ECU CHEVROLET OPTRA 2004 1.G Service Manual

For prompt and efficient assistance when calling, please
provide the following to the Roadside Assistance
Representative:
•Your name, home address, and home telephone
number
•Telephone number of your location
•Location of the vehicle
•Model, year, color, and license plate number
•Mileage, Vehicle Identification Number and delivery
date of the vehicle
•Description of the problem
While we hope you never have the occasion to use our
service, it is added security while traveling for you
and your family. Remember, we are only a phone
call away. Chevrolet Roadside Assistance:
1-800-CHEV-USA (1-800-234-8872), text telephone
(TTY) users, call 1-888-889-2438.
Chevrolet reserves the right to limit services or
reimbursement to an owner or driver when, in
Chevrolet’s judgement, the claims become excessive in
frequency or type of occurrence.
Roadside Assistance is not part of or included in the
coverage provided by the New Vehicle Limited Warranty.
Buick reserves the right to make any changes or
discontinue the Roadside Assistance program at any
time without notification.
Canadian Roadside Assistance
Vehicles purchased in Canada have an extensive
roadside assistance program accessible from anywhere
in Canada or the United States. Please refer to the
Warranty and Owner Assistance Information book.
Courtesy Transportation
Chevrolet has always exemplified quality and value in
its offering of motor vehicles. To enhance your
ownership experience, we and our participating dealers
are proud to offer Courtesy Transportation, a customer
support program for new vehicles.
The Courtesy Transportation program is offered to retail
purchase/lease customers in conjunction with the
Bumper-to-Bumper coverage provided by the New
Vehicle Limited Warranty. Several transportation options
are available when warranty repairs are required. This will
reduce your inconvenience during warranty repairs.
7-7

Brake
Parking......................................................2-28
System Inspection.......................................6-24
System Warning Light..................................3-30
Brake Fluid....................................................5-35
Brake Wear...................................................5-36
Brakes..........................................................5-35
Braking........................................................... 4-6
Braking in Emergencies..................................... 4-8
Break-In, New Vehicle.....................................2-18
Bulb Replacement...........................................5-44
Center High-Mounted Stoplamp (CHMSL)........5-48
Fog Lamps.................................................5-46
Front Turn Signal and Parking Lamps.............5-45
Halogen Bulbs............................................5-44
Headlamp Aiming........................................5-44
Headlamps.................................................5-44
Replacement Bulbs......................................5-49
Sidemarker Lamps.......................................5-47
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps........................................5-48
Turn Signal Lamps......................................5-46
Buying New Tires...........................................5-60
C
California Fuel.................................................. 5-6
Canada – Customer Assistance.......................... 7-4
Canadian Owners................................................ iiCanadian Roadside Assistance........................... 7-7
Canceling the Rear Door Security Lock..............2-10
Capacities and Specifications............................5-90
Carbon Monoxide...........4-25, 4-37, 2-11, 2-13, 2-33
Care of
Safety Belts................................................5-76
Your CD Player...........................................3-52
Your CDs ...................................................3-52
Cassette Tape Player Service...........................6-18
CD Messages........................................3-44, 3-50
Center High-Mounted Stoplamp (CHMSL)...........5-48
Center Rear Passenger Position, Safety Belts.....1-28
Chains, Tires..................................................5-63
Charging System Light....................................3-29
Check
Engine Light...............................................3-33
Check Engine Light.........................................3-33
Checking Coolant............................................5-23
Checking Engine Oil........................................5-14
Checking Things Under the Hood......................5-10
Chemical Paint Spotting...................................5-79
Child Restraints
Child Restraint Systems...............................1-35
Infants and Young Children...........................1-31
Lower Anchorages and Top Tethers for
Children (LATCH System)..........................1-42
Older Children.............................................1-29
Securing a Child Restraint Designed for the
LATCH System........................................1-45
2

