you money on its draw a picture of how it looks when assembled at one or more upkeep and operation. points in order to assure you get everything back in its proper The first two sections will be the most used, since they position. (We will supply exploded views whenever possible). contain maintenance and tune-up information and procedures. When making adjustments, especially tune-up adjustments, do Studies have shown that a properly tuned and maintained car them in order; often, one adjustment affects another, and you can get at least 10% better gas mileage than an out-of-tune cannot expect even satisfactory results unless each adjustment car. The other sections deal with the more complex systems of is made only when it cannot be changed by any other. your vehicle. Operating systems from engine through brakes 2. Overtorquing (or undertorquing): While it is more are covered to the extent that the average do-it-yourselfer common for overtorquing to cause damage, undertorquing can becomes mechanically involved. It will give you detailed cause a fastener to vibrate loose causing serious damage. instructions to help you change your own brake pads and Especially when dealing with aluminum parts, pay attention to shoes, replace spark plugs, and perform many more jobs that torque specifications and utilize a torque wrench in assembly. will save you money, give you personal satisfaction, and help If a torque figure is not available, remember that if you are you avoid expensive problems. using the right tool to do the job, you will probably not have to A secondary purpose of this book is a reference for owners strain yourself to get a fastener tight enough. The pitch of who want to understand their car and/or their mechanics most threads is so slight that the tension you put on the better. In this case, no tools at all are required. wrench will be multiplied many, many times in actual force on Before removing any bolts, read through the entire what you are tightening. A good example of how critical torque procedure. This will give you the overall view of what tools and is can be seen in the case of spark plug installation, especially supplies will be required. There is nothing more frustrating than where you are putting the plug into an aluminum cylinder having to walk to the bus stop on Monday morning because head. Too little torque can fail to crush the gasket, causing you were short one bolt on Sunday afternoon. So read ahead leakage of combustion gases and consequent overheating of and plan ahead. Each operation should be approached the plug and engine parts. Too much torque can damage the logically and all procedures thoroughly understood before threads or distort the plug, which changes the sp ark gap. attempting any work. There are many commercial products available for ensuring All sections contain adjustments, maintenance, removal and the fasteners won’t come loose, even if they are not torqued installation procedures and repair or overhaul procedures. just right (a very common brand is Loctite®). If you’re worried When repair is not considered practical, we tell you how to about getting something together tight enough to hold, but remove the part and then how to install the new or rebuilt loose enough to avoid mechanical damage during assembly, replacement. In this way, you at least save the labor costs. one of these products might offer substantial insurance. Read Backyard repair of such components as the alternator is just the label on the package and make sure the product is not practical. compatible with the materials, fluids, etc. involved. Two basic mechanic’s rules should be mentioned here. One, 3. Crossthreading. This occurs when a part such as a bolt whenever the left side of the car or engine is referred to, it is is screwed into a nut. or casting at the wrong angle and meant to specify the driver’s side of the car. Conversely, the forced. Crossthreading is more likely to occur if access is right side of the car means the passenger’s side. Secondly, difficult. It helps to clean and lubricate fasteners, and to begin most screws and bolts are removed by turning threading with the part to be installed going straight inward. counterclockwise, and tightened by turning clockwise. Then, start the bolt, spark plug, etc. with your fingers. If you Safety is always the most important rule. Constantly be encounter resistance, unscrew the part and start over again at aware of the dangers involved in working on an automobile a different angle until it can be inserted and turned several and take the proper precautions. (See the portion of this turns without much effort. Keep in mind that many parts, section on Servicing Your Vehicle Safely and the SAFETY especially spark plugs, use tapered threads so that gentle NOTICE on the acknowledgment page.) turning will automatically bring the part you’re threading to the Pay attention to the instructions provided. There are 3 proper angle if you don’t force it or resist a change in angle. common mistakes in mechanical work: Don’t put a wrench on the part until it’s been turned a couple 1. Incorrect