steering CHEVROLET CAVALIER 1996 3.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine I Long Trip/Highway Maintenance Schedule
90,000 Miles (150 000 km)
0 Change engine oil and filter (or every
12
months, whichever occurs first).
An Emission Control Service.
0 Lubricate the suspension, steering linkage
and the transaxle shift linkage (or
every
12 months, whichever occurs first).
0 Replace air cleaner filter. An Emission
Control Service.
0 Inspect fuel tank, cap and lines for damage
or leaks. Inspect fuel cap gasket for
any
damage. Replace parts as needed.
An Emission Control Service,
0 Inspect Exhaust Gas Recirculation (EGR)
system (2.2L Code
4 engine only).
An Emission Control Service.
I I 1 i
DATE ACTUAL MILEAGE SERVICED BY:
7-35

Downloaded from www.Manualslib.com manuals search engine I Long Trip/Highway Maintenance Schedule
97,500 Miles (162 500 km)
c] Change engine oil and filter (or every
12 months, whichever occurs first).
An Emission Control Service.
Lubricate the suspension, steering linkage
and the transaxle shift linkage (or every
12 months, whichever occurs first).
0 Rotate tires. See “Tire Inspection and Rotation” in the Index for proper rotation
pattern and additional information. During tire rotation, check brake calipers for freedom of movement. Refer to the
appropriate
GM service manual for proper
caliper service procedures.
100,000 Miles (166 000 km)
Drain, flush and refill cooling system
(or every
60 months since last service,
whichever occurs first). See “Engine
Coolant”
in the Index for what to use.
Inspect hoses. Clean radiator, condenser,
pressure cap
and neck. Pressure test the
cooling system and pressure cap.
An Emission
Control
Service.
Inspect spark plug wires (except 2.4L
Replace spark plugs. An Emission
Code T engine). An Emission Control Service.
Control Service.

Downloaded from www.Manualslib.com manuals search engine 2. Firmly apply both the parking brake (see “Parking
Brake” in the Index
if necessary) and the regular brake.
NOTE: Do not use the accelerator pedal, and be
ready to turn off the engine immediately if it starts.
3. On automatic transaxle vehicles, try to start the
engine in each gear. The starter should work only in
PARK
(P) or NEUTRAL (N). If the starter works in
any other position, your vehicle needs service.
On manual transaxle vehicles, put the shift lever in
NEUTRAL
(N), push the clutch down halfway and
try to start the engine. The starter should work only
when the clutch is pushed down all the way to the
floor. If the starter works when the clutch isn’t
pushed all the way down, your vehicle needs service.
Brake-Tkansaxle Shift Interlock (BTSI) Check
(Automatic Transaxle)
When
you are doing this check, the vehicle could
move suddenly. If it does, you or others could be
injured. Follow the steps below.
1. Before you start, be sure you have enough room around
the vehicle. It should be parked
on a level surface.
2. Firmly apply the parking brake (see “Parking Brake”
in the Index if necessary).
NOTE: Be ready to apply the regular brake
immediately
if the vehicle begins to move.
3. With the engine off, turn the key to the RUN position,
but don’t start the engine. Without applying the regular
brake,
try to move the shift lever out of PARK (P)
with normal effort. If the shift lever moves out of
PARK (P), your vehicle’s BTSI needs service.
Steering Column Lock Check
While parked, and with the parking brake set, try to turn
the key to LOCK in each shift lever position.
‘With an automatic transaxle, the key should turn to
LOCK only when the shift lever is in PARK
(P).
With a manual transaxle, the key should turn to LOCK
only when the shift lever is
in REVERSE (R).
On vehicles with a key release button, try to turn the key
to LOCK without pressing the button. The key should
turn to LOCK only when you press the key button.
On all vehicles, the key should come out only in LOCK.
I
- -
I Turn the steering wheel to the left and to the right. It
should only lock when turned to the right.
7-40

