Service Procedure

SERVICE PROCEDURE:

1. Check and, if necessary, reset throttle position sensor (TPS) setting as specified in the 1989-90 Geo Prizm Specifications located in computerized engine controls.

2. Disconnect negative (-) battery cable.





3. Disconnect electrical wire harness connector (Figure 1, 607) from manifold absolute pressure (MAP) sensor (Figure 1, 606)

4. Cut off MAP sensor wire harness connector (Figure 1, 607) directly behind connector housing.

5. Cut and remove 75 mm (approx. 3 inches) from end of protective conduit around MAP sensor wire harness.

NOTICE:
Be careful not to cut into any of wires inside conduit when cutting plastic sleeve.

6. Strip 8 to 11 mm (1/3 to 2/5 in.) of insulation from ends of wires of existing MAP sensor wire harness. Do same for wires of new jumper harness included in kit.
7. Attach (splice) jumper wire harness to MAP sensor wire harness on vehicle using the three special "crimp and seal" splice sleeves supplied in kit. These sleeves are the same type of special "sealed splice" sleeves as those supplied in Terminal Repair Kit J-38125A used for repairing SIR system wiring.

NOTICE:
Be certain wire colors are matched before splicing wires together.

Also, the special "crimp and seal" splice sleeves should be installed using the procedure described in section 9J (page 9J-17) of the 1992 Geo Storm Service Manual.

8. Position wire splices so that they are staggered and wrap all three wires together with electrician's tape.

NOTICE:
Extend tape wrapping to 50 to 70 mm (2 to 2-3/4 inches) passed ends of splices.

9. Disconnect vacuum hose to existing MAP sensor mounted on front of dash bulkhead.





10. Remove existing MAP sensor and replace it as shown in Figure 2 with new MAP sensor and new MAP sensor bracket assembly supplied in kit.

11. Reconnect vacuum hose removed in step 9.

12. Connect jumper harness connector to new MAP sensor. Snap "rosebud" retainer on jumper harness into hole on MAP sensor bracket as shown in Figure 2.





13. Route lower portion of MAP sensor wire harness through existing clip on intake plenum runner as shown in Figure 3. Use tie strap supplied in kit to create wire loop outside of clip.

14. Reattach negative (-) battery cable.

15. Road test vehicle and verify surge no longer exists.