order of assembly, disassembly or adjustment. of turns by hand. If you suddenly encounter resistance, and When taking something apart or putting it together, doing the part has not seated fully, don't force it. Screw it back out things in the wrong order usually just costs you extra time; and make sure it’s clean and threading properly. however in some cases it CAN damage components. Read the Always take your time and be patient; once you have some entire procedure before beginning disassembly. Do everything experience, working on your car will become an enjoyable in the order in which the instructions say you should do it, hobby. ROUTINE MAINTENANCE 1-3 TOOLS AND EQUIPMENT I See Figures 1, 2 and 3 maintenance, but only your personal needs and desire can accurately determine your list of tools. Naturally, without the proper tools and equipment it is The second list of tools is for tune-ups. While the tools impossible to properly service your vehicle. It would be involved here are slightly more sophisticated, they need not be impossible to catalog each tool that you would need to perform outrageously expensive. There are several inexpensive each or any operation in this book. It would also be unwise for tachometers on the market that are every bit as good for the the amateur to rush out and buy an expensive set of tools on average mechanic as a $100.00 professional model. Just be the theory that he may need one or more of them at sure that the meter goes to at least 1500 rpm on the scale sometime. and'that it can be used on 4, 6, or 8 cylinder engines. A basic The best approach is to proceed slowly, gathering together a list of tune-up equipment could include: good quality set of those tools that are used most frequently. 9. Tachometer. Don’t be misled by the low cost of bargain tools. It is far better 10. Spark plug wrench. to spend a little more for better quality. Forged wrenches, 6 or 11. Wire spark plug gauge/adjusting tools. 12-point sockets and fine tooth ratchets are by far preferable In addition to these basic tune-up tools there are several than their less expensive counterparts. As any good mechanic other tools and gauges you may find useful. These include: can tell you, there are few worse experiences than trying to 12. A compression gauge. The screw in type is slower to work on a car with bad tools. Your monetary savings will be use but it eliminates the possibility of a faulty reading due to far outweighed by frustration and mangled knuckles. escaping pressure. Begin accumulating those tools that are used most 13. A manifold vacuum gauge. frequently; those associated with routine maintenance and 14. A 12V test light. tune-up. 15. An induction meter. This is used for determining whether In addition to the normal assortment of pliers and or not there is current in a wire. These are handy for use if a screwdrivers, you should have the following tools for routine wire is broken somewhere in a wiring harness. maintenance jobs; As a final note, you will probably find a torque wrench 1. Metric and SAE wrenches, sockets and combination necessary for all but the most basic work. The beam type open end/box end wrenches in sizes from 3mm to 19mm, 1/s models are perfectly adequate although the newer click types in. to 3A in. and a spark plug socket (13/16 in. or % in. are more precise. depending on plug type). With Spectrum and Storm vehicles, you will most likely find that Metric tools are usually sufficient Special Tools or required for your purposes. If possible, buy various length socket drive extensions. One Normally, the use of special factory tools is avoided for break in this department is that the metric sockets available in repair procedures, since these are not readily available for the the U.S. will all fit the ratchet handles and extensions you may do-it-yourself mechanic. When it is possible to perform the job already have (V* in., % in., and % in. drive). 2. Jackstands for support. with more commonly available tools, it will be pointed out, but 3. Oil filter wrench. occasionally, a special tool was designed to perform a specific 4. Oil filler spout or funnel. function and should be used. Before substituting another tool, you should be convinced that neither your safety nor the 5. Grease gun for lubrication. 6. Hydrometer for checking the battery. performance of the vehicle will be compromised. Some special tools are available commercially from major 7. A container for draining oil. tool manufacturers. Others can be purchased from your 8. Many rags for wiping up the inevitable mess. In addition to the above items there are several other tools Chevrolet/Geo dealer or from the Kent-Moore SPX Corporation, 29784 Little Mack, Roseville, Ml 48066-2298. For fast service that are not absolutely necessary, but handy to have around. call the toll-free order line at 1-800-345-2233 Mon.-Fri. 8:00 'These include oil dry, a transmission funnel and the usual A.M-8:00 P.M. EST or Fax your order to 313-578-7375. supply of lubricants, antifreeze and fluids, although these can be purchased as needed. This is a basic list for routine