engine CHEVROLET CAVALIER 2004 3.G Service Manual

If You Do Decide To Pull A Trailer
If you do, here are some important points:
There are many different laws, including speed limit
restrictions, having to do with trailering. Make sure
your rig will be legal, not only where you live
but also where you will be driving. A good source
for this information can be state or provincial police.
Consider using a sway control. You can ask a hitch
dealer about sway controls.
Do not tow a trailer at all during the rst 1,000 miles
(1 600 km) your new vehicle is driven. Your engine,
axle or other parts could be damaged.
Then, during the rst 500 miles (800 km) that you
tow a trailer, do not drive over 50 mph (80 km/h)
and do not make starts at full throttle. This
helps your engine and other parts of your vehicle
wear in at the heavier loads.
Obey speed limit restrictions when towing a trailer.
Do not drive faster than the maximum posted
speed for trailers, or no more than 55 mph
(90 km/h), to save wear on your vehicle’s parts.
Do not tow when the outside air temperature is
above 100°F (38°C).
Do not tow more than 1,000 miles (1 600 km)
per year.Three important considerations have to do with weight:
The weight of the trailer.
The weight of the trailer tongue.
The total weight on your vehicle’s tires.
Weight of the Trailer
How heavy can a trailer safely be?
It should never weigh more than 1,000 lbs (450 kg). But
even that can be too heavy.
It depends on how you plan to use your rig. For
example, speed, altitude, road grades, outside
temperature and how much your vehicle is used to pull
a trailer are all important. And, it can also depend
on any special equipment that you have on your vehicle.
You can ask your dealer for our trailering information
or advice, or you can write us at:
Chevrolet Motor Division
Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
In Canada write to:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario, L1H 8P7
4-38

Total Weight on Your Vehicle’s Tires
Be sure your vehicle’s tires are inated to the upper limit
for cold tires. You’ll nd these numbers on the
Tire-Loading Information label. SeeLoading Your
Vehicle on page 4-31. Then be sure you do not go over
the GVW limit for your vehicle, including the weight
of the trailer tongue.
Hitches
It is important to have the correct hitch equipment.
Crosswinds, large trucks going by and rough roads are
a few reasons why you will need the right hitch. Here
are some rules to follow:
The rear bumper on your vehicle is not intended for
hitches. Do not attach rental hitches or other
bumper-type hitches to it. Use only a
frame-mounted hitch that does not attach to the
bumper.
Will you have to make any holes in the body of
your vehicle when you install a trailer hitch? If
you do, then be sure to seal the holes later when
you remove the hitch. If you do not seal them,
deadly carbon monoxide (CO) from your exhaust
can get into your vehicle. SeeEngine Exhaust
on page 2-28. Dirt and water can also enter
the vehicle.
Safety Chains
You should always attach chains between your vehicle
and your trailer. Cross the safety chains under the
tongue of the trailer so that the tongue will not drop to
the road if it becomes separated from the hitch.
Instructions about safety chains may be provided by the
hitch manufacturer or by the trailer manufacturer.
Follow the manufacturer’s recommendation for attaching
safety chains and do not attach them to the bumper.
Always leave just enough slack so you can turn
with your rig. And, never allow safety chains to drag on
the ground.
Trailer Brakes
Does your trailer have its own brakes? Be sure to read
and follow the instructions for the trailer brakes so you will
be able to install, adjust and maintain them properly. Do
not try to tap into your vehicle’s brake system. If you do,
both brake systems will not work well, or at all.
Driving with a Trailer
Towing a trailer requires a certain amount of experience.
Before setting out for the open road, you will want to
get to know your rig. Acquaint yourself with the feel of
handling and braking with the added weight of the trailer.
And always keep in mind that the vehicle you are
driving is now a good deal longer and not nearly as
responsive as your vehicle is by itself.
4-40