Downloaded from www.Manualslib.com manuals search engine Part C: Periodic Maintenance
Inspections
Listed below are inspections and services which should be
performed at least twice a year (for instance, each spring
and
fall). You should let your GM dealer’s service
department or other qualified service center do these jobs.
Make sure any necessary repairs are completed at once.
Proper procedures to perform these services may be
found
in a Chevrolet service manual. See “Service and
Owner Publications” in the Index.
Steering, Suspension and Front-Wheel-Drive
Axle
Boot and Seal Inspection
Inspect the front and rear suspension and steering system
for damaged, loose or missing parts, signs
of wear, or lack
of lubrication. Inspect the power steering lines and hoses
for proper hook-up, binding, leaks, cracks, chafing, etc.
Clean and then inspect the drive axle boot seals for
damage, tears or leakage. Replace seals
if necessary.
Exhaust System Inspection
Inspect the complete exhaust system. Inspect the body near
the exhaust system. Look for broken, damaged, missing or
out-of-position
parts as well as open seams, holes, loose
connections, or other conditions
which could cause a heat build-up in the floor pan or could let exhaust fumes into
the vehicle, See “Engine Exhaust”
in the Index.
Radiator and Heater Hose Inspection
Inspect the hoses and have them replaced if they are
cracked, swollen or deteriorated. Inspect all pipes,
fittings and clamps; replace as needed.
Throttle Linkage Inspection
Inspect the throttle linkage for interference or binding,
and for damage or missing parts. Replace parts as
needed. Replace any cables 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 hookup, 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.
Check parking brake adjustment. You may need to have
your brakes inspected more often if your driving habits
or conditions result
in frequent braking.
7-42

Downloaded from www.Manualslib.com manuals search engine Part D: Recommended Fluids and
Lubricants
NOTE: Fluids and lubricants identified below by name,
part number or specification may be obtained from your
SM dealer.
USAGE
Engine Oil
Engine Coolant
FLUID/LUBRICANT
Engine oil with the American
Petroleum Institute Certified For
Gasoline Engines “Starburst” symbol of the proper viscosity.
To
determine the preferred viscosity
for your vehicle’s engine, see
“Engine Oil” in the Index.
50/50 mixture of clean water
(preferably distilled) and GM
Goodwrench@ DEX-COOL
TM or
Havoline@ DEX-COOL TM
(orange-colored, silicate-free)
antifreeze conforming to GM
Specification 6277M. See “Engine
Coolant’’ in the Index.
USAGE
Coolant
Supplement
Sealer
Hydraulic Brake
System
Hydraulic Clutch System
Power Steering System
Manual
Transaxle
Automatic
Transaxle
Key Lock
Cylinders
FLUIDlLUBRICANT
GM Part No. 3634621 or
equivalent with a complete flush
and refill.
Delco Supreme
ll@ Brake Fluid
(GM
Part No. 1052535 or
equivalent DOT-3 brake fluid).
Hydraulic Clutch Fluid (GM Part
No. 12345347 or equivalent).
GM Power Steering Fluid
1050017
- 1 qt., or equivalent).
Synchromesh Transmission
Fluid (GM Part
No. 12345349
or equivalent).
DEXRON@ -111 Automatic
Transmission Fluid.
Multi-Pu ose Lubricant,
Superlube
% (GM Part
No. 1234624 1 or equivalent).
(GM Part
NO. 1052884 - 1
Pt.,

