brake CHEVROLET CAVALIER 2000 3.G Workshop Manual

5-26
CAUTION:
Incorrect wheel nuts or improperly tightened
wheel nuts can cause the wheel to become loose
and even come off. This could lead to an accident.
Be sure to use the correct wheel nuts. If you have
to replace them, be sure to get new GM original
equipment wheel nuts.
Stop somewhere as soon as you can and have
the nuts tightened with a torque wrench to
100 lb
-ft (140 N´m).
NOTICE:
Improperly tightened wheel nuts can lead to
brake pulsation and rotor damage. To avoid
expensive brake repairs, evenly tighten the wheel
nuts in the proper sequence and to the proper
torque specification.
Don't try to put a wheel cover on your compact spare
tire. It won't fit. Store the wheel cover in the trunk
until you have the flat tire repaired or replaced.
NOTICE:
Wheel covers won't fit on your compact spare.
If you try to put a wheel cover on your compact
spare, you could damage the cover or the spare.

6-
6-1
Section 6 Service and Appearance Care
Here you will find information about the care of your vehicle. This section begins with service and fuel information,
and then it shows how to check important fluid and lubricant levels. There is also technical information about your
vehicle, and a part devoted to its appearance care.
6
-2 Service
6
-3 Fuel
6
-5 Fuels in Foreign Countries
6
-5 Filling Your Tank
6
-7 Filling a Portable Fuel Container
6
-8 Checking Things Under the Hood
6
-12 Engine Oil
6
-17 Engine Air Cleaner/Filter
6
-18 Automatic Transaxle Fluid
(Three
-Speed Only)
6
-21 Automatic Transaxle Fluid
(Four
-Speed Only)
6
-22 Manual Transaxle Fluid
6
-22 Hydraulic Clutch
6
-23 Engine Coolant
6
-26 Surge Tank Pressure Cap6
-27 Power Steering Fluid
6
-28 Windshield Washer Fluid
6
-29 Brakes
6
-33 Battery
6
-33 Bulb Replacement
6
-41 Tires
6
-49 Appearance Care
6
-49 Cleaning the Inside of Your Vehicle
6
-51 Care of Safety Belts
6
-53 Cleaning the Outside of Your Vehicle
6
-54 Cleaning Your Convertible Top
6
-58 Vehicle Identification Number (VIN)
6
-59 Electrical System
6
-63 Replacement Bulbs
6
-63 Capacities and Specifications
6
-65 Normal Maintenance Replacement Parts

6-8
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 fire. These include liquids like gasoline,
oil, coolant, brake fluid, windshield washer and
other fluids, 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, first pull
the handle inside the vehicle
on the driver's side under
the instrument panel.

6-10 2.2L L4 Engine (Code 4)
When you open the hood, you'll see:
A. Coolant Surge Tank
B. Power Steering Fluid Reservoir
C. Engine Oil Fill Cap/Dipstick
D. Brake Fluid ReservoirE. Hydraulic Clutch Fluid
Reservoir (If Equipped)
F. Automatic Transaxle Fluid
Dipstick (If Equipped)G. Engine Air Cleaner/Filter
H. Battery
I. Windshield Washer
Fluid Reservoir

6-11 2.4L L4 Engine (Code T)
When you open the hood, you'll see:
A. Coolant Surge Tank
B. Engine Oil Fill Cap
C. Engine Oil Dipstick
D. Power Steering Fluid ReservoirE. Brake Fluid Reservoir
F. Hydraulic Clutch Fluid
Reservoir (If Equipped)
G. BatteryH. Engine Air Cleaner/Filter
I. Windshield Washer
Fluid Reservoir

6-19 How to Check
Because this operation can be a little difficult, you
may choose to have this done at the dealership
service department.
If you do it yourself, be sure to follow all the instructions
here, or you could get a false reading on the dipstick.
NOTICE:
Too much or too little fluid can damage your
transaxle. Too much can mean that some of the
fluid could come out and fall on hot engine parts
or exhaust system parts, starting a fire. Be sure
to get an accurate reading if you check your
transaxle fluid.
Wait at least 30 minutes before checking the transaxle
fluid level if you have been driving:

When outside temperatures are above 90F (32C).

At high speed for quite a while.

In heavy traffic
-- especially in hot weather.To get the right reading, the fluid should be at normal
operating temperature, which is 180F to 200F
(82C to 93C).
Get the vehicle warmed up by driving about 15 miles
(24 km) when outside temperatures are above 50F
(10C). If it's colder than 50F (10C), you may
have to drive longer.
Checking the Fluid Level
Prepare your vehicle as follows:

Park your vehicle on a level place. Keep the
engine running.

With the parking brake applied, place the shift
lever in PARK (P).