Driving on Grades
Notice:Do not tow on steep continuous grades
exceeding 6 miles (9.6 km). Extended, higher
than normal engine and transaxle temperatures may
result and damage your vehicle. Frequent stops
are very important to allow the engine and transaxle
to cool.
Reduce speed and shift to a lower gearbeforeyou start
down a long or steep downgrade. If you do not shift
down, you might have to use your brakes so much that
they would get hot and no longer work well.
Pay attention to the engine coolant gage. If the indicator
is in the red area, turn off the air conditioning to
reduce engine load. SeeEngine Overheating on
page 5-23.
Parking on Hills
{CAUTION:
You really should not park your vehicle, with a
trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.
But if you ever have to park your rig on a hill, here is
how to do it:
1. Apply your regular brakes, but do not shift into
PARK (P) yet. When parking uphill, turn your
wheels away from the curb. When parking downhill,
turn your wheels into the curb.
2. Have someone place chocks under the trailer
wheels.
3. When the wheel chocks are in place, release the
regular brakes until the chocks absorb the load.
4. Reapply the regular brakes. Then apply your
parking brake, and then shift to PARK (P).
5. Release the regular brakes.
4-42

When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you:
Start your engine.
Shift into a gear.
Release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the
chocks.
Maintenance When Trailer Towing
Your vehicle will need service more often when you are
pulling a trailer. SeePart A: Scheduled Maintenance
Services on page 6-4for more on this. Things that are
especially important in trailer operation are automatic
transaxle uid (don’t overll), engine oil, drive belt,
cooling system and brake system.Each of these is covered in this manual, and the Index
will help you nd them quickly. If you are trailering,
it is a good idea to review this information before you
start your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
Engine Cooling When Trailer Towing
Your cooling system may temporarily overheat during
severe operating conditions. SeeEngine Overheating on
page 5-23.
Towing a Trailer (Manual Transaxle)
Do not tow a trailer if your vehicle is equipped with a
manual transaxle.
4-43

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-4
Fuel................................................................5-4
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-6
Filling Your Tank............................................5-7
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood....................5-10
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Air Cleaner/Filter................................5-17
Automatic Transaxle Fluid..............................5-19
Manual Transaxle Fluid..................................5-19
Hydraulic Clutch...........................................5-19
Engine Coolant.............................................5-20
Coolant Surge Tank Pressure Cap..................5-23
Engine Overheating.......................................5-23
Cooling System............................................5-25
Power Steering Fluid.....................................5-30Windshield Washer Fluid................................5-31
Brakes........................................................5-32
Battery........................................................5-36
Jump Starting...............................................5-36
Bulb Replacement..........................................5-41
Halogen Bulbs..............................................5-41
Headlamps..................................................5-41
Front Turn Signal and Parking Lamps..............5-43
Taillamps and Turn Signal Lamps...................5-44
Back-Up Lamps............................................5-44
Replacement Bulbs.......................................5-44
Windshield Wiper Blade Replacement..............5-45
Tires..............................................................5-46
Ination - Tire Pressure.................................5-53
Tire Inspection and Rotation...........................5-54
When It Is Time for New Tires.......................5-55
Buying New Tires.........................................5-56
Uniform Tire Quality Grading..........................5-57
Wheel Alignment and Tire Balance..................5-58
Wheel Replacement......................................5-58
Tire Chains..................................................5-60
If a Tire Goes Flat........................................5-61
Changing a Flat Tire.....................................5-62
Compact Spare Tire......................................5-72
Section 5 Service and Appearance Care
5-1

Appearance Care............................................5-72
Cleaning the Inside of Your Vehicle.................5-73
Care of Safety Belts......................................5-75
Weatherstrips...............................................5-75
Cleaning the Outside of Your Vehicle..............5-75
Sheet Metal Damage.....................................5-77
Finish Damage.............................................5-77
Underbody Maintenance................................5-78
Chemical Paint Spotting.................................5-78
Vehicle Care/Appearance Materials..................5-78
Vehicle Identication......................................5-79
Vehicle Identication Number (VIN).................5-79
Service Parts Identication Label.....................5-80Electrical System............................................5-80
Add-On Electrical Equipment..........................5-80
Headlamp Wiring..........................................5-80
Windshield Wiper Fuses................................5-81
Power Windows and Other Power Options.......5-81
Fuses and Circuit Breakers............................5-81
Capacities and Specications..........................5-85
Normal Maintenance Replacement Parts..........5-86
Engine Drive Belt Routing..............................5-87
Section 5 Service and Appearance Care
5-2