Child Restraints (cont.)
Securing a Child Restraint in a Rear Seat
Position..................................................1-45
Securing a Child Restraint in the Right Front
Seat Position...........................................1-48
Top Strap...................................................1-39
Top Strap Anchor Location............................1-41
Where to Put the Restraint...........................1-38
Cigarette Lighter.............................................3-17
Cleaning
Inside of Your Vehicle..................................5-73
Outside of Your Vehicle................................5-76
Underbody Maintenance...............................5-79
Weatherstrips..............................................5-76
Cleaning Aluminum Wheels..............................5-78
Cleaning Exterior Lamps/Lenses.......................5-77
Cleaning Fabric/Carpet....................................5-73
Cleaning Glass Surfaces..................................5-75
Cleaning Interior Plastic Components.................5-75
Cleaning Leather............................................5-75
Cleaning the Top of the Instrument Panel...........5-75
Cleaning Tires................................................5-78
Cleaning Vinyl................................................5-75
Cleaning Windshield and Wiper Blades..............5-77
Climate Control System...................................3-19
Air Filter, Passenger Compartment.................3-23
Outlet Adjustment........................................3-22
Clock............................................................3-18Clutch and Brake Pedal Free Play Check...........6-19
Clutch, Hydraulic.............................................5-20
Compact Spare Tire........................................5-72
Control of a Vehicle.......................................... 4-5
Coolant
Engine Temperature Gage............................3-32
Heater, Engine............................................2-21
Surge Tank Pressure Cap.............................5-24
Cooling System..............................................5-27
Cruise Control.................................................. 3-9
Cruise Control Light........................................3-37
Cupholder(s)..................................................2-37
Current and Past Model Order Forms................7-13
Customer Assistance Information
Courtesy Transportation.................................. 7-7
Customer Assistance for Text Telephone (TTY)
Users....................................................... 7-4
Customer Assistance Offices........................... 7-4
Customer Satisfaction Procedure..................... 7-2
GM Mobility Program for Persons with
Disabilities................................................ 7-5
Reporting Safety Defects to General Motors.......7-12
Reporting Safety Defects to the Canadian
Government............................................7-12
Reporting Safety Defects to the United States
Government............................................7-11
Roadside Assistance Program......................... 7-6
Service Publications Ordering Information........7-12
3

D
Daytime Running Lamps (DRL).........................3-13
Daytime Running Lamps Indicator Light.............3-38
Defensive Driving............................................. 4-2
Defogging and Defrosting.................................3-21
Dinghy Towing................................................4-32
Disarming the System.....................................2-17
Doing Your Own Service Work........................... 5-4
Dolly Towing..................................................4-32
Dome Lamp...................................................3-15
Door
Ajar Light...................................................3-38
Central Door Unlocking System....................... 2-8
Door Ajar Reminder....................................... 2-9
Locks.......................................................... 2-7
Power Door Locks......................................... 2-9
Rear Door Security Locks............................... 2-9
Driver
Position, Safety Belt.....................................1-15
Seat Height Adjuster...................................... 1-4
Driving
At Night.....................................................4-14
City...........................................................4-19
Defensive..................................................... 4-2
Drunken....................................................... 4-2
Freeway.....................................................4-20Driving (cont.)
Hill and Mountain Roads..............................4-23
In Rain and on Wet Roads...........................4-16
Winter........................................................4-25
Driving on Snow or Ice....................................4-26
Driving Through Deep Standing Water...............4-18
Driving Through Flowing Water.........................4-18
E
Electrical System
Add-On Equipment......................................5-82
Fuses and Circuit Breakers...........................5-83
Headlamp Wiring.........................................5-82
Power Windows and Other Power Options......5-82
Windshield Wiper Fuses...............................5-82
Emergency Trunk Release Handle.....................2-12
Emissions Inspection and Maintenance
Programs...................................................3-35
Engine
Air Cleaner/Filter.........................................5-18
Battery.......................................................5-38
Check and Service Engine Soon Light............3-33
Coolant......................................................5-21
Coolant Heater............................................2-21
Coolant Temperature Gage...........................3-32
Cooling System Inspection............................6-23
4

