cooling CHEVROLET OPTRA 2004 1.G User Guide

The coolant level should be between the MIN (B) and
MAX (A) marks on the coolant surge tank when the
engine is cool. If it is not, you may have a leak at the
pressure cap or in the radiator hoses, heater hoses,
radiator, water pump or somewhere else in the cooling
system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them. If
you do, you can be burned.
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine re, and you could be
burned. Get any leak xed before you drive the
vehicle.
If there seems to be no leak, with the engine on, check
to see if the electric engine cooling fan is running.
If the engine is overheating, the fan should be running.
If it is not, your vehicle needs service.
Notice:Engine damage from running your engine
without coolant is not covered by your warranty.
5-28

How to Add Coolant to the Coolant
Surge Tank
Notice:This vehicle has a specic coolant ll
procedure. Failure to follow this procedure could
cause your engine to overheat and be severely
damaged.
If you have not found a problem yet, check to see if
coolant is visible in the surge tank. If coolant is visible but
the coolant level is not between the MIN (B) and MAX (A)
marks, add a 50/50 mixture ofclean, drinkable waterand
proper coolant at the coolant surge tank, but be sure the
cooling system, including the coolant surge tank pressure
cap, is cool before you do it. SeeEngine Coolant on
page 5-21for more information.
If no coolant is visible in the surge tank, add coolant as
follows:
{CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They
are under pressure, and if you turn the coolant
surge tank pressure cap — even a little — they
CAUTION: (Continued)
CAUTION: (Continued)
can come out at high speed. Never turn the
cap when the cooling system, including the
coolant surge tank pressure cap, is hot. Wait
for the cooling system and coolant surge tank
pressure cap to cool if you ever have to turn
the pressure cap.
5-29

{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
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 a proper coolant.Notice:In cold weather, water can freeze and crack
the engine, radiator, heater core and other parts.
Use the recommended coolant and the proper
coolant mixture.
{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.
5-30

1. Park the vehicle on a level surface.
You can remove the coolant surge tank pressure
cap when the cooling system, including the coolant
surge tank pressure cap and upper radiator
hose, is no longer hot. Turn the pressure cap slowly
counterclockwise (left) about two or two and
one-half turns. If you hear a hiss, wait for that to
stop. This will allow any pressure still left to be
vented out the discharge hose.
2. Then keep turning the pressure cap slowly, and
remove it.
5-31

3. Fill the coolant surge tank with the proper mixture
to the MAX (A) mark on the coolant surge tank.
Wait about five minutes, then check to see if
the level is below the MAX (A) mark. If the level is
below the MAX (A) mark, add additional coolant
to bring the level up to the MAX (A) mark. Repeat
this procedure until the level remains constant
at the MAX (A) mark for at least five minutes.4. With the coolant surge tank pressure cap off, start
the engine and let it run until you can feel the upper
radiator hose getting hot. Watch out for the
engine cooling fan.
By this time, the coolant level inside the coolant
surge tank may be lower. If the level is lower than
the MAX (A) mark, add more of the proper
mixture to the coolant surge tank until the level
reaches the MAX (A) mark.
5. Then replace the pressure cap. Be sure the
pressure cap is hand-tight and fully seated.
See your dealer, if necessary.
5-32

Wheel Alignment and Tire Balance
The wheels on your vehicle were aligned and balanced
carefully at the factory to give you the longest tire life
and best overall performance.
Scheduled wheel alignment and wheel balancing are
not needed. However, if you notice unusual tire wear or
your vehicle pulling one way or the other, the alignment
may need to be reset. If you notice your vehicle
vibrating when driving on a smooth road, your wheels
may need to be rebalanced.
Wheel Replacement
Replace any wheel that is bent, cracked or badly rusted
or corroded. If wheel nuts keep coming loose, the
wheel, wheel bolts and wheel nuts should be replaced.
If the wheel leaks air, replace it (except some
aluminum wheels, which can sometimes be repaired).
See your dealer if any of these conditions exist.
Your dealer will know the kind of wheel you need.
Each new wheel should have the same load-carrying
capacity, diameter, width, offset and be mounted
the same way as the one it replaces.If you need to replace any of your wheels, wheel bolts or
wheel nuts, replace them only with new GM original
equipment parts. This way, you will be sure to have the
right wheel, wheel bolts and wheel nuts for your vehicle.
{CAUTION:
Using the wrong replacement wheels, wheel
bolts or wheel nuts on your vehicle can be
dangerous. It could affect the braking and
handling of your vehicle, make your tires lose
air and make you lose control. You could have
a collision in which you or others could be
injured. Always use the correct wheel, wheel
bolts and wheel nuts for replacement.
Notice:The wrong wheel can also cause problems
with bearing life, brake cooling, speedometer or
odometer calibration, headlamp aim, bumper height,
vehicle ground clearance and tire or tire chain
clearance to the body and chassis.
SeeChanging a Flat Tire on page 5-64for more
information.
5-62

