Service Procedure
NOTICE: Many of the the procedures in this bulletin may also be found in the 1989 Geo Metro Service Manual sections 6 through 6E2. If further clarification or detail is required, these sections may be helpful.1. Determine which emission system is installed on vehicle by inspecting the vehicle emission control information label on underside of the engine compartment hood panel.
a. If information label indicates California emission system is installed and the state in which the vehicle is licensed/registered IS CALIFORNIA, no correction action is required. Install Campaign Identification Label and return vehicle to customer or to dealer stock.
b. If information label indicates California emission system is installed and the state in which the vehicle is licensed/registered IS NOT CALIFORNIA, corrective action is required to convert emission system from California to Federal. Follow procedure appropriate to vehicle model designation shown in VIN positions 4 and 5.
Vehicle Model Designations
MS - Metro MR - Metro LSi
For MR models only:
2. Relieve fuel pressure.
a. Place gearshift lever in "Neutral" (Manual Transmission) or "Park" (Automatic Transmission), set parking brake and block front (drive) wheels.
2. (Con't)
b. Remove fuel pump relay from underhood relay center located in front of the drivers side strut tower. Disconnect relay electrical connector.
c. Start engine and allow to stall.
d. Remove fuel filler cap.
e. crank engine an additional 30 seconds to remove any residue fuel in pressure line.
f. Disconnect negative battery cable.
3. Remove throttle body.
a. Remove air cleaner assembly.
b. Drain engine coolant.
c. Disconnect the following electrical connectors:
- Throttle switch (manual transmission) or throttle position sensor (automatic transmission).
- Fuel injector electrical connector.
- Coolant temperature sensor.
d. Disconnect the following hoses at the throttle body:
- Fuel feed and return hoses (2).
NOTICE: Use a shop towel to catch any fuel left in the fuel lines during removal of fuel lines.
- Engine coolant hoses (2).
- Various vacuum hoses.
e. Disconnect accelerator cable.
f. Disconnect throttle body attaching fasteners (4).
g. Remove throttle body and old gasket.
4. Remove intake manifold.
a. Disconnect the following electrical connectors at the intake manifold:
- EGR valve vacuum switching valve solenoid.
- ISC solenoid valve.
- Instrument panel temperature gauge.
b. Disconnect the following vacuum hoses at the intake manifold:
- Canister purge hoses (2).
- PCV valve hose.
- Brake booster hose.
c. Disconnect engine coolant hoses (2).
d. Disconnect ground wires (3).
e. Remove EGR valve VSV bracket assembly.
f. Remove intake manifold fasteners.
g. Remove intake manifold.
5. Remove distributor:
NOTICE: Before removing distributor, # 1 piston should be set at top dead center (TDC) and timing marks should indicate zero (0) degrees on front cover.
a. Disconnect three (3) spark plug wires at distributor cap.
b. Disconnect coil wire at distributor.
c. Disconnect two (2) vacuum hoses at distributor.
d. Disconnect electrical connector.
e. Remove two (2) fasteners holding distributor to the cylinder head.
f. Remove distributor.
6. Clean cylinder head of any remaining gasket material left by the intake manifold.
7. Transfer components from old intake manifold to new intake manifold.
a. Remove the following from the old intake manifold:
- Throttle body attaching studs (2).
- Bimetal vacuum switch valve for canister.
- Instrument panel temperature gauge sensor.
- Vacuum fuel vapor filter.
- PCV valve assembly.
- ISC solenoid valve and bracket assembly.
b. Install the following on the new intake manifold:
- Throttle body attaching studs (2).
- Bimetal vacuum switch valve for canister using a thread sealant.
- Instrument panel temperature gauge sensor using a thread sealant.
- Vacuum fuel vapor filter using a thread sealant.
- PCV valve assembly using two (2) fasteners previously removed.
- ISC solenoid valve and bracket assembly.
