Chevrolet Nova, Geo Prizm Repair & Service Manual 1985-1993

COMPONENT REMOVAL AND INSTALLATION

NOTE: Always use a new gasket at each pipe joint whenever the joint is disassembled. Use new nuts and bolts to hold the joint properly. These two low-cost items will serve to prevent future leaks as the system ages.

FRONT PIPE

1. Elevate and safely support the vehicle on jackstands.



2. Disconnect the oxygen sensor.



3. Remove the 2 bolts holding the pipe to the exhaust manifold.



4. Remove the 2 bolts holding the pipe to the catalytic converter.



5. Remove the bolts from the crossmember bracket and remove the pipe from under the car.



6. Attach the new pipe to the crossmember bracket. Install the bolts at both the manifold and the catalyst ends, leaving them finger tight until the pipe is correctly positioned. Make certain the gaskets are in place and straight.



7. Tighten the pipe-to-manifold bolts to 46 ft. lbs.



8. Tighten the bolts at the converter to 32 ft. lbs.



9. Reconnect the oxygen sensor.



10. Lower the vehicle to the ground, start the system and check for leaks. Small exhaust leaks will be most easily heard when the system is cold.

With the car safely supported on jackstands, the converter is removed simply by removing the 2 bolts at either end. The Nova models have an air suction pipe attached to the converter which must be disconnected (2 bolts) before removal.

When reinstalling the converter, install it with new gaskets and tighten the end bolts to 32 ft. lbs. Reconnect the air suction pipe (Nova) and lower the car to the ground.

INTERMEDIATE PIPE (RESONATOR PIPE)

1. Elevate and safely support the vehicle on jackstands.



2. Remove the 2 bolts holding the pipe to the catalytic converter.



3. Remove the bolts holding the intermediate pipe to the muffler inlet pipe.



4. Disconnect the rubber hangers and remove the pipe.



5. Install the new pipe by suspending it in place on the rubber hangers. Install the gaskets at each end and install the bolts finger tight.

BLOWER SPEED CONTROL SWITCH

REMOVAL AND INSTALLATION | 1985-1992

1. Disconnect the negative battery cable. Remove the illumination light from the control assembly.



2. Remove the 3 bolts and 3 screws and remove the glove box from the vehicle.



3. Disconnect the electrical connector from the blower resistor assembly.



4. Remove the 2 screws and remove the resistor from the vehicle.



5. Installation is the reverse of the removal procedure. Reconnect the negative battery cable. Check the blower motor for proper operation at all speeds after installation.

• Tune-up and routine maintenance
• Engine and overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams