brake CHEVROLET OPTRA 5 2007 1.G Workshop Manual

{CAUTION:
Incorrect wheel nuts or improperly
tightened wheel nuts can cause the wheel
to come loose and even come off. This
could lead to an accident. Be sure to use
the correct wheel nuts. If you have to
replace them, be sure to get new
GM original equipment wheel nuts. Stop
somewhere as soon as you can and have
the nuts tightened with a torque wrench to
the proper torque specication. See
Capacities and Specifications on page 352
for wheel nut torque specication.
Notice:Improperly tightened wheel nuts can
lead to brake pulsation and rotor damage.
To avoid expensive brake repairs, evenly
tighten the wheel nuts in the proper sequence
and to the proper torque specication. See
Capacities and Specifications on page 352for
the wheel nut torque specication.13. Tighten the wheel
nuts firmly in a
crisscross sequence,
as shown.
Notice:Wheel covers will not t on your
compact spare. If you try to put a wheel cover
on the compact spare, you could damage
the cover or the spare.
Do not try to put a wheel cover on your compact
spare tire. It will not fit. Store the wheel cover
in the cargo area until you have the flat tire
repaired or replaced.
332

Fuses Usage
AIRBAG Airbag
WPR Wiper
RADIO/CLK Radio/Clock
ECM Engine Control ModuleFuses Usage
AIRBAG Airbag
AUX LTR Extra Jack
TRN SIG
LAMPSTurn Signal Lamps
ABS Anti-lock Brake System
348

Fuses Usage
LTR Cigarette Lighter
CLSTR BTSICluster, Brake Transmission Shift
Interlock/Automatic Transaxle Shift
Lock (BTSI) Solenoid
RKE Remote Keyless Entry
BCK/UP Back-up
BLANK Not Used
TCM Transmission Control Module
BLANK Not Used
ENG FUSE
BOX DRLEngine Fuse Box, Daytime Running
Lamps
HAZRD LAMPS Hazard Lamps
A/C CLK Air Conditioning Switch, Clock
HVACHeating, Ventilation and Air
Conditioning
RKE Remote Keyless Entry
RADIO Radio
S/ROOF Sunroof
DLC Data Link Connector
SPARE SpareEngine Compartment Fuse Block
The engine compartment fuse block is located on
the driver’s side of the vehicle, near the battery.
SeeEngine Compartment Overview on page 258
for more information on location. To access the
fuses, press in the top flap to release the cover.
To reinstall the cover, push the cover until it is
secure.
349

Fuses Usage
STOP LAMPS Stoplamps
DR/LCK Door Lock
MIR HTD Heated Mirror
FRT FOG Front Fog
ILLUM LTLicense Plate Lamp, Parking
Lamp Left
INJ Injector
ENG SNSREvaporative Emission (EVAP)
Canister Purge Solenoid, Heated
Oxygen Sensor (HO2S), Cooling
Fan Relay, CMP Sensor
LOW BEAM LT Headlamp Low-Beam Left
ILLUM RTIllumination Circuit, Parking
Lamp Right
LOW BEAM RT Headlamp Low-Beam Right
SPARE Spare
SPARE Spare
SPARE Spare
BATT PWR Battery Power
ABS Anti-lock Brake System
HVAC BLWR HVAC Blower
IGN 2 Ignition 2Fuses Usage
IGN 1 Ignition 1
FUSE PLR Fuse Puller
COOL FAN
LOWCooling Fan Low
DEFOG Defog
COOL FAN HI Cooling Fan High
PWR WNDW Power Window
Relays Usage
COOL FAN
LOWCooling Fan Low
FRT FOG Front Fog
ILLUM Illumination Relay
A/C CMPRSR Air Conditioning Compressor
HORN Horn
DEFOG Defog
FUEL PUMP Fuel Pump
MAIN Main Relay
COOL FAN HI Cooling Fan High
PWR WNDW Power Window
HEAD LAMPS Headlamp Relay
351

Maintenance Schedule................................ 356
Introduction............................................... 356
Maintenance Requirements........................ 356
Your Vehicle and the Environment............ 356
How This Section is Organized................. 356
Part A: Scheduled Maintenance
Services................................................. 358
Using the Maintenance Schedule............... 358
Selecting the Right Schedule..................... 359
Short Trip/City Scheduled Maintenance..... 361
Long Trip/Highway Scheduled
Maintenance.......................................... 369
Part B: Owner Checks and Services......... 374
At Each Fuel Fill....................................... 374
At Least Once a Month............................. 374At Least Twice a Year.............................. 375
At Least Once a Year............................... 376
Part C: Periodic Maintenance
Inspections............................................. 380
Steering, Suspension and Front
Drive Axle Boot and Seal Inspection...... 380
Exhaust System Inspection........................ 380
Fuel System Inspection............................. 380
Engine Cooling System Inspection............. 381
Throttle System Inspection........................ 381
Brake System Inspection........................... 381
Part D: Recommended Fluids and
Lubricants.............................................. 382
Part E: Maintenance Record...................... 384
Section 6 Maintenance Schedule
355