Downloaded from www.Manualslib.com manuals search engine Ignition Switch ................................ 2-10
Illuminated Entry
............................... 2-42
Inflation. Tire
.................................. 6-37
Inside Daymight Rearview Mirror
................. 2-43
Inspections
Brakesystem
................................ 7-42
Exhaust Systems
............................. 7-42
Front-Wheel-Drive Axle Boot
.................. 7-42
Front-Wheel-Drive Axle Seal
................... 7-42
Radiator and Heater Hose
...................... 7-42
Steering
.................................... 7-42
Suspension
.................................. 7-42
Throttle Linkage
.............................. 7-42
Instrument Panel
............................... 2-60
Brightness Control
............................. 2-4 1
Cleaning
.................................... 6-46
Cluster
................................ 2-62. 2-63
FuseBlock
.................................. 6-54
Interior Lamps
................................. 2-41
Jack. Tire
.................................... 5-21
Jump Starting
................................... 5-2
Key Lock Cylinders Service
..................... 7-39
Key Release Button
............................. 2- 11
Keyless Entry System ............................ 2-5
Keys .......................................... 2-1 Labels
.................................. 4.31. 6.52
Certification
................................. 4-32
CertificationEire
............................. 4-31
Service Parts Identification
..................... 6-52
Tire-Loading Information
...................... 4-31
Vehicle Identification Number
................... 6-52
Lamps
........................................ 2-39
Fog
........................................ 2-41
Interior
..................................... 2-41
On Reminder ................................ 2-39
Latches. Seatback
................................ 1-4
Leaving Your Vehicle
............................. 2-5
Leaving Your Vehicle with the Engine Running ....... 2-25
Lighter
....................................... 2-47
Lights Air Bag Readiness
....................... 1-20. 2-66
Anti-Lock Brake System Warning
............ 2-68. 4-6
Brake System Warning
......................... 2-67
Charging System
............................. 2-66
CheckEngine
................................ 2-71
CheckGages
................................ 2-75
CheckOil
.................................... 2-74
Enhanced Traction System Active
............ 2-69. 4-8
Enhanced Traction System Warning Light
..... 2-68. 4-9
ETS Active
.............................. 2-69. 4-8
ETS Warning
............................. 2-68. 4-9
Interior
..................................... 2-41
Low Coolant Warning
......................... 2-70
9-6

Downloaded from www.Manualslib.com manuals search engine Oil Pressure Warning .......................... 2-73
Passlock Warning
........................... 2-75
Safety Belt Reminder
...................... 1.6. 2.65
Loading Your Vehicle
........................... 4-31
Cylinders
................................... 7-39
Door
........................................ 2-3
PowerDoor
.................................. 2-4
Rear Door Security
............................. 2-4
Steering Column Lock Check
................... 7-40
Tr~nk
....................................... 2-7
Low Coolant Warning Light
...................... 2-70
Lowering the Convertible Top Manually
............. 2-57
Lowering Your Convertible Top
................... 2-49
Lubricants and Fluids
............................ 7-43
Lubrication Service. Body
........................ 7-39
Up-Shift
.................................... 2-75
Locks
......................................... 2-3
Key Lock Cylinder Service
..................... 7-39
Maintenance. Normal Replacement
parts ........... 6-60
Maintenance Record ............................ 7-45
Maintenance Schedule
............................ 7- 1
Long Tripmighway Definition ................... 7-5
Long Tripmighway Intervals
..................... 7-5
Owner Checks and Services
..................... 7-38
Periodic Maintenance Inspections
................ 7-42
Recommended Fluids and Lubricants
............. 7-43 Scheduled Maintenance Services
.................. 7-3
Short Trip/City Definition
....................... 7-4
Short Trip/City Intervals
........................ 7-4
Maintenance. Underbody
......................... 6-50
Maintenance When Trailer Towing
................. 4-40
Malfunction Indicator Lamp
...................... 2-71
Manual Front Seat
............................... 1 . 1
Manual Lumbar Support .......................... 1-2
Manual Remote Control Mirror
.................... 2-44
Manual Transaxle
............................... 2-12
Check
...................................... 7-39
Fluid
....................................... 6-19
Shifting
..................................... 2-20
Starting Your Engine
.......................... 2-12
Methanol
...................................... 6-2
Mirrors
....................................... 2-44
Convex Outside
.............................. 2-45
Inside Daymight Rearview
..................... 2-43
Manual Remote Control
........................ 2-44
Power Remote Control
......................... 2-44
MountainRoads
................................ 4-23
Multifunction Lever
............................. 2-30
Neutral. Automatic Transaxle
.................... 2-17
Neutral. Manual Transaxle
........................ 2-21
New Vehicle “Break-In”
.......................... 2-9
Nightvision
................................... 4-16
9- /

