engine CHEVROLET CAVALIER 2003 3.G Owners Manual

100,000 Miles (166 000 km)
qReplace spark plugs.An Emission Control Service.
qChange automatic transaxle ¯uid and ®lter if the
vehicle is mainly driven under one or more of
these conditions:
þ In heavy city traffic where the outside
temperature regularly reaches 90ÉF (32ÉC) or
higher.
þ In hilly or mountainous terrain.
þ When doing frequent trailer towing.
þ Uses such as found in taxi, police or delivery
service.
If you do not use your vehicle under any of these
conditions, the ¯uid and ®lter do not require changing.
Manual transaxle ¯uid doesn't require change.
150,000 Miles (240 000 km)
qDrain, ¯ush and re®ll cooling system (or every
60 months since last service, whichever occurs ®rst).
See
Engine Coolant on page 5-22for what to use.
Inspect hoses. Clean radiator, condenser, pressure
cap and neck. Pressure test the cooling system
and pressure cap.
An Emission Control Service.
qInspect engine accessory drive belt.An Emission
Control Service.
6-18

Part B: Owner Checks and Services
Listed in this part are owner checks and services
which should be performed at the intervals speci®ed to
help ensure the safety, dependability and emission
control performance of your vehicle.
Be sure any necessary repairs are completed at once.
Whenever any ¯uids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
in Part D.
At Each Fuel Fill
It is important for you or a service station attendant to
perform these underhood checks at each fuel ®ll.
Engine Oil Level Check
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil on page 5-14for further
details.
Engine Coolant Level Check
Check the engine coolant level and add DEX-COOLž
coolant mixture if necessary. SeeEngine Coolant
on page 5-22for further details.
Windshield Washer Fluid Level Check
Check the windshield washer ¯uid level in the windshield
washer tank and add the proper ¯uid if necessary. See
Windshield Washer Fluid on page 5-34for further details.
At Least Once a Month
Tire In¯ation Check
Make sure tires are in¯ated to the correct pressures.
Don't forget to check your spare tire. SeeTires on
page 5-51for further details.
Cassette Tape Player Service
Clean cassette tape player. Cleaning should be done
every 50 hours of tape play. SeeAudio System(s)
on page 3-36for further details.
At Least Twice a Year
Restraint System Check
Make sure the safety belt reminder light and all your
belts, buckles, latch plates, retractors and anchorages
are working properly. Look for any other loose or
damaged safety belt system parts. If you see anything
that might keep a safety belt system from doing its
job, have it repaired. Have any torn or frayed safety belts
replaced.
Also look for any opened or broken air bag coverings,
and have them repaired or replaced. (The air bag
system does not need regular maintenance.)
6-19

Starter Switch Check
{CAUTION:
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.
2. Firmly apply both the parking brake and the regular
brake. See
Parking Brake on page 2-26if
necessary.
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
¯oor. If the starter works when the clutch isn't pushed
all the way down, your vehicle needs service.
Automatic Transaxle Shift Lock Control
System Check
{CAUTION:
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
on page 2-26if necessary.
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 needs service.
6-21

Ignition Transaxle Lock Check
While parked, and with the parking brake set, try to turn
the ignition 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 you press the key release
button.
On all vehicles, the key should come out only in LOCK.
Turn the steering wheel to the left and to the right. It
should only lock when turned to the right.
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
CAUTION: (Continued)
CAUTION: (Continued)
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 ¯ush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
6-22

Part C: Periodic
MaintenanceInspections
Listed in this part are inspections and services which
should be performed at least twice a year (for instance,
each spring and fall).
You should let your dealer's
service department do these jobs. Make sure any
necessary repairs are completed at once.
Proper procedures to perform these services may be
found in a service manual. SeeService Publications
Ordering Information on page 7-10.
Steering, Suspension and Front
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, cha®ng, 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 ¯oor pan or could let
exhaust fumes into the vehicle. See
Engine Exhaust
on page 2-30.
Fuel System Inspection
Inspect the complete fuel system for damage or leaks.
Engine Cooling System Inspection
Inspect the hoses and have them replaced if they
are cracked, swollen or deteriorated. Inspect all pipes,
®ttings 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.
6-23

