Engine CHEVROLET OPTRA 2005 1.G Service Manual

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...............................................5-5
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...................................................5-14
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............................................5-24
Power Steering Fluid.....................................5-28
Windshield Washer Fluid................................5-29Brakes........................................................5-30
Battery........................................................5-33
Jump Starting...............................................5-34
Headlamp Aiming...........................................5-37
Bulb Replacement..........................................5-38
Halogen Bulbs..............................................5-38
Headlamps..................................................5-38
Front Turn Signal and Parking Lamps..............5-39
Turn Signal Lamps (Side)..............................5-40
Fog Lamps..................................................5-40
Sidemarker Lamps (Front)..............................5-41
Sidemarker Lamps (Rear)..............................5-41
Center High-Mounted Stoplamp (CHMSL).........5-42
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-42
Replacement Bulbs.......................................5-43
Windshield Wiper Blade Replacement..............5-44
Tires..............................................................5-45
Tire Sidewall Labelling...................................5-46
Tire Terminology and Definitions.....................5-48
Inflation - Tire Pressure.................................5-51
Tire Inspection and Rotation...........................5-52
When It Is Time for New Tires.......................5-53
Buying New Tires.........................................5-54
Uniform Tire Quality Grading..........................5-55
Section 5 Service and Appearance Care
5-1

Wheel Alignment and Tire Balance..................5-56
Wheel Replacement......................................5-56
Tire Chains..................................................5-57
If a Tire Goes Flat........................................5-58
Changing a Flat Tire.....................................5-59
Removing the Spare Tire and Tools................5-60
Removing the Flat Tire and Installing the
Spare Tire................................................5-61
Storing a Flat or Spare Tire and Tools............5-65
Compact Spare Tire......................................5-66
Appearance Care............................................5-66
Fabric/Carpet...............................................5-67
Vinyl...........................................................5-68
Leather.......................................................5-68
Instrument Panel..........................................5-69
Interior Plastic Components............................5-69
Glass Surfaces.............................................5-69
Weatherstrips...............................................5-69
Washing Your Vehicle...................................5-69
Cleaning Exterior Lamps/Lenses.....................5-70
Finish Care..................................................5-70Windshield and Wiper Blades.........................5-71
Aluminum Wheels.........................................5-71
Tires...........................................................5-72
Sheet Metal Damage.....................................5-72
Finish Damage.............................................5-72
Underbody Maintenance................................5-73
Chemical Paint Spotting.................................5-73
Vehicle Care/Appearance Materials..................5-74
Vehicle Identication......................................5-75
Vehicle Identification Number (VIN).................5-75
Service Parts Identification Label.....................5-75
Electrical System............................................5-75
Add-On Electrical Equipment..........................5-75
Headlamp Wiring..........................................5-76
Windshield Wiper Fuses................................5-76
Power Windows and Other Power Options.......5-76
Fuses and Circuit Breakers............................5-76
Instrument Panel Fuse Block..........................5-77
Engine Compartment Fuse Block....................5-79
Capacities and Specications..........................5-82
Normal Maintenance Replacement Parts..........5-83
Section 5 Service and Appearance Care
5-2

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/fuel_charter.htm. Gasoline
meeting these specifications could provide improved
driveability and emission control system performance
compared to other gasoline.
California Fuel
If your vehicle is certified to meet California Emission
Standards, it is designed to operate on fuels that
meet California specifications. See the underhood
emission control label. 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 and your vehicle may fail a
smog-check test. SeeMalfunction Indicator Lamp on
page 3-36. 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.
5-5

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. In
most cases, 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. Also, your GM
dealer has additives that will help correct and prevent
most deposit-related problems.
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.
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.
5-6

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. 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 release
lever located on the floor
on the outboard side of the
driver’s seat.
5-7

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.
Hood Release
To open the hood, do the following:
1. Pull the hood release
handle inside the
vehicle. It is located on
the lower left side of
the instrument panel.
5-10

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

A. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-17.
B. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-14.
C. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-14.
D. Brake Fluid/Hydraulic Clutch Fluid Reservoir. See
“Brake Fluid” underBrakes on page 5-30and
Hydraulic Clutch on page 5-19.
E. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-28.F. Engine Coolant Surge Tank. SeeCooling System on
page 5-24.
G. Engine Compartment Fuse Block. SeeEngine
Compartment Fuse Block on page 5-79.
H. Battery. SeeBattery on page 5-33.
I. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-29.
5-13

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 3-38.
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.
1. Turn off the engine and give the oil several minutes
to drain back into the oil pan. If you do not do this,
the oil dipstick might not show the actual level.
2. Pull the dipstick and clean it with a paper towel or
cloth, then push it back in all the way. Remove it
again, keeping the tip down and check the level.
When to Add Engine Oil
If the oil is at or below the lower hole at the tip of the
dipstick (B), then you will need to add at least one quart
of oil. But you must use the right kind. This section
explains what kind of oil to use. For engine oil crankcase
capacity, seeCapacities and Specifications on
page 5-82.
Notice:Do not add too much oil. If your engine has
so much oil that the oil level gets above the upper
hole (A) that shows the proper operating range, your
engine could be damaged.
SeeEngine Compartment Overview on page 5-12for
the location of the engine oil fill cap.
Be sure to add enough oil to put the level somewhere in
the proper operating range, between the holes on the
dipstick. Push the dipstick all the way back in when you
are through.
5-14