Downloaded from www.Manualslib.com manuals search engine Odometer .................................... 2-63
Odometer. Trip
................................. 2-64
Off-Road Recovery
............................. 4- 12
Oil. Engine
.................................... 6-10
Oil Pressure Warning Light
....................... 2-73
Overdrive. Automatic Transaxle
................... 2- 19
Overheating Engine
............................. 5- 13
Owner Checks and Services
....................... 7-38
Owner Publications. Ordering
...................... 8-9
Paint Spotting. Chemical
........................ 6-50
Park Automatic Transaxle
.......................... 2- 17
Shifting
Into ................................. 2-24
Shifting Out
of ............................... 2-26
At Night
..................................... 2-8
Parking
Brake Mechanism Check
....................... 7-41
Brake
...................................... 2-23
Lots
........................................ 2-8
Over Things That Bum
........................ 2-27
WithaTrailer
................................ 4-39
Your Vehicle. Manual Transaxle
................. 2-26
Passenger Position
.............................. 1-25
Passing
....................................... 4-12
Passlock
TM ..................................... 2-9
Passlock
TM Warning Light ........................ 2-75
Periodic Maintenance Inspections
.................. 7-42 Power
Door Locks
................................... 2-4
Remote Control Mirror
........................ 2-44
Option Fuses
................................ 6-53
Steering
................................ 4.9. 6.26
Steering Fluid
................................ 6-26
Windows
................................... 2-29
Pregnancy. Use of Safety Belts
.................... 1-25
Problems on the Road
............................ 5-1
Publications. Service and Owner .................... 8-9
Radio Reception
.............................. 3-23
Radios
........................................ 3-7
Rain. Driving In
................................ 4-17
Raising the Convertible Top Manually
.............. 2-57
Raising Your Convertible Top
..................... 2-53
Rear DoorSecurityLocks
........................... 2-4
Outside Seat Position .......................... 1-26
Safety Belt Comfort Guides
..................... 1-29
Seatpassengers
.............................. 1-25
Towing
..................................... 5-11
Window Defogger
............................. 3-7
Reclining Front Seatbacks
......................... 1-2
Recreational Vehicle Towing
...................... 4-29
Refrigerants. Air Conditioning
.................... 6-58
Remote Trunk Release
............................ 2-8
RearTowing ................................... 5-11
Rearview Mirror. Inside Daymight
................. 2-43
9-8

