engine CHEVROLET EPICA 2004 1.G Service Manual

If you drive regularly in steep country, or if you are
planning to visit there, here are some tips that can make
your trips safer and more enjoyable.
•Keep your vehicle in good shape. Check all fluid
levels and also the brakes, tires, cooling system
and transaxle. These parts can work hard on
mountain roads.
•Know how to go down hills. The most important
thing to know is this: let your engine do some of
the slowing down. Shift to a lower gear when you
go down a steep or long hill.
{CAUTION:
If you do not shift down, your brakes could get
so hot that they would not work well. You would
then have poor braking or even none going
down a hill. You could crash. Shift down to let
your engine assist your brakes on a steep
downhill slope.
{CAUTION:
Coasting downhill in NEUTRAL (N) or with the
ignition off is dangerous. Your brakes will have
to do all the work of slowing down. They could
get so hot that they would not work well. You
would then have poor braking or even none
going down a hill. You could crash. Always have
your engine running and your vehicle in gear
when you go downhill.
•Know how to go uphill. Drive in the highest gear
possible.
•Stay in your own lane when driving on two-lane
roads in hills or mountains. Do not swing wide or cut
across the center of the road. Drive at speeds that let
you stay in your own lane.
•As you go over the top of a hill, be alert. There could
be something in your lane, like a stalled car or an
accident.
•You may see highway signs on mountains that warn
of special problems. Examples are long grades,
passing or no-passing zones, a falling rocks area or
winding roads. Be alert to these and take appropriate
action.
4-23

•Put on extra clothing or wrap a blanket around you.
If you have no blankets or extra clothing, make body
insulators from newspapers, burlap bags, rags, floor
mats — anything you can wrap around yourself or
tuck under your clothing to keep warm.
You can run the engine to keep warm, but be careful.
{CAUTION:
Snow can trap exhaust gases under your
vehicle. This can cause deadly CO (carbon
monoxide) gas to get inside. CO could
overcome you and kill you. You can not see
it or smell it, so you might not know it is in
your vehicle. Clear away snow from around
the base of your vehicle, especially any that
is blocking your exhaust pipe. And check
around again from time to time to be sure
snow does not collect there.
Open a window just a little on the side of
the vehicle that is away from the wind.
This will help keep CO out.
Run your engine only as long as you must. This saves
fuel. When you run the engine, make it go a little faster
than just idle. That is, push the accelerator slightly. This
uses less fuel for the heat that you get and it keeps the
battery charged. You will need a well-charged battery to
restart the vehicle, and possibly for signaling later on with
your headlamps. Let the heater run for a while.
4-27

Then, shut the engine off and close the window almost
all the way to preserve the heat. Start the engine again
and repeat this only when you feel really uncomfortable
from the cold. But do it as little as possible. Preserve the
fuel as long as you can. To help keep warm, you can get
out of the vehicle and do some fairly vigorous exercises
every half hour or so until help comes.
If You Are Stuck: In Sand, Mud,
Ice or Snow
In order to free your vehicle when it is stuck, you will
need to spin the wheels, but you do not want to spin your
wheels too fast. The method known as “rocking” can help
you get out when you are stuck, but you must use
caution.
{CAUTION:
If you let your tires spin at high speed, they can
explode, and you or others could be injured.
And, the transaxle or other parts of the vehicle
can overheat. That could cause an engine
compartment re or other damage. When you
are stuck, spin the wheels as little as possible.
Do not spin the wheels above 35 mph (55 km/h)
as shown on the speedometer.
Notice:Spinning your wheels can destroy parts
of your vehicle as well as the tires. If you spin
the wheels too fast while shifting your transaxle
back and forth, you can destroy your transaxle.
See “Rocking Your Vehicle To Get It Out.”
For information about using tire chains on your vehicle,
seeTire Chains on page 5-60.
4-28

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of
Your Vehicle..............................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specifications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling Your Tank............................................5-7
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-10
Hood Release..............................................5-11
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Air Cleaner/Filter................................5-17
Automatic Transaxle Fluid..............................5-19
Engine Coolant.............................................5-19
Coolant Surge Tank Pressure Cap..................5-21
Engine Overheating.......................................5-22
Cooling System............................................5-24
Power Steering Fluid.....................................5-30
Windshield Washer Fluid................................5-31
Brakes........................................................5-32Battery........................................................5-35
Jump Starting...............................................5-36
Headlamp Aiming...........................................5-40
Bulb Replacement..........................................5-41
Halogen Bulbs..............................................5-41
Headlamps..................................................5-41
Front Turn Signal Lamps...............................5-43
Center High-Mounted Stoplamp (CHMSL).........5-44
Parking Lamps.............................................5-45
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-46
Windshield Wiper Blade Replacement..............5-47
Tires..............................................................5-48
Inflation - 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......................................5-59
Tire Chains..................................................5-60
If a Tire Goes Flat........................................5-61
Changing a Flat Tire.....................................5-62
Spare Tire...................................................5-68
Section 5 Service and Appearance Care
5-1