Fuses Usage
HEAD LAMPS Headlamps
ECM Engine Control Module
IGN COIL Ignition Coil
I/P FUSE Instrument Panel Fuse
FUEL PUMP Fuel Pump
A/C Air Conditioning
HORN Horn
HI BEAM Headlamp High-Beam
DRIVER’S
PWR WNDWDriver’s Power Window
STOP LAMPS Stoplamps
DR/LCK Door Lock
MIR HTD Heated Mirror
FRT FOG Front Fog
ILLUM LTLicense Plate Lamp, Parking
Lamp Left
INJ Injector
ENG SNSREvaporative Emission (EVAP)
Canister Purge Solenoid, Heated
Oxygen Sensor (HO2S), Cooling Fan
Relay, CMP SensorFuses Usage
LOW BEAM LT Headlamp Low-Beam Left
ILLUM RTIllumination Circuit, Parking Lamp
Right
LOW BEAM RT Headlamp Low-Beam Right
SPARE Spare
SPARE Spare
SPARE Spare
BATT PWR Battery Power
ABS Anti-lock Brake System
HVAC BLWR HVAC Blower
IGN 2 Ignition 2
IGN 1 Ignition 1
FUSE PLR Fuse Puller
COOL FAN
LOWCooling Fan Low
DEFOG Defog
COOL FAN HI Cooling Fan High
PWR WNDW Power Window
5-88

Relays Usage
COOL FAN
LOWCooling Fan Low
FRT FOG Front Fog
ILLUM Illumination Relay
A/C CMPRSR Air Conditioning Compressor
HORN Horn
DEFOG DefogRelays Usage
FUEL PUMP Fuel Pump
MAIN Main Relay
COOL FAN HI Cooling Fan High
PWR WNDW Power Window
HEAD LAMPS Headlamp Relay
5-89

Capacities and Specications
The following approximate capacities are given in English and metric conversions. Please refer toPart D:
Recommended Fluids and Lubricants on page 6-24for more information.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a 1.41 lbs 0.64 kg
Brake/Clutch Fluid 0.53 quarts 0.5 L
Cooling System 7.9 quarts 7.5 L
Engine Oil with Filter 4.2 quarts 4.0 L
Fuel Tank 14.5 gallons 55 L
Power Steering Fluid 1.2 quarts 1.1 L
Transaxle, Automatic
Complete Overhaul 7.1–7.5 quarts 6.7–7.1 L
Transaxle, Manual
Complete Drain and Refill 1.9 quarts 1.8 L
Wheel Nut Torque 81 lb ft 110Y
All capacities are approximate. When adding, be sure to fill to the appropriate level, as recommended in this
manual.
Engine Specications
Engine VIN Code Transaxle Spark Plug Gap
2.0L L4 (L34) ZAutomatic and
Manual0.039 inch (1.0 mm)
5-90

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
How This Section is Organized.........................6-3
Part A: Scheduled Maintenance Services...........6-4
Using Your Maintenance Schedule....................6-4
Selecting the Right Schedule...........................6-5
Short Trip/City Scheduled Maintenance..............6-6
Long Trip/Highway Scheduled Maintenance......6-13
Part B: Owner Checks and Services................6-18
At Each Fuel Fill..........................................6-18
At Least Once a Month.................................6-18At Least Twice a Year...................................6-19
At Least Once a Year...................................6-20
Part C: Periodic Maintenance Inspections.........6-23
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection............................6-23
Exhaust System Inspection............................6-23
Fuel System Inspection..................................6-23
Engine Cooling System Inspection...................6-23
Throttle System Inspection.............................6-24
Brake System Inspection................................6-24
Part D: Recommended Fluids and Lubricants......6-24
Part E: Maintenance Record...........................6-26
Section 6 Maintenance Schedule
6-1