Pontiac Firefly / Chevrolet Metro 2000 Service Manual Collection

The GM sections provide component-service procedures; companion Mitchell articles add mechanical repair, system tests, and wiring information, with 2005 copyright and 2009 print timestamps. Use the application printed on each file when selecting a procedure, particularly for the earlier engine and transmission chapters.

Coverage differences: This is a collection of service-information extracts, not one continuous factory book. The Firefly name appears in the 2000 GM sections; companion headers identify Chevrolet Metro/Metro LSi.

The M60 overhaul article covers 1997–1999, M58/M42 teardown covers 1997–1998, and the 1.0L engine-mechanical article covers 1998–1999. The relearn, reminder, and trouble-code files are general references, not Metro-specific fault-isolation guides.

PDF Search, Bookmarks, and Wiring Detail

Text access and diagram labels: The 19 GM PDFs have searchable text, although image-based diagram labels are not searchable. Their embedded bookmarks use numbered labels such as “1.pdf” rather than descriptive chapter names. The other 45 PDFs have no embedded text search or bookmarks. Small labels in representative ABS and wiring diagrams require zooming.

The ZIP contains 64 printable PDFs totaling 1,700 pages, including the general references listed above. The main “Service manual” folder has 47 PDFs and 1,387 pages; “95-98” has 15 PDFs and 266 pages; the two trouble-code files account for the remaining 47 pages. The total includes 265 pages containing only repeated headers and footers.

Engine, Chassis, and Electrical Service Coverage

The following highlights are selected contents, not a complete contents list. Other included topics include radio/speaker replacement and rear-window defogger grid repair.

• Engine repair: 1.0L VIN 6 and 1.3L VIN 2 engine removal, cylinder-head and block inspection, timing-belt work, valve service, lubrication, cooling-system repairs, and exhaust replacement.

• Transaxles and driveline: M60 automatic service and earlier overhaul procedures, M58/M42 manual-transaxle teardown, clutch service, and wheel-drive-shaft repair.

• Brakes and ABS: Hydraulic-system bleeding, master-cylinder and caliper overhaul, drum-brake service, parking-brake adjustment, and ABS component replacement with connector views.

• Suspension and steering: Front and rear suspension service, wheel bearings, manual rack-and-pinion checks and replacement, and collapsible steering-column removal and installation.

• Electrical and restraints: Starter/generator testing, fuse and relay identification, analog instrument-panel diagnosis, SIR procedures, front/rear wiper/washer service, and system wiring diagrams.

• Heating and air conditioning: Blower-circuit diagnosis, control-cable adjustment, compressor-control and performance tests, and heater-core, evaporator, and condenser replacement.

• Body and interior: Separate 2-door and 4-door procedures for panels, doors, locks, window regulators, stationary glass, seats, seat belts, bumpers, and trim.

Suited to experienced mechanics who can use scan tools, electrical test equipment, and the specialist service tools called out in the repair procedures.

Engine and Transmission Repair Depth

Engine chapters include crankshaft-seal replacement, piston and bearing selection, oil-pump inspection, and step-by-step procedures for cylinder-head work and timing-belt replacement. Cooling sections cover draining/flushing and thermostat, water-pump, and radiator replacement.

The 1.0L timing-belt article warns that rotating the crankshaft or camshaft with the belt removed can damage pistons.

The 2000–2001 M60 service files cover fluid/filter changes, cooler flushing and flow checks, cable and range-switch adjustment, intermediate-servo work, solenoids/harnesses, vehicle-speed-sensor replacement, and valve-body service.

The earlier overhaul chapter goes inside the oil pump, clutches, shafts, differential, planetary assemblies, one-way clutch, and upper/lower valve bodies; it adds time-lag, stall-speed, line-pressure, road, and engine-braking tests.

The cooler-flushing section warns that alcohol- or glycol-based solutions can damage flushing equipment, cooler parts, and transaxle components, including internal seals. Referenced tools include J-28467-A engine support equipment, J-28712 drive-axle boot protectors, J-35944-series flushing equipment, and J-37968/J-37972 cylinder-head tools.

ABS, Steering, and Circuit Diagnosis

The ABS file provides Cell 44 schematics, component views, and eight connector end-view tables for the EBCM, relays, solenoids, hydraulic modulator, motor pack, drive gear, wheel-speed sensors, and jumper harnesses. It is a component-service chapter, not a complete ABS DTC fault-isolation section.

Separate brake files add master-cylinder bench bleeding, system flushing, rotor refinishing, and wheel-cylinder overhaul.

The manual-steering chapter states that steering-gear overhaul is not recommended; its exploded view is for reference.

The 2001 wiring file includes 34 circuit figures. Examples span anti-lock brakes, computer data lines, engine-performance circuits, ground/power distribution, charging/starting, and the supplemental-restraint system. SIR material adds scan-tool diagnostics, DTC identification, post-collision inspection, disabling/activation, and component replacement.

Body Fit and Interior Service

Body sections include panel-gap and flushness specifications, fastener tables, and component illustrations for hood, hinge, latch, fender, battery-tray, and liftgate/trunk-hardware work. Separate body-style data supports selecting the appropriate fit specifications after panel replacement.

Brake, SIR, refrigerant, steering-column, and under-vehicle work should be carried out with the applicable system isolated and the vehicle safely supported.

Selected Rotor and Drum Inspection Limits

The 2000 GM disc-brake specifications give a 15 mm minimum rotor thickness and 0.10 mm maximum lateral runout for rotor inspection.

Drum inspection uses different maximum inside diameters: 182 mm for 2-door models and 202 mm for 4-door models, alongside limits for out-of-round, taper, and runout.