brakes CHEVROLET CAVALIER 2004 3.G Owner's Manual

Driving on Grades
Notice:Do not tow on steep continuous grades
exceeding 6 miles (9.6 km). Extended, higher
than normal engine and transaxle temperatures may
result and damage your vehicle. Frequent stops
are very important to allow the engine and transaxle
to cool.
Reduce speed and shift to a lower gearbeforeyou start
down a long or steep downgrade. If you do not shift
down, you might have to use your brakes so much that
they would get hot and no longer work well.
Pay attention to the engine coolant gage. If the indicator
is in the red area, turn off the air conditioning to
reduce engine load. SeeEngine Overheating on
page 5-23.
Parking on Hills
{CAUTION:
You really should not park your vehicle, with a
trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.
But if you ever have to park your rig on a hill, here is
how to do it:
1. Apply your regular brakes, but do not shift into
PARK (P) yet. When parking uphill, turn your
wheels away from the curb. When parking downhill,
turn your wheels into the curb.
2. Have someone place chocks under the trailer
wheels.
3. When the wheel chocks are in place, release the
regular brakes until the chocks absorb the load.
4. Reapply the regular brakes. Then apply your
parking brake, and then shift to PARK (P).
5. Release the regular brakes.
4-42

When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you:
Start your engine.
Shift into a gear.
Release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the
chocks.
Maintenance When Trailer Towing
Your vehicle will need service more often when you are
pulling a trailer. SeePart A: Scheduled Maintenance
Services on page 6-4for more on this. Things that are
especially important in trailer operation are automatic
transaxle uid (don’t overll), engine oil, drive belt,
cooling system and brake system.Each of these is covered in this manual, and the Index
will help you nd them quickly. If you are trailering,
it is a good idea to review this information before you
start your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
Engine Cooling When Trailer Towing
Your cooling system may temporarily overheat during
severe operating conditions. SeeEngine Overheating on
page 5-23.
Towing a Trailer (Manual Transaxle)
Do not tow a trailer if your vehicle is equipped with a
manual transaxle.
4-43

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-4
Fuel................................................................5-4
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-6
Filling Your Tank............................................5-7
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood....................5-10
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Air Cleaner/Filter................................5-17
Automatic Transaxle Fluid..............................5-19
Manual Transaxle Fluid..................................5-19
Hydraulic Clutch...........................................5-19
Engine Coolant.............................................5-20
Coolant Surge Tank Pressure Cap..................5-23
Engine Overheating.......................................5-23
Cooling System............................................5-25
Power Steering Fluid.....................................5-30Windshield Washer Fluid................................5-31
Brakes........................................................5-32
Battery........................................................5-36
Jump Starting...............................................5-36
Bulb Replacement..........................................5-41
Halogen Bulbs..............................................5-41
Headlamps..................................................5-41
Front Turn Signal and Parking Lamps..............5-43
Taillamps and Turn Signal Lamps...................5-44
Back-Up Lamps............................................5-44
Replacement Bulbs.......................................5-44
Windshield Wiper Blade Replacement..............5-45
Tires..............................................................5-46
Ination - Tire Pressure.................................5-53
Tire Inspection and Rotation...........................5-54
When It Is Time for New Tires.......................5-55
Buying New Tires.........................................5-56
Uniform Tire Quality Grading..........................5-57
Wheel Alignment and Tire Balance..................5-58
Wheel Replacement......................................5-58
Tire Chains..................................................5-60
If a Tire Goes Flat........................................5-61
Changing a Flat Tire.....................................5-62
Compact Spare Tire......................................5-72
Section 5 Service and Appearance Care
5-1

A. Coolant Surge Tank. SeeCooling System on
page 5-25.
B. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-13.
C. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-13.
D. Brake Fluid Reservoir. See “Brake Fluid” under
Brakes on page 5-32.
E. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-30.
F. Clutch Master Cylinder Reservoir (If Equipped) (Not
Shown). SeeHydraulic Clutch on page 5-19.
G. Battery. SeeBattery on page 5-36.
H. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-17.
I. Windshield Washer Fluid Reservoir. SeeWindshield
Washer Fluid on page 5-31.
J. Engine Compartment Fuse Block. See “Engine
Compartment Fuse Block” underFuses and Circuit
Breakers on page 5-81.Engine Oil
If the oil pressure light
appears on the instrument
cluster, it means you
need to check your engine
oil level right away.
For more information, seeOil Pressure Light on
page 3-32.
You should check your engine oil level regularly; this is
an added reminder.
Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
Turn off the engine and give the oil several minutes to
drain back into the oil pan. If you don’t, the oil
dipstick might not show the actual level.
5-13

Adding Washer Fluid
Open the cap with the
washer symbol on it. Add
washer uid until the
tank is full. SeeEngine
Compartment Overview on
page 5-12for reservoir
location.
Notice:
When using concentrated washer uid, follow the
manufacturer’s instructions for adding water.
Do not mix water with ready-to-use washer uid.
Water can cause the solution to freeze and
damage your washer uid tank and other parts
of the washer system. Also, water does not
clean as well as washer uid.
Fill your washer uid tank only three-quarters
full when it is very cold. This allows for
expansion if freezing occurs, which could
damage the tank if it is completely full.
Do not use engine coolant (antifreeze) in your
windshield washer. It can damage your washer
system and paint.
Brakes
Brake Fluid
Your brake master cylinder reservoir is lled with DOT-3
brake uid. SeeEngine Compartment Overview on
page 5-12for the location of the reservoir.
5-32