Service
Your dealer knows your vehicle best and wants you to
be happy with it. We hope you will go to your dealer
for all your service needs. You will get genuine GM parts
and GM-trained and supported service people.
We hope you will want to keep your GM vehicle all GM.
Genuine GM parts have one of these marks:
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many fluids, and
some component wear by-products contain and/or emit
these chemicals.
5-3

Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle can
affect the airflow around it. This may cause wind noise
and affect windshield washer performance. Check with
your dealer before adding equipment to the outside of
your vehicle.
Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
Use regular unleaded gasoline with a posted octane
of 87 or higher. If the octane is less than 87, you may
get a heavy knocking noise when you drive. If this
occurs, use a gasoline rated at 87 octane or higher as
soon as possible. Otherwise, you might damage
your engine. A little pinging noise when you accelerate
or drive uphill is considered normal. This does not
indicate a problem exists or that a higher-octane fuel is
necessary. If you are using 87 octane or higher-octane
fuel and hear heavy knocking, your engine needs
service.
Gasoline Specications
It is recommended that gasoline meet specifications
which were developed by automobile manufacturers
around the world and contained in the World-Wide
Fuel Charter which is available from the Alliance
of Automobile Manufacturers at www.autoalliance.org.
Gasoline meeting these specifications could provide
improved driveability and emission control system
performance compared to other gasoline.
In Canada, look for the
“Auto Makers’ Choice”
label on the pump.
Canada Only
5-5

California Fuel
If your vehicle is certified to meet California Emission
Standards (see the underhood emission control label),
it is designed to operate on fuels that meet California
specifications. If this fuel is not available in states
adopting California emissions standards, your vehicle
will operate satisfactorily on fuels meeting federal
specifications, but emission control system performance
may be affected. The malfunction indicator lamp may
turn on (seeMalfunction Indicator Lamp on page 3-39)
and your vehicle may fail a smog-check test. If this
occurs, return to your authorized GM dealer for
diagnosis. If it is determined that the condition is caused
by the type of fuel used, repairs may not be covered
by your warranty.
Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work
properly. You should not have to add anything to your
fuel. However, some gasolines contain only the
minimum amount of additive required to meet U.S.
Environmental Protection Agency regulations.General Motors recommends that you buy gasolines that
are advertised to help keep fuel injectors and intake
valves clean. If your vehicle experiences problems due to
dirty injectors or valves, try a different brand of gasoline.
Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines may be available in
your area to contribute to clean air. General Motors
recommends that you use these gasolines, particularly if
they comply with the specifications described earlier.
Notice:Your vehicle was not designed for fuel that
contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in your fuel
system and also damage the plastic and rubber
parts. That damage would not be covered under
your warranty.
Some gasolines that are not reformulated for low
emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese tricarbonyl
(MMT); ask the attendant where you buy gasoline
whether the fuel contains MMT. General Motors does
not recommend the use of such gasolines. Fuels
containing MMT can reduce the life of spark plugs and
the performance of the emission control system may
be affected. The malfunction indicator lamp may turn on.
If this occurs, return to your authorized GM dealer for
service.
5-6

Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel may be hard
to find. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly
repairs caused by use of improper fuel would not
be covered by your warranty.
To check the fuel availability, ask an auto club, or contact
a major oil company that does business in the country
where you will be driving.
Filling Your Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to you
and others, read and follow all the instructions
on the pump island. Turn off your engine when
you are refueling. Do not smoke if you are near
fuel or refueling your vehicle. Keep sparks,
ames and smoking materials away from fuel.
CAUTION: (Continued)
CAUTION: (Continued)
Do not leave the fuel pump unattended when
refueling your vehicle — this is against the law
in some places. Keep children away from the
fuel pump; never let children pump fuel.
To open the fuel filler door,
pull up on the fuel filler
door release lever located
on the floor to the left
of the driver’s seat.
The fuel cap is located behind a hinged door on the
passenger’s side of your vehicle. To remove the
fuel cap, turn it slowly to the left (counterclockwise).
5-7

Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
damaged if this occurs. To help avoid injury
to you and others:
Dispense gasoline only into approved
containers.
Do not ll a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed
or on any surface other than the ground.
Bring the ll nozzle in contact with the
inside of the ll opening before operating
the nozzle. Contact should be maintained
until the lling is complete.
Do not smoke while pumping gasoline.
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 re. These include liquids like fuel,
oil, coolant, brake uid, windshield washer and
other uids, 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.
5-10

Engine Compartment Overview
When you open the hood on the engine, you will see the following:
5-12