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1996 GEO Prizm CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT GEO REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1996 GEO Prizm AUTOMOBILES
Cooling Fans -> Passenger Cars Except Saturn -> Troubleshooting -> 1996 Century & Ciera -> 1996 Corvette -> Achieva, Grand Am & Skylark -> Aurora & Riviera -> Beretta & Corsica -> Bonneville, Eighty Eight, LeSabre, LSS, Ninety Eight, Park Avenue & Regency -> Camaro & Firebird -> Caprice, Fleetwood, Impala SS & Roadmaster -> Catera -> Cavalier & Sunfire -> Concours, DeVille, Eldorado & Seville -> Cutlass & Malibu -> Cutlass Supreme, Grand Prix, Lumina, Monte Carlo & Regal -> Fleetwood -> Metro -> Prizm
Vehicle: 1996 GEO Prizm LSI 1.8 L4 GAS
Achieva, Grand Am & Skylark
If the cooling fan continues to run with the ignition switch in the Off position after engine coolant temperature lowers, replace cooling fan relay.
Aurora & Riviera
Refer to "System Diagnosis & Testing."
Beretta & Corsica
- If cooling fan does not operate, inspect fuse and fuse link.
- If cooling fan runs with ignition switch in the Off position, replace the cooling fan relay.
- Ensure ground is clean and tight.
- With engine cold and at idle speed, move A/C selector switch to the NORM position: cooling fa...
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BRAKE SERVICE PROCEDURES FOR 1996 GEO Prizm AUTOMOBILES
Disc Brakes -> Toyota/GM Single Piston Caliper -> Caliper Service -> Assemble -> Disassemble -> Front Caliper -> Installation -> Rear Caliper -> Removal
Vehicle: 1996 GEO Prizm LSI 1.6 L4 GAS
Front Caliper
Removal
- Siphon 2/3 of the brake fluid from master cylinder, raise and support vehicle, and remove wheels.
- Reinstall two wheel nuts to retain rotor, then remove caliper mounting bolts, Fig. .
- Remove union nut securing brake hose to caliper and drain fluid into suitable container. If caliper is only being removed for brake pad replacement, do not disconnect brake hose.
- Compress piston as needed, then remove caliper. If brake hose remains connected, secure caliper aside to prevent hose from being stretched.
Disassemble
- Remove two caliper slide bushings, four dust boots and s...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 GEO Prizm AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Fuel Pressure Relief -> 1993-05 Nova, Prizm & Vibe
Vehicle: 1996 GEO Prizm LSI 1.6 L4 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strategy.
- Lo...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 GEO Prizm AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1996 GEO Prizm LSI 1.8 L4 GAS
- Disconnect battery ground.
- Raise and support vehicle.
- Remove wheel and tire assembly.
- Remove driveshaft nut cap, then cotter pin, hub nut and washer.
- Remove tie rod end nut, then separate tie rod from steering knuckle, using tie rod end puller tool No. J-6627-A, or equivalent.
- Remove ball joint pinch bolt, then pry ball joint from knuckle.
- Remove drive axle assembly from transaxle ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 GEO Prizm AUTOMOBILES
Alternator, Replace
Vehicle: 1996 GEO Prizm 1.6 L4 GAS
- Disconnect battery ground cable at battery.
- Remove protective cover, then nut from B+ terminal on alternator.
- Remove electrical connector from alternator.
- Remove drive belt adjuster bolt.
- Remove drive belt.
- Remove alternator mounting bolts.
- Re...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 GEO Prizm AUTOMOBILES
General Motors Corp./Saturn Cars -> Check Gauge Warning Lamp ->
Vehicle: 1996 GEO Prizm 1.6 L4 GAS
The Check Gauge warning lamp will light to warn the driver to inspect the oil pressure gauge, engine coolant temperature ga...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 GEO Prizm AUTOMOBILES
Radiator, Replace
Vehicle: 1996 GEO Prizm LSI 1.6 L4 GAS
- Disconnect battery ground cable, then drain cooling system.
- Remove coolant recovery reservoir cap and hoses.
- Remove upper radiator hose at radiator, Fig. .
- Remove lower radiator hose at thermostat housing.
- Unclip oxygen sensor electrical connector from fan shroud.
- Raise and properly support vehicle.
- Remove engine splash shield.
- Remove lower radiator hose from vehicle...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1996 GEO Prizm AUTOMOBILES
Serpentine Drive Belt, Replace -> Installation -> Removal
Vehicle: 1996 GEO Prizm LSI 1.6 L4 GAS
Removal
- Rotate serpentine belt tensioner pulley clockwise to release tension from belt using a 3/8 drive socket wrench.
- Remove serpentine belt from pulleys.
Installation
- ...
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COMPONENT LOCATION DIAGRAMS FOR 1996 GEO Prizm AUTOMOBILES
Component location diagrams for most 1996 GEO Prizm cars and light trucks sold in the U.S. from 1990+.
Engine Compartment Components Diagram for 1996 GEO Prizm 1.6 L4 GAS Components on diagram: |
LH Side Of I/P Diagram for 1996 GEO Prizm LSI 1.8 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1996 GEO Prizm AUTOMOBILES
OEM drawn wiring diagrams for most 1996 GEO Prizm cars and light trucks sold in the U.S.
1996 GEO Prizm LSI 1.6 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1996 GEO Prizm AUTOMOBILES
OEM TSB listings for most 1996 GEO Prizm cars and light trucks sold in the U.S. from 1985+.
Document: INFORMATION ON USE OF DIAGNOSTIC WORKSHEET - REVISED Vehicle: 1996 GEO Prizm LSI 1.6 L4 GAS Auto Systems: |
Document: DIAGNOSIS OF CRACKED OR BROKEN TRANSMISSION CASE - REVISED Vehicle: 1996 GEO Prizm LSI 1.6 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1996 GEO Prizm AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 GEO Prizm cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1996 GEO Prizm cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1996 GEO Prizm cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1996 GEO Prizm cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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