With your foot on the brake pedal, move the
shift lever through each gear range, pausing for
about three seconds in each range. Then, position
the shift lever in PARK (P).

Let the engine run at idle for three to five minutes.

6-29
Brakes
Brake Fluid
Your brake master
cylinder reservoir is on
the driver's side of the
engine compartment.
It is filled with DOT
-3
brake fluid.
There are only two reasons why the brake fluid level in the
reservoir might go down. The first is that the brake fluid goes
down to an acceptable level during normal brake lining wear.
When new linings are put in, the fluid level goes back up.
The other reason is that fluid is leaking out of the brake
system. If it is, you should have your brake system fixed,
since a leak means that sooner or later your brakes won't
work well, or won't work at all.So, it isn't a good idea to ªtop offº your brake fluid.
Adding brake fluid won't correct a leak. If you add fluid
when your linings are worn, then you'll have too much
fluid when you get new brake linings. You should add
(or remove) brake fluid, as necessary, only when work is
done on the brake hydraulic system.CAUTION:
If you have too much brake fluid, it can spill on
the engine. The fluid will burn if the engine is hot
enough. You or others could be burned, and your
vehicle could be damaged. Add brake fluid only
when work is done on the brake hydraulic system.
When your brake fluid falls to a low level, your brake
warning light will come on. See ªBrake System Warning
Lightº in the Index.

6-30
What to Add
When you do need brake fluid, use only DOT
-3 brake
fluid. Use new brake fluid from a sealed container only.
Refer to ªRecommended Fluids and Lubricantsº in the
Maintenance Schedule.
Always clean the brake fluid reservoir cap and the area
around the cap before removing it. This will help keep
dirt from entering the reservoir.
CAUTION:
With the wrong kind of fluid in your brake
system, your brakes may not work well, or they
may not even work at all. This could cause a
crash. Always use the proper brake fluid.
NOTICE:

Using the wrong fluid can badly damage
brake system parts. For example, just a few
drops of mineral
-based oil, such as engine
oil, in your brake system can damage brake
system parts so badly that they'll have to
be replaced. Don't let someone put in the
wrong kind of fluid.

If you spill brake fluid on your vehicle's
painted surfaces, the paint finish can be
damaged. Be careful not to spill brake fluid
on your vehicle. If you do, wash it off
immediately. See ªAppearance Careº in
the Index.

6-31 Brake Wear
Your vehicle has front disc brakes and rear drum brakes.
Disc brake pads have built
-in wear indicators that make
a high
-pitched warning sound when the brake pads are
worn and new pads are needed. The sound may come
and go or be heard all the time your vehicle is moving
(except when you are pushing on the brake pedal firmly).
CAUTION:
The brake wear warning sound means that soon
your brakes won't work well. That could lead to
an accident. When you hear the brake wear
warning sound, have your vehicle serviced.
NOTICE:
Continuing to drive with worn-out brake pads
could result in costly brake repair.
Some driving conditions or climates may cause a
brake squeal when the brakes are first applied or
lightly applied. This does not mean something is
wrong with your brakes.
See ªCaliper/Knuckle Maintenance Inspectionº in
Section 7 of this manual under Part C ªPeriodic
Maintenance Inspections.º
Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly torque wheel nuts in the
proper sequence to GM specifications.
Your rear drum brakes don't have wear indicators,
but if you ever hear a rear brake rubbing noise, have the
rear brake linings inspected immediately. Also, the rear
brake drums should be removed and inspected each time
the tires are removed for rotation or changing. When
you have the front brake pads replaced, have the rear
brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.
See ªBrake System Inspectionº in Section 7 of this
manual under Part C ªPeriodic Maintenance Inspections.º

6-32 Brake Pedal Travel
See your dealer if the brake pedal does not return to
normal height, or if there is a rapid increase in pedal
travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a moderate brake stop, your disc
brakes adjust for wear. If you rarely make a moderate or
heavier stop, then your brakes might not adjust correctly.
If you drive in that way, then
-- very carefully -- make
a few moderate brake stops about every 1,000 miles
(1 600 km), so your brakes will adjust properly.
If your brake pedal goes down farther than normal, your
rear drum brakes may need adjustment. Adjust them by
backing up and firmly applying the brakes a few times.
Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together
if the vehicle is to have really good braking. Your
vehicle was designed and tested with top
-quality GM
brake parts. When you replace parts of your braking
system
-- for example, when your brake linings wear
down and you have to have new ones put in
-- be sure
you get new approved GM replacement parts. If you
don't, your brakes may no longer work properly. For
example, if someone puts in brake linings that are wrong
for your vehicle, the balance between your front and
rear brakes can change
-- for the worse. The braking
performance you've come to expect can change in many
other ways if someone puts in the wrong replacement
brake parts.