Part D: Recommended Fluids and
Lubricants
Fluids and lubricants identi®ed below by name, part
number or speci®cation may be obtained from your
dealer.
Usage Fluid/Lubricant
Engine OilEngine oil with the American
Petroleum Institute Certi®ed for
Gasoline Engines starburst symbol
of the proper viscosity. To determine
the preferred viscosity for your
vehicle's engine, see
Engine Oil on
page 5-14.
Engine Coolant50/50 mixture of clean, drinkable
water and use only
DEX-COOL
žCoolant. SeeEngine
Coolant on page 5-22.
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake ¯uid.
Windshield
Washer SolventGM Optikleen
žWasher Solvent or
equivalent.
Usage Fluid/Lubricant
Hydraulic
Clutch SystemHydraulic Clutch Fluid (GM Part No.
U.S. 12345347, in Canada
10953517, or equivalent DOT-3
brake ¯uid).
Power Steering
SystemGM Power Steering Fluid (GM Part
No. U.S. 1052884, in Canada
993294, or equivalent).
Manual
TransaxleDEXRON
ž-III Automatic
Transmission Fluid.
Automatic
TransaxleDEXRON
ž-III Automatic
Transmission Fluid.
Key Lock
CylindersMulit-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474, or equivalent).
Manual
Transaxle Shift
LinkageChassis Lubricant (GM Part No.
U.S. 12377985, in Canada
88901242, or equivalent) or lubricant
meeting requirements of NLGI #2,
Category LB or GC-LB.
Clutch Linkage
Pivot PointsEngine oil.
6-25

Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to General
Motors
In addition to notifying NHTSA (or Transport Canada) 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
In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
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
Transmission, Transaxle, Transfer
Case Unit Repair Manual
This manual provides information on unit repair service
procedures, adjustments, and speci®cations for GM
transmissions, transaxles, and transfer cases.
RETAIL SELL PRICE: $50.00
Service Bulletins
Service Bulletins give technical service information
needed to knowledgeably service General Motors cars
and trucks. Each bulletin contains instructions to
assist in the diagnosis and service of your vehicle.
In Canada, information pertaining to Product Service
Bulletins can be obtained by contacting your General
Motors dealer or by calling 1-800-GM-DRIVE
(1-800-463-7483).
7-10

A
Accessory Power Outlets.................................3-16
Adding Washer Fluid.......................................5-34
Additional Program Information........................... 7-9
Additives, Fuel................................................. 5-5
Add-On Electrical Equipment............................5-80
Adjusting the Speakers
(Balance/Fade)....................3-38, 3-42, 3-52, 3-66
Air Bag Systems.............................................1-49
How Does an Air Bag Restrain?....................1-56
Servicing Your Air Bag-Equipped Vehicle.........1-58
What Makes an Air Bag In¯ate?....................1-55
What Will You See After an Air
Bag In¯ates?...........................................1-56
When Should an Air Bag In¯ate?...................1-55
Where Are the Air Bags?..............................1-52
Air Bag .........................................................3-24
Readiness Light..........................................3-24
Air Cleaner/Filter, Engine.................................5-18
AM-FM Radio.................................................3-37
AM ...............................................................3-76
Antenna, Fixed Mast.......................................3-78
Antenna, XMŸ Satellite Radio Antenna System . . 3-79
Anti-lock Brake System (ABS)............................ 4-6
Anti-Lock Brake, System Warning Light..............3-27
Appearance Care............................................5-71
Care of Safety Belts....................................5-74
Chemical Paint Spotting...............................5-77
Cleaning the Inside of Your Vehicle................5-71Appearance Care (cont.)
Cleaning the Outside of Your Vehicle..............5-74
Finish Damage............................................5-77
Sheet Metal Damage...................................5-77
Underbody Maintenance...............................5-77
Vehicle Care/Appearance Materials................5-78
Weatherstrips..............................................5-74
Arming the System.........................................2-15
Ashtrays........................................................3-16
Audio System(s).............................................3-36
AM-FM Radio.............................................3-37
Care of Your Cassette Tape Player................3-77
Care of Your CD Player...............................3-78
Care of Your CDs........................................3-78
Chime Level Adjustment...............................3-79
Fixed Mast Antenna.....................................3-78
Personal Choice Radio Controls....................3-75
Radio with Cassette and CD.........................3-63
Radio with CD....................................3-39, 3-49
Setting the Time for Radios with Radio
Data Systems (RDS)................................3-36
Setting the Time for Radios without
Radio Data Systems (RDS).......................3-36
Theft-Deterrent Feature................................3-76
Understanding Radio Reception.....................3-76
XMŸ Satellite Radio Antenna System............3-79
Automatic Transaxle Inspection.........................6-20
Automatic Transaxle Shift Lock Control
System Check.............................................6-21
1

