brake CHEVROLET CLASSIC 2004 Repair Manual

Ignition Transaxle Lock Check
While parked, and with the parking brake set, try to turn
the ignition key to OFF in each shift lever position.
The key should turn to OFF only when the shift lever is
in PARK (P).
On all vehicles, the key should come out only in OFF.
Parking Brake and Automatic
Transaxle Park (P) Mechanism Check
{CAUTION:
When you are doing this check, your vehicle
could begin to move. You or others could be
injured and property could be damaged. Make
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.Park on a fairly steep hill, with the vehicle facing
downhill. Keeping your foot on the regular brake, set the
parking brake.
•To check the parking brake’s holding ability: With
the engine running and transaxle in NEUTRAL
(N), slowly remove foot pressure from the regular
brake pedal. Do this until the vehicle is held by the
parking brake only.
•To check the PARK (P) mechanism’s holding
ability: With the engine running, shift to PARK (P).
Then release the parking brake followed by the
regular brake.
Underbody Flushing Service
At least every spring, use plain water to flush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
6-19

Engine Cooling System Inspection
Inspect the hoses and have them replaced if they
are cracked, swollen or deteriorated. Inspect all pipes,
fittings and clamps; replace as needed. Clean the
outside of the radiator and air conditioning condenser.
To help ensure proper operation, a pressure test of
the cooling system and pressure cap is recommended
at least once a year.
Throttle System Inspection
Inspect the throttle system for interference or binding,
and for damaged or missing parts. Replace parts
as needed. Replace any components that have high
effort or excessive wear. Do not lubricate accelerator
and cruise control cables.
Brake System Inspection
Inspect the complete system. Inspect brake lines and
hoses for proper hook-up, binding, leaks, cracks,
chafing, etc. Inspect disc brake pads for wear and rotors
for surface condition. Also inspect drum brake linings
for wear and cracks. Inspect other brake parts, including
drums, wheel cylinders, calipers, parking brake, etc.
The parking brake is self-adjusting and no manual
adjustment is required. You may need to have your
brakes inspected more often if your driving habits
or conditions result in frequent braking.
6-21

Part D: Recommended Fluids and
Lubricants
Fluids and lubricants identified below by name, part
number or specification may be obtained from your
dealer.
Usage Fluid/Lubricant
Engine OilEngine oil which meets GM Standard
GM6094M and displays the
American Petroleum Institute
Certified for Gasoline Engines
starburst symbol. To determine the
proper viscosity for your vehicle’s
engine, seeEngine Oil on page 5-13.
Engine Coolant50/50 mixture of clean, drinkable
water and use only DEX-COOL
®
Coolant. SeeEngine Coolant on
page 5-19.
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake fluid.
Windshield
Washer SolventGM Optikleen
®Washer Solvent.
Usage Fluid/Lubricant
Power Steering
SystemGM Power Steering Fluid (GM Part
No. U.S. 89021184, in Canada
89021186).
Automatic
TransaxleDEXRON
®-III Automatic
Transmission Fluid.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474).
Hood Latch
Assembly,
Secondary
Latch, Pivots,
Spring Anchor
and Release
PawlLubriplate Lubricant Aerosol (GM
Part No. U.S. 12346293, in Canada
992723) or lubricant meeting
requirements of NLGI #2, Category
LB or GC-LB.
Hood and Door
HingesMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 109435474).
Weatherstrip
ConditioningDielectric Silicone Grease (GM Part
No. U.S. 12345579, in Canada
992887).
6-22

