engine CHEVROLET OPTRA 2004 1.G Manual PDF

What to Add
When you do need brake fluid, use only DOT-3 brake
fluid. Use new brake fluid from a sealed container
only. SeePart D: Recommended Fluids and Lubricants
on page 6-24.
Always clean the brake fluid 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 5-73.
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 firmly.
5-36

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.
Battery
Your new vehicle comes with a maintenance free
battery. When it is time for a new battery, get one that
has the replacement number shown on the original
battery’s label. SeeEngine Compartment Overview on
page 5-12for battery location.Warning:Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
Vehicle Storage
If you are not going to drive your vehicle for 25 days
or more, remove the black, negative (−) cable from
the battery. This will help keep your battery from
running down.
{CAUTION:
Batteries have acid that can burn you and gas
that can explode. You can be badly hurt if you
are not careful. SeeJump Starting on
page 5-39for tips on working around a battery
without getting hurt.
Contact your dealer to learn how to prepare your
vehicle for longer storage periods.
5-38

Notice:If you leave your radio or other accessories
on during the jump starting procedure, they could
be damaged. The repairs would not be covered
by your warranty. Always turn off your radio and
other accessories when jump starting your vehicle.
3. Turn off the ignition on both vehicles. Unplug
unnecessary accessories plugged into the cigarette
lighter or in the accessory power outlet. Turn off
the radio and all lamps that are not needed. This will
avoid sparks and help save both batteries. And it
could save your radio!
4. Open the hoods and locate the batteries. Find the
positive (+) and negative (−) terminal locations on
each vehicle. Your vehicle’s positive (+) terminal is
located under a red tethered cap on the battery.
The negative (–) terminal is located under a
black tethered cap on the battery. SeeEngine
Compartment Overview on page 5-12for more
information on location. Flip the caps up to access
the positive (+) and negative (–) terminals.
{CAUTION:
An electric fan can start up even when the
engine is not running and can injure you.
Keep hands, clothing and tools away from
any underhood electric fan.
{CAUTION:
Using a match near a battery can cause battery
gas to explode. People have been hurt doing
this, and some have been blinded. Use a
ashlight if you need more light.
CAUTION: (Continued)
5-40

CAUTION: (Continued)
Be sure the battery has enough water. You do
not need to add water to the battery installed
in your new vehicle. But if a battery has ller
caps, be sure the right amount of uid is there.
If it is low, add water to take care of that rst.
If you don’t, explosive gas could be present.
Battery uid contains acid that can burn you.
Do not get it on you. If you accidentally get it
in your eyes or on your skin, ush the place
with water and get medical help immediately.
{CAUTION:
Fans or other moving engine parts can injure
you badly. Keep your hands away from moving
parts once the engine is running.
5. Check that the jumper cables do not have loose or
missing insulation. If they do, you could get a
shock. The vehicles could be damaged, too.
Before you connect the cables, here are some
things you should know. Positive (+) will go
to positive (+) or to a remote positive (+) terminal if
the vehicle has one. Negative (−) will go to a
heavy, unpainted metal engine part or to a remote
negative (−) terminal if the vehicle with the dead
battery has one.
Do not connect positive (+) to negative (−)oryou
will get a short that would damage the battery
and maybe other parts, too. And do not connect the
negative (−) cable to the negative (−) terminal on
the dead battery because this can cause sparks.
6. Connect the red positive (+) cable to the positive (+)
terminal of the dead battery. Use a remote
positive (+) terminal if the vehicle has one.
5-41

7. Do not let the other end
touch metal. Connect it
to the positive (+)
terminal of the good
battery. Use a remote
positive (+) terminal if
the vehicle has one.
8. Now connect the black
negative (−) cable to
the negative (−)
terminal of the good
battery. Use a remote
negative (−) terminal
if the vehicle has one.Do not let the other end touch anything until the
next step. The other end of the negative (−) cable
does not go to the dead battery. It goes to a
heavy, unpainted metal engine part or to a remote
negative (−) terminal on the vehicle with the
dead battery.
9. Connect the other end
of the negative (−)
cable at least 18 inches
(45 cm) away from
the dead battery,
but not near engine
parts that move.
The electrical
connection is just as
good there, and
the chance of sparks
getting back to the
battery is much less.
10. Now start the vehicle with the good battery and run
the engine for a while.
11. Try to start the vehicle that had the dead battery.
If it will not start after a few tries, it probably needs
service.
5-42