Automatic Transaxle........................................2-19
Fluid..........................................................5-20
Operation...................................................2-22
B
Backing Up....................................................4-38
Battery Replacement......................................... 2-6
Battery Run-Down Protection............................3-15
Battery..........................................................5-39
Before Leaving on a Long Trip.........................4-21
Body Lubrication Service..................................6-20
Brake Fluid....................................................5-35
Brake Wear...................................................5-37
Brake............................................................2-26
Parking......................................................2-26
System Inspection.......................................6-24
System Warning Light..................................3-26
Brakes..........................................................5-35
Braking in Emergencies..................................... 4-8
Braking........................................................... 4-6
Break-In, New Vehicle.....................................2-17
Bulb Replacement...........................................5-45
Back-Up Lamps...........................................5-49
Front Turn Signal and Parking Lamps.............5-47
Halogen Bulbs............................................5-45
Headlamps.................................................5-45Bulb Replacement (cont.)
Replacement Bulbs......................................5-49
Taillamps and Turn Signal Lamps..................5-48
Buying New Tires...........................................5-55C
California Fuel.................................................. 5-5
Caliper/Knuckle MaintenanceInspection.............6-24
Canada ± Customer Assistance.......................... 7-4
Canadian Owners................................................ ii
Canadian Roadside Assistance........................... 7-7
Canceling the Rear Door Security Lock............... 2-9
Capacities and Speci®cations............................5-85
Carbon Monoxide...........4-24, 4-34, 4-40, 2-10, 2-30
Care of.........................................................5-74
Safety Belts................................................5-74
Your Cassette Tape Player............................3-77
Your CD Player...........................................3-78
Your CDs ...................................................3-78
Cassette Tape Messages.................................3-72
Cassette Tape Player Service...........................6-19
CD Adapter Kits.............................................3-73
Center Console Storage Area...........................2-35
Chains, Tires..................................................5-59
Charging System Light....................................3-25
Check Engine Light.........................................3-30
2

Checking Coolant............................................5-23
Checking Engine Oil........................................5-14
Checking Things Under the Hood......................5-10
Checking Your Restraint Systems......................1-58
Check...........................................................3-30
Engine Light...............................................3-30
Gages Warning Light...................................3-34
Chemical Paint Spotting...................................5-77
Child Restraints..............................................1-35
Child Restraint Systems...............................1-35
Infants and Young Children...........................1-32
Lower Anchorages and Top Tethers for
Children (LATCH System)..........................1-41
Older Children.............................................1-29
Securing a Child Restraint Designed for
the LATCH System...................................1-43
Securing a Child Restraint in a Rear
Seat Position...........................................1-43
Securing a Child Restraint in the Right
Front Seat Position...................................1-46
Top Strap Anchor Location............................1-40
Top Strap...................................................1-39
Where to Put the Restraint...........................1-38
Chime Level Adjustment..................................3-79
Cigarette Lighter.............................................3-16
Cleaning Aluminum or Chrome-Plated Wheels.....5-76
Cleaning Exterior Lamps/Lenses.......................5-75
Cleaning Fabric/Carpet....................................5-71
Cleaning Glass Surfaces..................................5-73Cleaning Interior Plastic Components.................5-73
Cleaning the Top of the
Instrument Panel.........................................5-73
Cleaning Tires................................................5-77
Cleaning Vinyl................................................5-73
Cleaning Windshield and Wiper Blades..............5-76
Cleaning........................................................5-71
Inside of Your Vehicle..................................5-71
Outside of Your Vehicle................................5-74
Underbody Maintenance...............................5-77
Weatherstrips..............................................5-74
Climate Control System...................................3-17
Outlet Adjustment........................................3-20
Clutch, Hydraulic.............................................5-21
Compact Disc Messages.................3-48, 3-63, 3-75
Compact Spare Tire........................................5-70
Content Theft-Deferrent....................................2-15
Control of a Vehicle.......................................... 4-5
Convenience Net............................................2-36
Coolant.........................................................3-29
Engine Temperature Gage............................3-29
Heater, Engine............................................2-21
Low Warning Light.......................................3-30
Surge Tank Pressure Cap.............................5-24
Cooling System..............................................5-27
Cruise Control.................................................. 3-8
Cupholder(s)..................................................2-35
Current and Past Model Order Forms................7-11
3