There are only two reasons why the brake uid level in
the reservoir might go down. The rst is that the
brake uid goes down to an acceptable level during
normal brake lining wear. When new linings are put in,
the uid level goes back up. The other reason is
that uid is leaking out of the brake system. If it is, you
should have your brake system xed, since a leak
means that sooner or later your brakes will not work
well, or will not work at all.
So, it is not a good idea to “top off” your brake uid.
Adding brake uid will not correct a leak. If you add uid
when your linings are worn, then you will have too
much uid when you get new brake linings. You should
add (or remove) brake uid, as necessary, only when
work is done on the brake hydraulic system.
{CAUTION:
If you have too much brake uid, it can spill on
the engine. The uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
uid only when work is done on the brake
hydraulic system.
When your brake uid falls to a low level, your brake
warning light will come on. SeeBrake System Warning
Light on page 3-25.
5-33

What to Add
When you do need brake uid, use only DOT-3 brake
uid. Use new brake uid from a sealed container
only. SeePart D: Recommended Fluids and Lubricants
on page 6-25.
Always clean the brake uid 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 uid 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
uid.
Notice:
Using the wrong uid 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 will have to be replaced. Do not
let someone put in the wrong kind of uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged. Be
careful not to spill brake uid on your vehicle. If
you do, wash it off immediately. SeeAppearance
Care on page 5-72.
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 rmly).
{CAUTION:
The brake wear warning sound means that
soon your brakes will not 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.
5-34

Some driving conditions or climates may cause a brake
squeal when the brakes are rst applied or lightly
applied. This does not mean something is wrong with
your brakes.
SeeCaliper/Knuckle Maintenance Inspection on
page 6-24.
Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to GM torque specications.
Your rear drum brakes do not 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.
SeeBrake System Inspection on page 6-24.
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 rmly 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 need new ones put in — be sure
you get new approved GM replacement parts. If you do
not, 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 have come to expect can change
in many other ways if someone puts in the wrong
replacement brake parts.
5-35

Tire Size
The following illustration shows an example of a typical
passenger car tire size.
(A) P-Metric Tire:The United States version of a
metric tire sizing system. The letter “P” as the
rst character in the tire size means a passenger
vehicle tire engineered to standards set by the U. S.
Tire and Rim Association.
(B) Tire Width:The three-digit number indicates the
tire section width in millimeters from sidewall to sidewall.
(C) Aspect Ratio:A two-digit number that indicates
the tire height-to-width measurements. For example, if
the tire size aspect ratio is “70,” as shown in item “C” of
the illustration, it would mean that the tire’s sidewall is
70% as high as it is wide.(D) Construction Code:A letter code is used to
indicate the type of ply construction in the tire. The letter
“R” means radial ply construction; the letter “D” means
diagonal or bias ply construction; and the letter “B”
means belted-bias ply construction.
(E) Rim Diameter:Diameter of the wheel in inches.
(F) Service Description:These characters represent
the load range and the speed rating of a tire. The
load range represents the load carrying capacity a tire is
certied to carry. The load index can range from 1 to
279. The speed rating is the maximum speed a tire
is certied to carry a load. Speed ratings range from “A”
to “Z”.
Tire Terminology and Denitions
Air Pressure:The amount of air inside the tire pressing
outward on each square inch of the tire. Air pressure
is expressed in pounds per square inch (psi) or
kilopascal (kPa).
Accessory Weight:This means the combined weight
of optional accessories. Some examples of optional
accessories are, automatic transmission, power steering,
power brakes, power windows, power seats, and air
conditioning.
Aspect Ratio:The relationship of a tire’s height to its
width.
5-50

Tire Chains
{CAUTION:
If your vehicle has P195/65R15 or P205/55R16
size tires, don’t use tire chains, there’s not
enough clearance.
Tire chains used on a vehicle without the
proper amount of clearance can cause damage
to the brakes, suspension or other vehicle
parts. The area damaged by the tire chains
could cause you to lose control of your vehicle
and you or others may be injured in a crash.
Use another type of traction device only if its
manufacturer recommends it for use on your
vehicle and tire size combination and road
CAUTION: (Continued)
CAUTION: (Continued)
conditions. Follow that manufacturer’s
instructions. To help avoid damage to your
vehicle, drive slowly, readjust or remove the
device if it’s contacting your vehicle, and don’t
spin your wheels.
If you do nd traction devices that will t,
install them on the front tires.
Notice:If your vehicle has a tire size other than
P195/65R15 or P205/55R16 size tires, use tire chains
only where legal and only when you must. Use
only SAE Class “S” type chains that are the proper
size for your tires. Install them on the front tires
and tighten them as tightly as possible with the ends
securely fastened. Drive slowly and follow the
chain manufacturer’s instructions. If you can hear
the chains contacting your vehicle, stop and
retighten them. If the contact continues, slow down
until it stops. Driving too fast or spinning the
wheels with chains on will damage your vehicle.
5-60