engine CHEVROLET CAVALIER 2004 3.G Workshop Manual

Checking Things Under
the Hood
{CAUTION:
An electric fan under the hood can start up
and injure you even when the engine is not
running. Keep hands, clothing and tools away
from any underhood electric fan.
{CAUTION:
Things that burn can get on hot engine parts
and start a re. These include liquids like fuel,
oil, coolant, brake uid, windshield washer and
other uids, and plastic or rubber. You or
others could be burned. Be careful not to drop
or spill things that will burn onto a hot engine.
Hood Release
To open the hood, do the following.
1. Pull the handle located
inside the vehicle on
the driver’s side
under the instrument
panel.
5-10

Engine Compartment Overview
When you open the hood on the engine, you’ll see the following:
5-12

A. Coolant Surge Tank. SeeCooling System on
page 5-25.
B. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-13.
C. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-13.
D. Brake Fluid Reservoir. See “Brake Fluid” under
Brakes on page 5-32.
E. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-30.
F. Clutch Master Cylinder Reservoir (If Equipped) (Not
Shown). SeeHydraulic Clutch on page 5-19.
G. Battery. SeeBattery on page 5-36.
H. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-17.
I. Windshield Washer Fluid Reservoir. SeeWindshield
Washer Fluid on page 5-31.
J. Engine Compartment Fuse Block. See “Engine
Compartment Fuse Block” underFuses and Circuit
Breakers on page 5-81.Engine Oil
If the oil pressure light
appears on the instrument
cluster, it means you
need to check your engine
oil level right away.
For more information, seeOil Pressure Light on
page 3-32.
You should check your engine oil level regularly; this is
an added reminder.
Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
Turn off the engine and give the oil several minutes to
drain back into the oil pan. If you don’t, the oil
dipstick might not show the actual level.
5-13

Pull out the dipstick and clean it with a paper towel or
cloth, then push it back in all the way. Remove it again,
keeping the tip down, and check the level.
When to Add Engine Oil
If the oil is at or below the MIN mark, then you will need
to add at least one quart of oil. But you must use the
right kind. This section explains what kind of oil to use.
For engine oil crankcase capacity, seeCapacities
and Specications on page 5-85.
Notice:Do not add too much oil. If your engine has
so much oil that the oil level gets above the upper
mark that shows the proper operating range,
your engine could be damaged.SeeEngine Compartment
Overview on page 5-12for
the location of the
engine oil ll cap.
Be sure to add enough oil to put the level somewhere in
the proper operating range. Push the dipstick all the
way back in when you are through.
What Kind of Engine Oil to Use
Look for two things:
GM6094M
Your vehicle’s engine requires oil meeting GM
Standard GM6094M. You should look for and use
only an oil that meets GM Standard GM6094M.
5-14

Notice:Use only engine oil identied as meeting
GM Standard GM6094M and showing the American
Petroleum Institute Certied For Gasoline Engines
starburst symbol. Failure to use the recommended
oil can result in engine damage not covered by
your warranty.
GM Goodwrench
®oil meets all the requirements for
your vehicle.
If you are in an area of extreme cold, where the
temperature falls below−20°F (−29°C), it is
recommended that you use either an SAE 5W-30
synthetic oil or an SAE 0W-30 oil. Both will provide
easier cold starting and better protection for your engine
at extremely low temperatures.
Engine Oil Additives
Do not add anything to your oil. The recommended oils
with the starburst symbol that meet GM Standard
GM6094M are all you will need for good performance
and engine protection.
When to Change Engine Oil
If any one of these are true for you, use the short
trip/city maintenance schedule:
Most trips are less than 5 miles (8 km). This is
particularly important when outside temperatures
are below freezing.
Most trips include extensive idling (such as frequent
driving in stop-and-go traffic).
You frequently tow a trailer or use a carrier on top
of your vehicle.
The vehicle is used for delivery service, police, taxi
or other commercial application.
Driving under these conditions causes engine oil to
break down sooner. If any one of these is true for your
vehicle, then you need to change your oil and lter
every 3,000 miles (5 000 km) or 3 months — whichever
occurs rst.
If none of them is true, use the long trip/highway
maintenance schedule. Change the oil and lter every
7,500 miles (12 500 km) or 12 months — whichever
occurs rst. Driving a vehicle with a fully warmed engine
under highway conditions will cause engine oil to
break down slower.
Your vehicle has a unique oil lter element. When
installing the lter cap do not exceed 18 lb-ft (25Y).
Inspect the condition of the O-ring and replace if
damaged.
See your dealer for additional information.
5-16