Service
Your dealer knows your vehicle best and wants you to
be happy with it. We hope you will go to your dealer
for all your service needs. You will get genuine GM parts
and GM-trained and supported service people.
We hope you will want to keep your GM vehicle all GM.
Genuine GM parts have one of these marks:
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many uids, and
some component wear by-products contain and/or emit
these chemicals.
5-3

Gasoline Octane
Use regular unleaded gasoline with a posted octane
of 87 or higher. If the octane is less than 87, you may
get a heavy knocking noise when you drive. If this
occurs, use a gasoline rated at 87 octane or higher as
soon as possible. Otherwise, you might damage
your engine. A little pinging noise when you accelerate
or drive uphill is considered normal. This does not
indicate a problem exists or that a higher-octane fuel is
necessary. If you are using 87 octane or higher-octane
fuel and hear heavy knocking, your engine needs
service.
Gasoline Specications
It is recommended that gasoline meet specications
which were developed by automobile manufacturers
around the world and contained in the World-Wide Fuel
Charter which is available from the Alliance of
Automobile Manufacturers at
www.autoalliance.org/fuel_charter.htm. Gasoline
meeting these specications could provide improved
driveability and emission control system performance
compared to other gasoline.In Canada, look for the
“Auto Makers’ Choice”
label on the pump.California Fuel
If your vehicle is certied to meet California Emission
Standards (see the underhood emission control label), it
is designed to operate on fuels that meet California
specications. If this fuel is not available in states
adopting California emissions standards, your vehicle will
operate satisfactorily on fuels meeting federal
specications, but emission control system performance
may be affected. The malfunction indicator lamp may turn
on (seeMalfunction Indicator Lamp on page 3-29) and
your vehicle may fail a smog-check test. If this occurs,
return to your authorized GM dealer for diagnosis. If it is
determined that the condition is caused by the type of fuel
used, repairs may not be covered by your warranty.Canada Only
5-5

Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work
properly. You should not have to add anything to your
fuel. However, some gasolines contain only the
minimum amount of additive required to meet U.S.
Environmental Protection Agency regulations. General
Motors recommends that you buy gasolines that
are advertised to help keep fuel injectors and intake
valves clean. If your vehicle experiences problems due
to dirty injectors or valves, try a different brand of
gasoline.
Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines may be available in
your area to contribute to clean air. General Motors
recommends that you use these gasolines, particularly if
they comply with the specications described earlier.
Notice:Your vehicle was not designed for fuel that
contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in your fuel
system and also damage the plastic and rubber
parts. That damage would not be covered under
your warranty.Some gasolines that are not reformulated for
low emissions may contain an octane-enhancing
additive called methylcyclopentadienyl manganese
tricarbonyl (MMT); ask the attendant where you
buy gasoline whether the fuel contains MMT. General
Motors does not recommend the use of such gasolines.
Fuels containing MMT can reduce the life of spark
plugs and the performance of the emission control
system may be affected. The malfunction indicator lamp
may turn on. If this occurs, return to your authorized
GM dealer for service.
Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel may be hard
to nd. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly
repairs caused by use of improper fuel would not
be covered by your warranty.
To check the fuel availability, ask an auto club, or
contact a major oil company that does business in the
country where you will be driving.
5-6

Filling Your Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your
engine when you are refueling. Do not smoke
if you are near fuel or refueling your vehicle.
Keep sparks, ames and smoking materials
away from fuel. Do not leave the fuel pump
unattended when refueling your vehicle — this
is against the law in some places. Keep
children away from the fuel pump; never let
children pump fuel.The tethered fuel cap is located behind a hinged fuel
door on the passenger’s side of the vehicle.
5-7