Vehicle Data Collection and Event
Data Records
Your vehicle, like other modern motor vehicles, has a
number of sophisticated computer systems that monitor
and control several aspects of the vehicle’s performance.
Your vehicle uses on-board vehicle computers to monitor
emission control components to optimize fuel economy,
to monitor conditions for airbag deployment and, if so
equipped, to provide anti-lock braking and to help the
driver control the vehicle in difficult driving situations.
Some information may be stored during regular
operations to facilitate repair of detected malfunctions;
other information is stored only in a crash or near crash
event by computer systems commonly called event data
recorders (EDR).
In a crash or near crash event, computer systems, such
as the Airbag Sensing and Diagnostic Module (SDM) in
your vehicle may record information about the condition
of the vehicle and how it was operated, such as engine
speed, brake applications, throttle position, vehicle
speed, seat belt usage, airbag readiness, airbag
performance data, and the severity of a collision. This
information has been used to improve vehicle crash
performance and may be used to improve crash
performance of future vehicles and driving safety. Unlike
the data recorders on many airplanes, these on-board
systems do not record sounds, such as conversation of
vehicle occupants.To read this information, special equipment is needed
and access to the vehicle or the SDM is required.
GM will not access information about a crash event or
share it with others other than•with the consent of the vehicle owner or, if the
vehicle is leased, with the consent of the lessee,
•in response to an official request of police or similar
government office,
•as part of GM’s defense of litigation through the
discovery process, or
•as required by law.
In addition, once GM collects or receives data, GM may
•use the data for GM research needs,
•make it available for research where appropriate
confidentiality is to be maintained and need is
shown, or
•share summary data which is not tied to a specific
vehicle with non-GM organizations for research
purposes.
Others, such as law enforcement, may have access to
the special equipment that can read the information
if they have access to the vehicle or SDM.
If your vehicle is equipped with OnStar, please check
the OnStar subscription service agreement or manual for
information on its operations and data collection.
7-10

Reporting Safety Defects
Reporting Safety Defects to the
United States Government
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic
Safety Administration (NHTSA), in addition to notifying
General Motors.
If NHTSA receives similar complaints, it may open an
investigation, and if it finds that a safety defect exists in
a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer or
General Motors.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 366-0123 in
the Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation
Washington, D.C. 20590
You can also obtain other information about motor
vehicle safety from the hotline.
Reporting Safety Defects to General
Motors
In addition to notifying NHTSA in a situation like this, we
certainly hope you’ll notify us. Please call us at
1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
7-11

A
Accessory Power Outlets.................................3-16
Adding Washer Fluid.......................................5-33
Additional Program Information........................... 7-9
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment............................5-89
Adjusting the Speakers (Balance/Fade)......3-40, 3-45
Air Bag
Readiness Light..........................................3-26
Air Bag System, Supplemental Restraint
System (SRS).............................................1-56
Air Cleaner/Filter, Engine.................................5-17
Airbag Sensing and Diagnostic Module (SDM)....7-10
AM ...............................................................3-54
Antenna, Fixed Mast.......................................3-56
Anti-lock Brake System (ABS)............................ 4-6
Anti-Lock Brake System Warning Light...............3-28
Appearance Care............................................5-80
Care of Safety Belts....................................5-83
Chemical Paint Spotting...............................5-86
Cleaning the Inside of Your Vehicle................5-80
Cleaning the Outside of Your Vehicle..............5-83
Finish Damage............................................5-85
Sheet Metal Damage...................................5-85
Underbody Maintenance...............................5-86
Vehicle Care/Appearance Materials................5-86
Weatherstrips..............................................5-83
Ashtrays........................................................3-17Audio System(s).............................................3-36
Care of Your Cassette Tape Player................3-55
Care of Your CD Player...............................3-56
Care of Your CDs........................................3-56
Chime Level Adjustment...............................3-56
Fixed Mast Antenna.....................................3-56
Radio with Cassette and CD.........................3-43
Radio with CD............................................3-38
Setting the Time for Radios with Radio Data
Systems (RDS)........................................3-37
Setting the Time for Radios without Radio
Data Systems (RDS)................................3-37
Theft-Deterrent Feature................................3-54
Understanding Radio Reception.....................3-54
Automatic Headlamp System............................3-13
Automatic Transaxle
Fluid..........................................................5-19
Operation...................................................2-20
Automatic Transaxle Inspection.........................6-17
Automatic Transaxle Shift Lock Control System
Check........................................................6-18
B
Backing Up....................................................4-42
Battery..........................................................5-38
Battery Replacement......................................... 2-6
Battery Run-Down Protection............................3-16
Before Leaving on a Long Trip.........................4-20
1