8. Install new intake manifold.
a. Install new intake manifold gasket to cylinder head.
b. Install intake manifold to cylinder head.
c. Install six (6) fasteners to intake manifold. Tighten the fasteners from the center of the intake manifold out to 23 N-m (17 lb.ft.).
d. Connect canister purge hoses (2).
e. Connect engine coolant hoses (2).
f. Connect PCV valve hose.
g. Connect brake booster hose.
h. Reconnect the following electrical connectors:
- ISC solenoid.
- Instrument panel temperature gauge.
- Three (3) ground wires.
NOTICE: The three (3) ground wires were originally attached to the lower back part of the intake manifold. The wires must now be rerouted to the right side runner of the new intake manifold. Also, the EGR VSV electrical connector should be taped back to the wiring harness.
9. Install new throttle body.
a. Install new throttle-body-to-intake-manifold gasket onto new throttle body unit.
NOTICE: Be sure all of the old throttle body gasket has been removed before installing the throttle body to the intake manifold.
b. Install throttle body to intake manifold.
c. Install throttle body attaching fasteners (4). Tighten to 2.0 N-m (18 lb.in.).
d. Connect accelerator cable to throttle lever and bracket.
e. Connect two (2) fuel feed and return hoses.
f. Connect coolant lines.
g. Connect various vacuum lines except for lines to the three front connectors of the throttle body. These lines will be connected in steps 10g - 10m.
h. Connect the following electrical connectors:
- Coolant temperature sensor.
- Fuel injector.
- Throttle switch (manual transmission) or throttle position sensor (automatic transmission).
10. Install new distributor.
a. Align distributor shaft drive gear mark with distributor housing marks.
b. Install distributor to cylinder head.
C. Install two (2) flange bolts and tighten.
d. Connect electrical connector.
e. Connect three (3) spark plug wires.
f. Connect coil wire.
g. Connect new 380 mm length vacuum hose (Fig. 1, # 3) from vacuum controller (distributor) top connection (furthest away from distributor body) to gas filter (Fig. 1, # 6 - vacuum source at intake manifold).
h. Connect new 280 mm length vacuum hose (Fig. 1, # 2) from vacuum controller (distributor) bottom connector (closest to distributor body) to center connector of 3 connectors on the front of TBI.
i. Attach both 280 mm (Fig. 1, # 2) and 380 mm (Fig. 1, # 3) vacuum hoses to the intake manifold near extreme left hand side (driver side) using vacuum hose clamp (Part # 96055329 - Fig. 1, # 4) provided in kit and bolt previously removed.
j. Attach 380 mm vacuum hose (Fig. 1, # 3) to PCV hose from cylinder head cover with PCV and vacuum hose clip (Part # 96056807 - Fig. 1, # 5) provided in kit.
k. Connect hose (existing) from evaporative canister to left hand (driver side) hose connector of 3 connectors on the front of TBI.
l. Attach evaporative canister hose to 280 mm vacuum hose (Fig. 1, # 2) using clip (Fig. 1, # 7) previously removed.
m. Install vacuum plug (Part # 96051388 - Fig. 1, # 1) provided in kit to the right hand (passenger side) hose connector of three connectors on front of throttle body.
For MS and MR models:
11. Replace ECM.
NOTICE: For MS vehicles, it is first necessary to disconnect the negative battery cable prior to proceeding with the ECM replacement. This cable was disconnected on MR vehicles in Step 2f.
a. Remove passenger compartment fuse block located left of steering column.
b. Remove 3 fasteners holding ECM to bracket.
11. (Con't)
c. Disconnect ECM connector.
d. Remove ECM.
e. Install new ECM (Use part listed in "PARTS INFORMATION" section of this bulletin which is appropriate to the vehicle model and transmission type).
f. Connect ECM connectors.
g. Reinstall three (3) fasteners and tighten securely.
h. Reinstall fuse block to mounting bracket.
12. Reconnect negative battery cable.
13. Install new emission control information label in place of existing label.
For MR models only:
14. Install air cleaner assembly to throttle body.
NOTICE: Remove EGR valve modulator bracket from air cleaner body prior to installation.
15. Replenish coolant.
16. Set ignition timing per new underhood emissions label.
For MS and MR models:
17. Install Campaign Identification Label.