What to Do with Used Oil
Used engine oil contains certain elements that may be
unhealthy for your skin and could even cause cancer.
Do not let used oil stay on your skin for very long. Clean
your skin and nails with soap and water, or a good
hand cleaner. Wash or properly dispose of clothing or
rags containing used engine oil. See the manufacturer’s
warnings about the use and disposal of oil products.
Used oil can be a threat to the environment. If you
change your own oil, be sure to drain all the oil from the
lter before disposal. Never dispose of oil by putting it
in the trash, pouring it on the ground, into sewers, or into
streams or bodies of water. Instead, recycle it by
taking it to a place that collects used oil. If you have a
problem properly disposing of your used oil, ask
your dealer, a service station or a local recycling center
for help.
Engine Air Cleaner/Filter
SeeEngine Compartment Overview on page 5-12for
the location of the engine air cleaner/lter.
When to Inspect the Engine Air
Cleaner/Filter
Inspect the air cleaner/lter every 15,000 miles
(25 000 km) and replace every 30,000 miles
(50 000 km). If you are driving in dusty/dirty conditions,
inspect the lter at each oil change.
5-17

How to Inspect the Engine Air
Cleaner/Filter
To inspect the air cleaner/lter remove the lter from the
vehicle and lightly shake the lter to release loose
dust and dirt. If the lter remains caked with dirt, a new
lter is required.
To inspect or replace the lter, remove the screws that
hold the cover on and lift off the cover. Be sure to
reinstall the cover tightly.
{CAUTION:
Operating the engine with the air cleaner/lter
off can cause you or others to be burned. The
air cleaner not only cleans the air, it helps to
stop ame if the engine backres. If it is not
there and the engine backres, you could be
burned. Do not drive with it off, and be careful
working on the engine with the air cleaner/
lter off.
Notice:If the air cleaner/lter is off, a backre can
cause a damaging engine re. And, dirt can
easily get into your engine, which will damage it.
Always have the air cleaner/lter in place when you
are driving.
5-18

When to Check and What to Use
Refer to the Maintenance
Schedule to determine
how often you should
check the uid level in your
master cylinder reservoir
and for the proper
uid. SeePart B: Owner
Checks and Services
on page 6-18andPart D:
Recommended Fluids
and Lubricants on
page 6-25.
How to Check and Add Fluid
You do not need to check the uid level unless you
suspect a clutch problem. To check the uid level, take
the cap off. If the uid reaches the step inside the
reservoir, the uid level is correct. SeeEngine
Compartment Overview on page 5-12for more
information on location.
Engine Coolant
The cooling system in your vehicle is lled with
DEX-COOL®engine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs rst, if you add
only DEX-COOL
®extended life coolant.
The following explains your cooling system and how to
add coolant when it is low. If you have a problem
with engine overheating, seeEngine Overheating on
page 5-23.
A 50/50 mixture of clean, drinkable water and
DEX-COOL
®coolant will:
Give freezing protection down to−34°F (−37°C).
Give boiling protection up to 265°F (129°C).
Protect against rust and corrosion.
Help keep the proper engine temperature.
Let the warning lights and gages work as
they should.
5-20

Notice:Using coolant other than DEX-COOL®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
What to Use
Use a mixture of one-halfclean, drinkable waterand
one-half DEX-COOL®coolant which will not damage
aluminum parts. If you use this coolant mixture, you do
not need to add anything else.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
CAUTION: (Continued)
CAUTION: (Continued)
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and DEX-COOL
®coolant.
Notice:If you use an improper coolant mixture,
your engine could overheat and be badly damaged.
The repair cost would not be covered by your
warranty. Too much water in the mixture can freeze
and crack the engine, radiator, heater core and
other parts.
If you have to add coolant more than four times a year,
have your dealer check your cooling system.
Notice:If you use the proper coolant, you do not
have to add extra inhibitors or additives which claim
to improve the system. These can be harmful.
5-21

Checking Coolant
The surge tank is located
in the engine compartment
on the passenger’s side
of the vehicle. SeeEngine
Compartment Overview
on page 5-12for more
information on location.
{CAUTION:
Turning the surge tank pressure cap when the
engine and radiator are hot can allow steam
and scalding liquids to blow out and burn you
badly. Never turn the surge tank pressure
cap — even a little — when the engine and
radiator are hot.
The vehicle must be on a level surface. When your
engine is cold, the coolant level should be at the FULL
COLD mark.If the low coolant light
comes on and stays on, it
means you are low on
engine coolant. SeeLow
Coolant Warning Light
on page 3-29.
Adding Coolant
If you need more coolant, add the proper DEX-COOL®
coolant mixtureat the surge tank, but only when the
engine is cool. If the surge tank is empty, a special ll
procedure is necessary. SeeEngine Overheating
on page 5-23for instructions on “How to Add Coolant to
the Coolant Surge Tank.”
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol,
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.
When replacing the pressure cap, make sure it is
hand-tight.
5-22