Notice:If the jumper cables are removed in the
wrong order, electrical shorting may occur and
damage the vehicle. The repairs would not be
covered by your warranty. Remove the jumper
cables in the correct order, making sure that the
cables do not touch each other or other metal.
A. Heavy, Unpainted Metal Engine Part or Remote
Negative (–) Terminal
B. Good Battery or Remote Positive (+) and Remote
Negative (–) Terminals
C. Dead Battery or Remote Positive (+) TerminalTo disconnect the jumper cables from both vehicles,
do the following:
1. Disconnect the black negative (−) cable from the
vehicle that had the dead battery.
2. Disconnect the black negative (−) cable from the
vehicle with the good battery.
3. Disconnect the red positive (+) cable from the
vehicle with the good battery.
4. Disconnect the red positive (+) cable from the other
vehicle.
5. Return the caps over the positive (+) and
negative (–) terminals to their original positions.
Jumper Cable Removal
5-43

Tire Size
The following illustration shows an example of a typical
passenger car tire size.
(A) Passenger (P-Metric) Tire:The United States
version of a metric tire sizing system. The letter “P” as
the first 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 carry capacity a tire is
certified to carry. The speed rating is the maximum
speed a tire is certified to carry a load. Speed ratings
range from “A” to “Z”.
5-54

CAUTION: (Continued)
3. Turn off the engine and do not restart
while the vehicle is raised.
4. Do not allow passengers to remain in the
vehicle.
To be even more certain the vehicle won’t
move, you should put blocks at the front and
rear of the tire farthest away from the one
being changed. That would be the tire on the
other side, at the opposite end of the vehicle.
The following steps will tell you how to use the jack and
change a tire.
5-65

Vehicle Identication
Vehicle Identication Number (VIN)
This is the legal identifier for your vehicle. It appears on
a plate in the front corner of the instrument panel, on
the driver’s side. You can see it if you look through the
windshield from outside your vehicle. The VIN also
appears on the Vehicle Certification and Service Parts
labels and the certificates of title and registration.
Engine Identication
The 8th character in your VIN is the engine code. This
code will help you identify your engine, specifications
and replacement parts.
Service Parts Identication Label
You will find this label inside of the glove box. It is very
helpful if you ever need to order parts. On this label is:
•your VIN,
•the model designation,
•paint information and
•a list of all production options and special equipment.
Be sure that this label is not removed from the
vehicle.
5-81

Fuses and Circuit Breakers
The wiring circuits in your vehicle are protected from
short circuits by a combination of fuses, circuit breakers
and fusible thermal links in the wiring itself.
Look at the silver-colored band inside the fuse. If the
band is broken or melted, replace the fuse. Be sure you
replace a bad fuse with a new one of the identical
size and rating.
There are spare fuses provided in the engine
compartment fuse block. If you ever have a problem on
the road and do not have a spare fuse, you can borrow
one that has the same amperage. Just pick a feature of
your vehicle that you can get along without — like the
radio or cigarette lighter — and use its fuse, if it is the
correct amperage. Replace it as soon as you can.
There are two fuse blocks in your vehicle: the instrument
panel fuse block and the engine compartment fuse block.
There is a fuse puller located on the engine
compartment fuse block. It can be used to easily
remove fuses from the fuse block.
Instrument Panel Fuse Block
The instrument panel fuse block is located on the end of
the instrument panel, on the driver’s side of the
vehicle. To access the fuses, open the fuse panel door
by pulling out.
To reinstall the door, insert the tabs at the back end
first, then push the door into the instrument panel
to secure it.Sedan shown, Hatchback similar
5-83