Chevrolet Metro / Geo Metro 2000–2001 Repair Manual Collection

The GM articles provide component replacement procedures and specifications, while the Metro technical articles add mechanical repair, electrical testing, and system diagnosis. The separate code lists provide fault-code definitions.

Earlier engine and transmission articles are supplemental references. Their printed applications must be checked before using them for later-model repairs. The general reference articles also contain information for other vehicles.

PDF Search, Navigation and Page Count

Search and diagram access: Text search is available in the 19 GM article PDFs, although labels inside illustrations may not be searchable. These files have numbered PDF bookmarks; the other 45 PDFs have neither searchable text nor embedded bookmarks.

Small labels in the checked ABS and main wiring diagrams require zooming. Some labels in the earlier wiring supplement are partly illegible. The individual generator and starter articles contain diagram captions without the drawings; charging and starting circuits are provided separately in WIRING.pdf.

English ZIP download containing 64 printable PDFs and 1,700 pages total, including 265 pages containing only repeated headers. The separate trouble-code references are included in that total.

Engine, Transmission and Electrical Workshop Coverage

The following are selected contents, rather than a complete table of contents. Other included topics cover exhaust-component replacement and rear-window defogger grid repairs.

• Engine repair: Valve adjustment, timing-belt replacement, cylinder-head service, engine/transaxle removal, oil-pump work, and model-specific internal inspection and assembly data.

• Transmission and clutch: Automatic-transaxle servicing and removal, clutch replacement, cable adjustment, bearing inspection, and separately dated transmission-overhaul references.

• Brake service: ABS component replacement, master-cylinder and caliper overhaul, wheel-cylinder repair, hydraulic bleeding, rotor inspection, and parking-brake adjustment.

• Electrical and SIR diagnosis: Battery and generator tests, starter symptom charts, airbag diagnostic procedures, connector views, component locations, and wiring diagrams.

• Suspension and steering: Front strut, control-arm, wheel-bearing, rear suspension, steering-column, manual rack-and-pinion, and wheel-drive-shaft procedures.

• Cooling and HVAC: Cooling-system draining and flushing, water-pump and thermostat replacement, A/C performance testing, and compressor-control troubleshooting.

• Body and interior: Panel alignment, doors and locks, window regulators, stationary glass, bumpers, seats, seat belts, and interior trim replacement.

This material suits experienced mechanics who can interpret wiring diagrams and use electrical test equipment, lifting equipment, and the scan-tool functions specified for ABS work.

Engine Repair and Internal Inspection

The 1.3L engine article covers manifolds, crankshaft seals, camshaft and rocker assemblies, pistons and rings, bearings, cylinder-block inspection, and oil-pump clearances. Piston identification marks and color-coded main-bearing selection tables connect the internal measurements to component selection.

Valve-guide and seal work identifies Valve Guide/Seal Installer J-37968; oil-pump installation specifies Oil Seal Guide J-34853. The valve-seal section warns that hammering during seal installation can cause damage.

The article provides model-specific overhaul information and refers to separate general Engine Overhaul Procedures for work beyond its scope.

Clutch and Automatic-Transaxle Service

The clutch article distinguishes the M42 application from M58, with inspection data, disc orientation, pilot and release-bearing service, CPP switch adjustment, and Clutch Centering Tool J-34860. It provides step-by-step clutch replacement procedures, but expressly does not provide clutch overhaul procedures.

The M60 service article covers fluid and filter changes, cooler flushing and flow checks, shift and throttle-valve cables, range-switch adjustment, intermediate-servo service, solenoids, wiring harnesses, and valve-body/accumulator work.

Its equipment references include Servo Cover Depressor J-35534 and Transaxle Oil Cooler and Line Flusher J-35944-A. Dexron-III ATF specifications and separate severe-use service intervals are included.

ABS, Starting and Charging Diagnosis

ABS coverage includes EBCM replacement, hydraulic modulator and motor-pack service, drive gears, solenoid valves, wheel-speed sensors, relays, and connector end views.

The replacement instructions call for Gear Tension Relief, Motor Rehome, and the Automated ABS brake motor-pack Diagnosis Test. These scan-tool functions are referenced within the repair instructions rather than supplied as complete diagnostic routines.

The modulator section explains how spring-loaded gear movement can damage its piston. Motor-pack fluid contamination can cause premature failure; dropped or damaged motor packs are replacement items.

Battery testing with J-42000, generator symptom charts, and rectifier, rotor, stator, brush, and condenser tests help distinguish battery or cable faults from generator faults before removal. The SIR article adds system checks and fault-specific diagnostic procedures.

Circuit references include Cell 44: Power, Ground and Indicators, Cell 44: DLC and Solenoids, and Cell 44: Wheel Speed Sensors and Motor Pack. Separate electrical illustrations include Charging Circuit, Manual A/C-Heater System Wiring Diagram (2000–01 Metro), and Defogger Schematics.

Chassis, Body and Climate-Control Details

Wheel-drive-shaft coverage extends to intermediate-shaft, joint, and seal work. Its handling warnings explain the risk of bearing separation when the front wheels carry vehicle weight with a shaft or axle nut removed.

The manual rack-and-pinion article covers inspection and removal/installation, but states that steering-gear overhaul is not recommended; its exploded view is informational.

Body sections distinguish 2-door and 4-door panel clearances and flushness, with step-by-step procedures for doors, hood, fenders, liftgate, trunk lid, and stationary glass. Conventional brake sections supply rotor limits and configuration-specific rear-drum data.

Cooling data distinguishes automatic and manual configurations. HVAC information includes R-134a and PAG-oil specifications, pressure and outlet-temperature tables, manifold-gauge testing, and refrigerant-recovery requirements.

A Preview of Valve and Clutch Inspection Data

For the 1.3L engine, cold valve clearance is 0.005–0.007 in (0.13–0.17 mm) at the intake and 0.009–0.011 in (0.23–0.27 mm) at the exhaust. Separate hot specifications accompany the adjustment information.

The clutch inspection tables specify maximum disc runout of 0.031 in (0.79 mm) and flywheel runout of 0.004 in (0.10 mm), alongside rivet-depth and bearing-inspection information.