Body Lubrication Service..................................6-17
Brake
Parking......................................................2-23
System Inspection.......................................6-21
System Warning Light..................................3-27
Brake Adjustment............................................5-37
Brake Fluid....................................................5-34
Brake Pedal Travel.........................................5-37
Brake Wear...................................................5-36
Brakes..........................................................5-34
Braking........................................................... 4-6
Braking in Emergencies..................................... 4-8
Break-In, New Vehicle.....................................2-16
Bulb Replacement...........................................5-45
Center High-Mounted Stoplamp (CHMSL)........5-47
Front Turn Signal Lamps..............................5-47
Halogen Bulbs............................................5-45
Headlamps.................................................5-45
Replacement Bulbs......................................5-50
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps........................................5-48
Buying New Tires...........................................5-62
C
California Fuel.................................................. 5-5
Capacities and Specifications............................5-95
Carbon Monoxide...................4-23, 4-38, 2-11, 2-27Care of
Safety Belts................................................5-83
Your Cassette Tape Player............................3-55
Your CD Player...........................................3-56
Your CDs ...................................................3-56
Cassette Tape Messages.................................3-50
Cassette Tape Player Service...........................6-16
CD Adapter Kits.............................................3-51
CD Messages........................................3-42, 3-53
Center Console Storage Area...........................2-31
Center High-Mounted Stoplamp (CHMSL)...........5-47
Center Rear Passenger Position, Safety Belts.....1-27
Chains, Tires..................................................5-66
Charging System Light....................................3-27
Check Engine Light.........................................3-30
Checking Coolant............................................5-21
Checking Engine Oil........................................5-13
Checking Your Restraint Systems......................1-62
Chemical Paint Spotting...................................5-86
Child Restraints
Child Restraint Systems...............................1-39
Infants and Young Children...........................1-35
Lower Anchorages and Top Tethers for
Children (LATCH System)..........................1-45
Older Children.............................................1-32
Securing a Child Restraint Designed for the
LATCH System........................................1-48
Securing a Child Restraint in a Center Rear
Seat Position...........................................1-50
2

Inspection
Brake System.............................................6-21
Engine Cooling System................................6-21
Exhaust System..........................................6-20
Fuel System...............................................6-20
Part C - Periodic Maintenance.......................6-20
Steering, Suspension and Front Drive Axle
Boot and Seal.........................................6-20
Throttle System...........................................6-21
Instrument Panel
Cluster.......................................................3-23
Overview..................................................... 3-2
Instrument Panel Brightness.............................3-15
Instrument Panel Fuse Block
(Passenger’s Side).......................................5-92
Instrument Panel Fuse Block
(Driver’s Side).............................................5-91
Interior Lamps................................................3-15
J
Jump Starting.................................................5-39
K
Key Lock Cylinders Service..............................6-17
Keyless Entry System....................................... 2-3
Keys............................................................... 2-2
L
Lamps
Exterior......................................................3-13
Interior.......................................................3-15
Lap Belt........................................................1-28
Lap-Shoulder Belt...................................1-14, 1-24
LATCH System
Child Restraints...........................................1-45
Securing a Child Restraint Designed for the
LATCH System........................................1-48
Leaving Your Vehicle.......................................2-11
Leaving Your Vehicle With the Engine
Running.....................................................2-25
Light
Air Bag Readiness.......................................3-26
Anti-Lock Brake System Warning...................3-28
Brake System Warning.................................3-27
Charging System.........................................3-27
Door Ajar...................................................3-34
Low Coolant Warning...................................3-29
Low Washer Fluid Warning...........................3-34
Malfunction Indicator....................................3-30
Oil Pressure...............................................3-33
Passlock
®Warning.......................................3-34
Safety Belt Reminder...................................3-25
Service Vehicle Soon...................................3-35
Loading Your Vehicle.......................................4-32
Lockout Protection..........................................2-11
7