If the Light Is On Steady.................................3-34
If You Are Caught in a Blizzard.........................4-27
If You Are Stuck in Sand, Mud, Ice or Snow.......4-30
Ignition Positions.............................................2-18
Ignition Transaxle Lock Check..........................6-21
Infants and Young Children, Restraints...............1-31
Inflation - Tire Pressure...................................5-57
Inspection
Brake System.............................................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...........................................6-24
Instrument Panel
Cluster.......................................................3-26
Overview..................................................... 3-2
Instrument Panel Brightness.............................3-14
Instrument Panel Fuse Block............................5-83
Interior Lamps................................................3-14
J
Jump Starting.................................................5-39
K
Key Lock Cylinders Service..............................6-20
Keyless Entry System....................................... 2-3
Keys............................................................... 2-2
L
Lamps
Exterior......................................................3-12
Fog Lamps.................................................5-46
Interior.......................................................3-14
Lamps On Reminder.......................................3-13
Lap-Shoulder Belt...................................1-16, 1-25
LATCH System
Child Restraints...........................................1-42
Securing a Child Restraint Designed for the
LATCH System........................................1-45
Leaving Your Vehicle.......................................2-10
Leaving Your Vehicle With the Engine Running......2-30
Liftgate..........................................................2-13
Light
Air Bag Readiness.......................................3-28
Anti-Lock Brake System Warning...................3-31
Brake System Warning.................................3-30
Charging System.........................................3-29
Cruise Control.............................................3-37
Daytime Running Lamps Indicator..................3-38
7

Light (cont.)
Door Ajar...................................................3-38
Fog Lamp..................................................3-37
Highbeam On.............................................3-38
Hold Mode.................................................3-32
Low Fuel Warning.......................................3-39
Malfunction Indicator....................................3-33
Oil Pressure...............................................3-36
Safety Belt Reminder...................................3-28
Safety Belt Reminder Tone...........................3-28
Speed Sensitive Power Steering (SSPS)
Warning Light..........................................3-31
Loading Your Vehicle.......................................4-33
Lockout Protection..........................................2-10
Locks
Central Door Unlocking System....................... 2-8
Door........................................................... 2-7
Leaving Your Vehicle....................................2-10
Lockout Protection.......................................2-10
Power Door.................................................. 2-9
Rear Door Security Locks............................... 2-9
Long Trip/Highway Definition.............................. 6-6
Long Trip/Highway Intervals............................... 6-6
Long Trip/Highway Scheduled Maintenance........6-13
Loss of Control...............................................4-13
Low Fuel Warning Light...................................3-39
Lumbar
Manual Controls............................................ 1-4M
Maintenance, Normal Replacement Parts............5-91
Maintenance Schedule
At Each Fuel Fill.........................................6-18
At Least Once a Month................................6-18
At Least Once a Year..................................6-20
At Least Twice a Year..................................6-19
Brake System Inspection..............................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.....6-13
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4
Part B - Owner Checks and Services.............6-18
Part C - Periodic Maintenance Inspections......6-23
Part D - Recommended Fluids and
Lubricants...............................................6-24
Part E - Maintenance Record........................6-26
Selecting the Right Schedule.......................... 6-5
Short Trip/City Scheduled Maintenance............. 6-6
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection..........................6-23
Throttle System Inspection............................6-24
Using Your................................................... 6-4
Your Vehicle and the Environment................... 6-2
8

