2000–2001 Chevrolet Metro / Geo Metro Service & Repair Manual (P/N IDs 426452–353816)

• Covers 2000 Pontiac Firefly (Canada) / Chevrolet Metro (VIN M) service information and 2001 Chevrolet Metro LSi, with dedicated 2000–01 engine coverage for the 1.3L 4-cylinder, engine VIN code 2
• The 2000 Firefly/Metro sections are archived General Motors service-information pages dated October 20, 2010 and carry individual GM Document IDs; the 2001 Metro LSi articles in the package are reproduced by Mitchell Repair Information
• Covers the 1.3L engine from valve adjustment and timing-belt work through cylinder-head service, engine/transaxle removal, oil-pump work, bearings, pistons, seals, and other internal repair specifications
• Identifies the ECC/Suzuki M60 3-speed automatic transaxle and distinguishes the 1.3L M42 5-speed clutch application from the 1.0L M58 setup
• Includes ABS, hydraulic/disc/drum brakes, wheel drive shafts, front and rear suspension, manual rack-and-pinion steering, SIR, starting/charging, HVAC, body alignment, doors, stationary glass, and related electrical systems
• Named electrical and component illustrations include Cell 44: Power, Ground and Indicators, Cell 44: DLC and Solenoids, Cell 44: Wheel Speed Sensors and Motor Pack, Charging System Wiring Diagram (Metro), Manual A/C-Heater System Wiring Diagram (2000–01 Metro), and Defogger Schematics
• Factory-style service data identifies specialist tools such as Battery Tester J-42000, Clutch Centering Tool J-34860, Servo Cover Depressor J-35534, Transaxle Oil Cooler and Line Flusher J-35944-A, Valve Guide/Seal Installer J-37968, and Oil Seal Guide J-34853
• The PDF package also contains separate legacy service material. Some transmission-overhaul and earlier engine files are labeled 1997–99 or 1998 rather than 2000–01 and should be treated as supplemental reference material, not as proof of later-model overhaul coverage

Powertrain and Repair Coverage

The 2000–01 1.3L engine article goes well beyond routine maintenance. It covers engine identification, valve-clearance adjustment, engine and transaxle removal, intake and exhaust manifolds, cylinder head, crankshaft seals, timing belt, camshaft and rocker assemblies, flywheel, oil pan, oil pump, and internal inspection and overhaul data. Cold valve clearance is 0.005–0.007 in (0.13–0.17 mm) intake and 0.009–0.011 in (0.23–0.27 mm) exhaust; hot specifications are also provided.

Internal repair information includes main and connecting-rod bearings, pistons and rings, cylinder block, valves and springs, camshaft, rocker shafts, and oil-pump clearances. The article specifies special tooling for valve-guide and seal work. One manualspecific repair trap is explicit: Valve Guide/Seal Installer J-37968 is to be used with hand pressure when installing the valve-guide seals, not driven with a hammer.

For the 1.3L manual-transaxle application, the clutch section identifies the Suzuki M42 5-speed and covers clutch free-play adjustment, clutch assembly removal and inspection, pilot and release bearings, cable service, and CPP switch adjustment. Clutch disc runout is limited to 0.031 in (0.79 mm), flywheel runout to 0.004 in (0.10 mm), and the 1.3L new-disc rivet depth is 0.060 in (1.50 mm). The article also specifies clutch-disc orientation and J-34860 centering-tool use; it expressly does not provide clutch overhaul procedures.

The M60 automatic-transaxle material covers fluid and filter service, oil-cooler flushing and flow checking, shift and throttle-valve cable adjustment, range-switch adjustment, intermediate-servo work, shift solenoids and wiring harness, and speedometer-driven-gear service. It specifies Dexron-III ATF, with fluid/filter changes at 50,000 miles under listed severe-use conditions and 100,000 miles otherwise.

Electrical and Braking System Walkthrough

The charging-system section is built around the Mitsubishi 55-amp generator with an internal IC voltage regulator. Bench and on-vehicle testing covers the battery, rectifier, rotor, stator, brushes, and condenser. Generator regulated output is listed at 14.7–15.0 volts with 55 amps maximum output; the pulley nut is tightened to 65 N·m (48 lb ft). Belt deflection is 0.20–0.27 in for a new belt and 0.24–0.31 in after the belt has been run.

ABS coverage is unusually detailed. It includes the EBCM, hydraulic modulator, motor pack, brake solenoids, front and rear wheel-speed sensors, relays, connector end views, and dedicated circuit schematics. Repair procedures cover EBCM replacement, modulator and motor-pack service, modulator gears, solenoid valves, sensor harnesses, and scan-tool checks including Gear Tension Relief, Motor Rehome, and the Automated ABS brake motor-pack Diagnosis Test.

The repair cautions here matter. The modulator retains mechanical load, so the specified Gear Tension Relief function precedes modulator removal. Allowing a modulator drive gear to rotate while its retaining nut is removed can drive the piston into the bore and damage it. Brake fluid entering the motor pack can also cause premature failure, and the manual treats a dropped or damaged motor pack as a replacement item rather than a repairable assembly.

Conventional brake coverage is equally specific: master-cylinder overhaul and bench bleeding, hydraulic-system bleeding and flushing, booster replacement, disc-pad and rotor service, caliper overhaul, drum and shoe work, wheel-cylinder overhaul, and parking-brake adjustment. Maximum front rotor lateral runout is 0.10 mm (0.004 in), minimum rotor thickness is 15 mm (0.59 in), and rear-drum limits distinguish the 2-door and 4-door configurations.

Specification Highlights

Driveline repair data includes wheel-drive-shaft replacement, intermediate-shaft service, and inner and outer joint/seal work. The drive axle nut specification is 175 N·m (129 lb ft). The manual warns that loading the front wheel with the shaft or axle nut removed can separate the inner bearing race and damage brake or suspension components.

Cooling specifications distinguish 1.3L automatic and manual configurations: total capacity is 4.73 L (5.0 qt) with the automatic transaxle and 4.6 L (4.9 qt) with the manual transmission. The manual A/C system specifies 17.6–21.1 oz of R-134a and 3.4 oz of PAG oil, along with pressure and outlet-temperature test tables, manifold-gauge testing, component checks, and refrigerant recovery requirements.

Body repair sections provide separate 2-door and 4-door sheet-metal tolerances. Examples include a 5.0 mm front-door-to-fender gap, 4.3 mm hood-to-headlamp gap, and 3.6 mm hood-to-fender gap, along with hood, fender, liftgate, trunk-lid, door, bumper, windshield, quarter-window, rear-window, and liftgate-glass repair procedures.

One final scope distinction is worth noting before a major steering repair: the 2000–01 manual rack-and-pinion section covers service, adjustment, and removal/installation, but states that steering-gear overhaul is not recommended; its exploded rack view is provided for information rather than as an overhaul procedure.