Locks
Delayed Locking........................................... 2-8
Door........................................................... 2-7
Leaving Your Vehicle....................................2-11
Lockout Protection.......................................2-11
Power Door.................................................. 2-8
Programmable Automatic Door Locks............... 2-9
Rear Door Security Locks.............................2-10
Long Trip/Highway Definition.............................. 6-6
Long Trip/Highway Intervals............................... 6-6
Long Trip/Highway Scheduled Maintenance........6-12
Loss of Control...............................................4-13
Low Coolant Warning Light..............................3-29
Low Washer Fluid Warning Light.......................3-34
M
Maintenance, Normal Replacement Parts............5-96
Maintenance Schedule
At Each Fuel Fill.........................................6-16
At Least Once a Month................................6-16
At Least Once a Year..................................6-17
At Least Twice a Year..................................6-17
Brake System Inspection..............................6-21
Engine Cooling System Inspection.................6-21
Exhaust System Inspection...........................6-20
Fuel System Inspection................................6-20Maintenance Schedule (cont.)
How This Section is Organized....................... 6-3
Introduction.................................................. 6-2
Long Trip/Highway Scheduled Maintenance.......6-12
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4
Part B - Owner Checks and Services.............6-16
Part C - Periodic MaintenanceInspections......6-20
Part D - Recommended Fluids and
Lubricants...............................................6-22
Part E - Maintenance Record........................6-23
Selecting the Right Schedule.......................... 6-5
Short Trip/City Scheduled Maintenance............. 6-6
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection..........................6-20
Throttle System Inspection............................6-21
Using Your................................................... 6-4
Your Vehicle and the Environment................... 6-2
Maintenance When Trailer Towing.....................4-44
Making Turns.................................................4-42
Malfunction Indicator Light................................3-30
Manual Seats................................................... 1-2
Matching Transmitter(s) to Your Vehicle............... 2-5
Mexico, Central America and Caribbean
Islands/Countries (Except Puerto Rico
and U.S. Virgin Islands) – Customer
Assistance................................................... 7-5
8

Mirrors
Manual Rearview Mirror................................2-29
Outside Convex Mirror.................................2-30
Outside Power Mirrors..................................2-30
Outside Remote Control Mirrors.....................2-29
MyGMLink.com................................................ 7-3
N
New Vehicle Break-In......................................2-16
Normal Maintenance Replacement Parts............5-96
O
Odometer......................................................3-24
Off-Road Recovery..........................................4-11
Oil
Engine.......................................................5-13
Pressure Light.............................................3-33
Older Children, Restraints................................1-32
Online Owner Center........................................ 7-3
Operation......................................................3-18
Operation Tips................................................3-21
Other Warning Devices...................................... 3-5
Outlet Adjustment............................................3-21Outside
Convex Mirror.............................................2-30
Power Mirrors.............................................2-30
Remote Controls Mirrors...............................2-29
Overseas – Customer Assistance........................ 7-5
Owner’s Information........................................7-12
P
Park (P)
Shifting Into................................................2-24
Shifting Out of............................................2-26
Parking
Brake........................................................2-23
Over Things That Burn.................................2-26
Parking Brake and Automatic Transaxle Park (P)
Mechanism Check.......................................6-19
Parking on Hills..............................................4-43
Part A - Scheduled Maintenance Services............ 6-4
Part B - Owner Checks and Services................6-16
Part C - Periodic MaintenanceInspections..........6-20
Part D - Recommended Fluids and Lubricants.......6-22
Part E - Maintenance Record...........................6-23
Passing.................................................4-11, 4-42
Passlock
®......................................................2-16
9