Malfunction Indicator Light................................3-33
Manual Lumbar Controls.................................... 1-4
Manual Seats............................................1-2, 1-3
Manual Transaxle............................................2-19
Fluid..........................................................5-20
Operation...................................................2-27
Manual Transaxle Check..................................6-19
Manual Windows............................................2-15
Map Lamps....................................................3-15
Matching Transmitter(s) to Your Vehicle............... 2-5
Mexico, Central America and Caribbean Islands/
Countries (Except Puerto Rico and U.S. Virgin
Islands) – Customer Assistance....................... 7-5
Mirrors
Manual Rearview Mirror................................2-35
Outside Convex Mirror.................................2-36
Outside Heated Mirrors................................2-37
Outside Manual Mirrors................................2-35
Outside Power Mirrors..................................2-36
MyGMLink.com................................................ 7-3
N
New Vehicle Break-In......................................2-18
Normal Maintenance Replacement Parts............5-91
O
Odometer......................................................3-27
Off-Road Recovery..........................................4-11
Oil
Engine.......................................................5-14
Pressure Light.............................................3-36
Older Children, Restraints................................1-29
Online Owner Center........................................ 7-3
Opening a Rear Door When the Security
Lock is On.................................................2-10
Other Warning Devices...................................... 3-5
Outlet Adjustment............................................3-22
Outside
Convex Mirror.............................................2-36
Heated Mirrors............................................2-37
Manual Mirrors............................................2-35
Power Mirrors.............................................2-36
Overseas – Customer Assistance........................ 7-5
Owners, Canadian............................................... ii
Owner’s Information........................................7-13
P
Park (P)
Shifting Into................................................2-29
Shifting Out of............................................2-31
9

Parking
Brake........................................................2-28
Over Things That Burn.................................2-32
Parking Brake and Automatic Transaxle Park (P)
Mechanism Check.......................................6-22
Parking Your Vehicle.......................................2-32
Part A - Scheduled Maintenance Services............ 6-4
Part B - Owner Checks and Services................6-18
Part C - Periodic Maintenance Inspections..........6-23
Part D - Recommended Fluids and Lubricants.......6-24
Part E - Maintenance Record...........................6-26
Passenger Compartment Air Filter.....................3-23
Passing.........................................................4-11
Plan Ahead When Possible................................ 7-8
Playing a CD.........................................3-42, 3-46
Playing the Radio...................................3-40, 3-44
Power
Accessory Outlets........................................3-16
Door Locks.................................................. 2-9
Electrical System.........................................5-82
Steering Fluid.............................................5-33
Windows....................................................2-15
Power Steering................................................ 4-9
Pretensioners, Safety Belt................................1-28
Q
Questions and Answers About Safety Belts.........1-14
R
Radios..........................................................3-40
Care of Your CD Player...............................3-52
Care of Your CDs........................................3-52
Radio with CD....................................3-40, 3-44
Theft-Deterrent............................................3-51
Understanding Reception..............................3-51
Rear Door Security Locks.................................. 2-9
Rear Seat Armrest..........................................2-39
Rear Seat Operation......................................... 1-8
Rear Seat Passengers, Safety Belts..................1-24
Rear Window and Outside Mirror Defogger.........3-22
Rear Window Washer/Wiper............................... 3-9
Rearview Mirrors.............................................2-35
Reclining Seatbacks.......................................... 1-5
Recreational Vehicle Towing.............................4-31
Remote Keyless Entry System............................ 2-3
Remote Keyless Entry System, Operation............ 2-4
Remote Trunk Release....................................2-12
Removing the Flat Tire and Installing the
Spare Tire..................................................5-67
Removing the Spare Tire and Tools...................5-66
Replacement Bulbs.........................................5-49
Replacing Brake System Parts..........................5-38
Reporting Safety Defects
Canadian Government..................................7-12
General Motors...........................................7-12
United States Government............................7-11
10