Downloaded from www.Manualslib.com manuals search engine Second Gear. Automatic Transaxle ............ 2- 18. 2. 19
Second Gear. Manual Transaxle ................... 2-21
Security System
................................. 2-9
Service
........................................ 6-1
Bulletins. Ordering
............................. 8-9
Manuals. Ordering
............................. 8-9
Parts Identification Label
....................... 6-52
Publications. Ordering
.......................... 8-9
Work. Doing
Your Own ......................... 6- 1
Service and Appearance Care ...................... 6-1
Service and Owner Publications
.................... 8-9
Service Publications
.............................. 8-9
Servicing Your Air Bag-Equipped Chevrolet
......... 1-24
Sheet Metal Damage
............................ 6-49
Shift Lever
............................... 2- 16. 2-20
Shift Light
............................... 2-22. 2-75
Shiftspeeds
................................... 2-22
Shifting
Automatic Transaxle
.......................... 2- 16
Into Park (P)
................................. 2-24
OutofPUk
.................................. 2-26
Shifting. Manual Transaxle
....................... 2-20
Shoulder Belt Height Adjuster
..................... 1-14
Skidding
...................................... 4-14
Sound Equipment. Adding
........................ 3-23
Spare Tire. Compact
............................. 5-32
Specifications and Capacities
...................... 6-58
Specifications. Engine
........................... 6-59
SignalingTurns
................................ 2-31 Speech Impaired. Customer Assistance
............... 8-3
Speedometer
................................... 2-63
Stains. Cleaning
................................ 6-45
Starter Switch Check
............................ 7-39
Starting Your Engine
.................. 2.12.2.13. 2.14
Steam
........................................ 5-13
Steering
....................................... 4-9
Column Lock Check
.......................... 7-40
In Emergencies
............................... 4-11
Power
.................................. 4.9. 6.26
Tips
........................................ 4-10
Wheel. Tilt
.................................. 2-30
Storage Compartments
........................... 2-45
Storage. Vehicle
................................ 6-32
Stuck:
In Sand. Mud. Ice or Snow .................. 5-33
Sunvisors
.................................... 2-48
Sunroof
....................................... 2-48
Supplemental Restraint System
.................... 1 . 19
Surge
Tank. Coolant ............................. 5-17
Surge Tank Pressure Cap ......................... 6-25
Symbols. Vehicle
................................ viii
Tachometer
.................................. 2-64
Taillamp Bulb Replacement
....................... 6-34
TapePlayerCare
............................... 3-24
Theft
.......................................... 2-8
Theft-Deterrent Feature. CD Player
................ 3-20
SRS ......................................... 1-19

Downloaded from www.Manualslib.com manuals search engine THEFTLOCK” ................................ 3-20
Thermostat
.................................... 6-26
Third Gear. Automatic Transaxle
................... 2- 19
Third Gear. Manual Transaxle
..................... 2-21
Tilt Steering Wheel
............................. 2-30
Time. Setting the
................................ 3-7
Tire Chains
.................................... 6-43
TireLoading
................................... 4-31
Tire-Loading Information Label
................... 4-3 1
Tires
......................................... 6-36
Alignment and Balance
........................ 6-41
BuyingNew
................................. 6-39
Chains
..................................... 6-43
Changing a Flat
.............................. 5-21
Cleaning
.................................... 6-49
Compact Spare
............................... 5-32
Inflation
.................................... 6-37
Inflation Check
............................... 7-38
Inspection and Rotation
........................ 6-38
Pressure
.................................... 6-37
Temperature
................................. 6-4 1
Traction
.................................... 6-40
Treadwe ar
................................... 6-40
Uniform Quality Grading
....................... 6-40
Used Replacement Wheel
...................... 6-42
Wear Indicators
.............................. 6-39
Wheel Replacement
........................... 6-41
When
It’s Time for New ....................... 6-39
Loading
.................................... 4-31 TopStrap
..................................... 1-36
Torque Lock
................................... 2-25
Torque, Wheel Nut
......................... 5-29, 6-58
Towing From the Front
............................... 4-29
From the Rear
............................... 4-31
Front
........................................ 5-9
Rear ....................................... 5-11
Recreational Vehicle
.......................... 4-29
Towing a Trailer
........................... 4-33. 4-40
Towing Your Vehicle
............................. 5-7
Towing Your Vehicle From the Front
............... 4-29
Towing Your Vehicle From the Rear
................ 4-31
Trailer Brakes
..................................... 4-37
Driving on Grades
............................ 4-39
Driving with
................................. 4-38
Hitches
..................................... 4-37
Maintenance When Towing
..................... 4-40
Parking on Hills
.............................. 4-39
Safety Chains
................................ 4-37
Tongueweight
............................... 4-36
Total Weight on Tires
.......................... 4-36
Towing
................................ 4-33, 4-40
Turnsignals
................................. 4-39
Weight
..................................... 4-35
Automatic
.............................. 6-17. 6-19
Manual
..................................... 6-19
Transaxle Fluid
9-11