brake CHEVROLET CAVALIER 2003 3.G Repair Manual

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

Brake System Inspection
Inspect the complete system. Inspect brake lines and
hoses for proper hook-up, binding, leaks, cracks,
cha®ng, 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.
Caliper/Knuckle
MaintenanceInspection
If you operate your vehicle in a highly corrosive
environment, as indicated by the shaded areas on the
map following this text, your vehicle may require
additional brake service. Refer to the appropriate GM
service bulletin for the proper caliper inspection
procedure. As necessary, caliper pins and knuckle
brake pad abutments should be lubricated at every other
tire rotation. Also, see your GM dealer's service
department or quali®ed service center for additional
information.
6-24

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

I
If No Steam Is Coming From Your Engine..........5-26
If Steam Is Coming From Your Engine...............5-25
If the Light Is Flashing.....................................3-31
If the Light Is on Steady..................................3-32
If You Are Stuck in Sand, Mud, Ice or Snow.......4-29
If You Do Decide To Pull A Trailer.....................4-35
If You're Caught in a Blizzard...........................4-27
Ignition Positions.............................................2-17
Ignition Transaxle Lock Check..........................6-22
Infants and Young Children, Restraints...............1-32
In¯ation -- Tire Pressure..................................5-52
Inspection......................................................6-24
Brake System.............................................6-24
Caliper/Knuckle Maintenance.........................6-24
Engine Cooling System................................6-23
Exhaust System..........................................6-23
Fuel System...............................................6-23
Part C - Periodic Maintenance.......................6-23
Steering, Suspension and Front Drive Axle
Boot and Seal.........................................6-23
Throttle System...........................................6-23
Instrument Panel Brightness.............................3-14
Instrument Panel Fuse Block............................5-82
Instrument Panel.............................................3-22
Cluster.......................................................3-22
Overview..................................................... 3-2
Interior Lamps................................................3-14
J
Jump Starting.................................................5-40
K
Key Lock Cylinders Service..............................6-20
Key Release Button (Manual Transaxle).............2-19
Keyless Entry System....................................... 2-3
Keys............................................................... 2-2
L
Lamps On Reminder.......................................3-12
Lamps...........................................................3-12
Exterior......................................................3-12
Interior.......................................................3-14
Lap-Shoulder Belt...................................1-15, 1-23
LATCH System...............................................1-41
Child Restraints...........................................1-41
Securing a Child Restraint Designed for the
LATCH System........................................1-43
Latches, Seatback............................................ 1-6
Leaving Your Vehicle With the Engine Running . . . 2-28
Leaving Your Vehicle.......................................2-10
7

Light.............................................................3-24
Air Bag Readiness.......................................3-24
Anti-Lock Brake System Warning...................3-27
Brake System Warning.................................3-26
Charging System.........................................3-25
Check Gages Warning.................................3-34
Enhanced Traction System (ETS)
Active Light.............................................3-29
Enhanced Traction System (ETS)
Warning Light..........................................3-28
Low Coolant Warning...................................3-30
Malfunction Indicator....................................3-30
Oil Pressure...............................................3-33
Passlock
žWarning.......................................3-34
Safety Belt Reminder...................................3-24
Service Vehicle Soon...................................3-35
Up-Shift.....................................................3-26
Loading Your Vehicle.......................................4-32
Lockout Protection..........................................2-10
Locks............................................................. 2-7
Door........................................................... 2-7
Leaving Your Vehicle....................................2-10
Lockout Protection.......................................2-10
Power Door.................................................. 2-8
Rear Door Security Locks............................... 2-9
Long Trip/Highway De®nition.............................. 6-6Long Trip/Highway Intervals............................... 6-6
Long Trip/Highway Scheduled Maintenance........6-14
Loss of Control...............................................4-14
Low Coolant Warning Light..............................3-30
M
Maintenance, Normal Replacement Parts............5-86
Maintenance Schedule.....................................6-19
At Each Fuel Fill.........................................6-19
At Least Once a Month................................6-19
At Least Once a Year..................................6-20
At Least Twice a Year..................................6-19
Brake System Inspection..............................6-24
Caliper/Knuckle MaintenanceInspection..........6-24
Engine Cooling System Inspection.................6-23
Exhaust System Inspection...........................6-23
Fuel System Inspection................................6-23
How This Section is Organized....................... 6-3
Introduction.................................................. 6-2
Long Trip/Highway Scheduled Maintenance.....6-14
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4
Part B - Owner Checks and Services.............6-19
Part C - Periodic MaintenanceInspections......6-23
Part D - Recommended Fluids
and Lubricants.........................................6-25
8

Operation......................................................3-17
Other Warning Devices...................................... 3-4
Outlet Adjustment............................................3-20
Outside.........................................................2-33
Breakaway Mirrors.......................................2-33
Convex Mirror.............................................2-33
Power Mirrors.............................................2-32
Remote Control Mirror..................................2-32
Overseas ± Customer Assistance........................ 7-5
Owners, Canadian............................................... ii
Owner's Information........................................7-11
P
Park (P)........................................................2-27
Shifting Into................................................2-27
Shifting Out of............................................2-29
Parking Brake and Automatic Transaxle Park (P)
Mechanism Check.......................................6-22
Parking on Hills..............................................4-39
Parking Your Vehicle.......................................2-29
Parking.........................................................2-26
Brake........................................................2-26
Over Things That Burn.................................2-30Part A - Scheduled Maintenance Services............ 6-4
Part B - Owner Checks and Services................6-19
Part C - Periodic MaintenanceInspections..........6-23
Part D - Recommended Fluids and Lubricants....6-25
Part E - Maintenance Record...........................6-27
Passing.................................................4-12, 4-38
Passlock
ž......................................................2-16
Personal Choice Radio Controls........................3-75
Plan Ahead When Possible................................ 7-7
Playing a Cassette Tape..................................3-71
Playing a Compact Disc..................3-47, 3-57, 3-73
Playing the Radio...................3-37, 3-40, 3-50, 3-64
Power Steering...............................................4-10
Power...........................................................3-16
Accessory Outlets........................................3-16
Door Locks.................................................. 2-8
Electrical System.........................................5-81
Steering Fluid.............................................5-33
Windows....................................................2-14
Q
Questions and Answers About Safety Belts.........1-13
10