Restraint System Check...................................6-19
Checking Your Restraint Systems...................1-60
Replacing Restraint System Parts After a
Crash.....................................................1-61
Restraint Systems
Checking....................................................1-60
Replacing Parts...........................................1-61
Right Front Passenger Position, Safety Belts......1-24
Roadside
Assistance Program....................................... 7-6
Rocking Your Vehicle To Get It Out...................4-30
Running Your Engine While You Are Parked.......2-34
S
Safety Belt
Pretensioners..............................................1-28
Reminder Light............................................3-28
Reminder Tone............................................3-28
Safety Belts
Care of......................................................5-76
Center Rear Passenger Position....................1-28
Driver Position............................................1-15
How to Wear Safety Belts Properly................1-15
Questions and Answers About Safety Belts.....1-14
Rear Seat Passengers.................................1-24
Right Front Passenger Position......................1-24
Safety Belt Use During Pregnancy.................1-23
Safety Belts Are for Everyone.......................1-10Safety Warnings and Symbols.............................. iii
Seats
Driver Seat Height Adjuster............................. 1-4
Head Restraints............................................ 1-7
Manual..................................................1-2, 1-3
Manual Lumbar............................................. 1-4
Rear Seat Operation...................................... 1-8
Reclining Seatbacks...................................... 1-5
Securing a Child Restraint
Designed for the LATCH System...................1-45
Rear Seat Position......................................1-45
Right Front Seat Position..............................1-48
Security While You Travel.................................. 7-6
Selecting the Right Schedule, Maintenance.......... 6-5
Service........................................................... 5-3
Adding Equipment to the Outside of Your
Vehicle..................................................... 5-5
Doing Your Own Work................................... 5-4
Engine Soon Light.......................................3-33
Publications Ordering Information...................7-12
Service Bulletins.............................................7-13
Service Manuals.............................................7-12
Setting Preset Stations............................3-41, 3-45
Setting the Tone (Bass/Treble)..................3-41, 3-45
Sheet Metal Damage.......................................5-78
Shift Speeds..................................................2-28
Shifting Into Park (P).......................................2-29
Shifting Out of Park (P)...................................2-31
Short Trip/City Definition.................................... 6-5
11

Tires (cont.)
Inflation - Tire Pressure................................5-57
Inspection and Rotation................................5-58
Uniform Tire Quality Grading.........................5-60
Wheel Alignment and Tire Balance.................5-62
Wheel Replacement.....................................5-62
When It Is Time for New Tires......................5-59
To Use the Engine Coolant Heater....................2-22
Top Strap......................................................1-39
Top Strap Anchor Location...............................1-41
Torque Lock...................................................2-30
Towing
Recreational Vehicle.....................................4-31
Towing a Trailer..........................................4-37
Your Vehicle...............................................4-31
Transaxle
Fluid, Automatic...........................................5-20
Fluid, Manual..............................................5-20
Transaxle Operation, Automatic.........................2-23
Transaxle Operation, Manual............................2-27
Transmission, Transaxle, Transfer Case Unit
Repair Manual............................................7-12
Transportation Options...................................... 7-8
Trip Odometer................................................3-27
Trunk............................................................2-11
Turn and Lane-Change Signals.......................... 3-6
Turn Signal/Multifunction Lever........................... 3-6U
Underbody Flushing Service.............................6-22
Understanding Radio Reception........................3-51
Uniform Tire Quality Grading............................5-60
United States – Customer Assistance.................. 7-4
Used Replacement Wheels..............................5-63
Using an MP3 CD..........................................3-47
Using Cleaner on Fabric..................................5-74
Using the Rear Door Security Lock...................2-10
V
Vehicle
Control........................................................ 4-5
Damage Warnings........................................... iv
Loading......................................................4-33
Parking Your...............................................2-32
Symbols......................................................... iv
Vehicle Data Collection and Event Data
Recorders..................................................7-10
Vehicle Identification
Number (VIN).............................................5-81
Service Parts Identification Label...................5-81
Vehicle Storage..............................................5-38
Ventilation Adjustment......................................3-22
Visor Vanity Mirror..........................................2-16
Visors...........................................................2-16
13