Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Chevrolet Prizm 1998-2002. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your Prizm like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.
This manual for Chevrolet Prizm 1998-2002 is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.
2002 ENGINES Engine Mechanical - 1.8L (Unit Repair) - Prizm
EXHAUST MANIFOLD REMOVAL
1. Remove the exhaust manifold brace to the manifold bolt (1).
Fig. 11: Removing Exhaust Manifold Brace To Manifold Bolt
2. Remove the 6 upper heat insulator bolts.
3. Remove the heat insulator.
4. Remove the 5 exhaust manifold nuts (1-5).
5. Remove the exhaust manifold.
Fig. 12: Removing Exhaust Manifold
INTAKE MANIFOLD REMOVAL
1. Remove the intake manifold support bracket bolts (7).
2. Remove the intake manifold support bracket.
3. Remove the intake manifold bolts and nuts.
4. Remove the intake manifold from the cylinder head.
Fig. 13: Removing Intake Manifold From Cylinder Head
CRANKSHAFT PULLEY REMOVAL
Tools Required: J 8614-01 Pinion Flange Holder
1. Remove the crankshaft pulley retaining bolt using J 8614-01 to prevent crankshaft rotation when loosening the bolt.
2. Remove the crankshaft pulley.
Fig. 14: Removing Crankshaft Pulley Retaining Bolt
CYLINDER HEAD COVER REMOVAL
1. Remove the 9 cylinder head cover bolts.
2. Remove the seal washers.
3. Remove the cylinder head cover (1) with the gasket from the cylinder head.
Fig. 15: Removing Cylinder Head Cover
WATER PUMP REMOVAL
Important: The drive belt tensioner must be unloaded and the drive belt removed before the water pump is removed.
1. Remove the water pump assembly to the timing chain housing bolts (2).
2. Remove the water pump.
3. Remove the water pump O-ring.
Fig. 16: Removing Water Pump Assembly To Timing Chain Housing Bolts
TIMING CHAIN TENSIONER REMOVAL
1. Remove the timing chain tensioner nuts (1,2).
2. Remove the timing chain tensioner.
Fig. 17: Removing Timing Chain Tensioner Nuts
TIMING CHAIN HOUSING REMOVAL
1. Remove the following components:
The crankshaft position sensor bolt (5)
2. Remove the drive belt tensioner nut.
3. Remove the following components from the mounting surface:
The drive belt tensioner bolt
Fig. 18: Removing Crankshaft Position Sensor Bolt
4. Remove the following fasteners:
The timing chain cover bolts (2-14)
The nuts (1, 15)
5. Gently pry the timing chain cover away from the cylinder block and remove the timing chain cover.
Fig. 19: Removing Timing Chain Cover Bolts And Nuts
TIMING CHAIN AND SPROCKETS REMOVAL
1. Remove the following components:
The timing chain dampener bolts (1)
The timing chain dampener
The timing chain shoe bolts
The timing chain shoe
Fig. 20: Removing Timing Chain Dampener Bolts
2. Remove the following components simultaneously:
The crankshaft sprocket
The timing chain