Selecting the Right Schedule
First you will need to decide which of the
two schedules is right for your vehicle. Here
is how to decide which schedule to follow:
Short Trip/City Denition
Follow the Short Trip/City Scheduled Maintenance
if any one of these conditions is true for your
vehicle:
•Most trips are less than 5 miles (8 km).
This is particularly important when outside
temperatures are below freezing.
•Most trips include extensive idling, such as
frequent driving in stop-and-go traffic.
•If the vehicle is used for delivery service,
police, taxi, or other commercial application.
One of the reasons you should follow this schedule
if you operate your vehicle under any of these
conditions is that these conditions cause engine oil
to break down sooner.
Short Trip/City Intervals
Every 3,000 Miles (5 000 km):Engine Oil and
Filter Change and Engine Oil Pan Drain Plug
Washer Replacement (or 3 months, whichever
occurs first).
Every 6,000 Miles (10 000 km):Tire Rotation.
Every 15,000 Miles (25 000 km):Engine Air
Cleaner Filter Inspection. Passenger Compartment
Air Filter Replacement. Drive Belt(s) Inspection.
Every 30,000 Miles (50 000 km):Engine Air
Cleaner Filter Replacement. Spark Plug
Replacement. EVAP System Service. PCV
System Service. Timing Belt Inspection.
Brake/Clutch Fluid Change (or 24 months,
whichever occurs first).
Every 60,000 Miles (100 000 km):Spark Plug
Wire Replacement. Timing Belt Replacement.
EVAP System Solenoid Valve Replacement.
359

Every 90,000 Miles (150 000 km):Fuel Filter
Replacement.
Every 150,000 Miles (240 000 km):Cooling
System Service.
These intervals only summarize maintenance
services. Be sure to follow the complete scheduled
maintenance on the following pages.
Long Trip/Highway Denition
Follow this scheduled maintenanceonlyif none of
the conditions from the Short Trip/City Scheduled
Maintenance are true. Do not use this schedule
if the vehicle is driven in a dusty area or used off
paved roads. Use the Short Trip/City schedule
for these conditions.
Driving a vehicle with a fully warmed engine
under highway conditions will cause engine oil to
break down slower.
Long Trip/Highway Intervals
Every 7,500 Miles (12 500 km):Engine Oil and
Filter Change and Engine Oil Pan Drain Plug
Washer Replacement (or every 12 months,
whichever occurs first). Tire Rotation.
Every 15,000 Miles (25 000 km):Engine Air
Cleaner Filter Inspection. Passenger Compartment
Air Filter Replacement. Drive Belt(s) Inspection.
Every 30,000 Miles (50 000 km):Engine Air
Cleaner Filter Replacement. Spark Plug
Replacement. EVAP System Service. PCV
System Service. Timing Belt Inspection.
Brake/Clutch Fluid Change (or 24 months,
whichever occurs first).
Every 60,000 Miles (100 000 km):Spark Plug
Wire Replacement. Timing Belt Replacement.
EVAP System Solenoid Valve Replacement.
Every 90,000 Miles (150 000 km):Fuel Filter
Replacement.
Every 150,000 Miles (240 000 km):Cooling
System Service.
These intervals only summarize maintenance
services. Be sure to follow the complete scheduled
maintenance on the following pages.
360

Short Trip/City Scheduled
Maintenance
The services shown in this schedule up to
100,000 miles (166 000 km) should be repeated
after 100,000 miles (166 000 km) at the same
intervals for the life of this vehicle. The services
shown at 150,000 miles (240 000 km) should be
repeated at the same interval after 150,000 miles
(240 000 km) for the life of this vehicle.
SeePart B: Owner Checks and Services on
page 374andPart C: Periodic Maintenance
Inspections on page 380.
Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that
the failure to perform this maintenance item will not
nullify the emission warranty or limit recall liability
prior to the completion of the vehicle’s useful life.
We, however, urge that all recommended
maintenance services be performed at the indicated
intervals and the maintenance be recorded.
+A good time to check your brakes is during
tire rotation. See Brake System Inspection
on page 381.
3,000 Miles (5 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
6,000 Miles (10 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
❑Rotate tires. SeeTire Inspection and Rotation
on page 316for proper rotation pattern and
additional information.(See footnote +.)
9,000 Miles (15 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
361

27,000 Miles (45 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
30,000 Miles (50 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
❑Replace passenger compartment air filter.
If you drive regularly under dusty conditions, the
filter may require replacement more often.
❑Replace engine air cleaner filter. SeeEngine
Air Cleaner/Filter on page 264for more
information.
❑Rotate tires. SeeTire Inspection and Rotation
on page 316for proper rotation pattern and
additional information.(See footnote +.)
❑Replace spark plugs.An Emission Control
Service.
❑Inspect drive belt(s).
❑Inspect timing belt.❑Inspect EVAP canister, vapor lines, and EVAP
vent solenoid valve.An Emission Control
Service. (See footnote †.)
❑Inspect PCV system.An Emission Control
Service. (See footnote †.)
❑Change brake/clutch fluid (or every 24 months,
whichever occurs first).33,000 Miles (55 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
36,000 Miles (60 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
❑Rotate tires. SeeTire Inspection and Rotation
on page 316for proper rotation pattern and
additional information.(See footnote +.)
363

54,000 Miles (90 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
❑Rotate tires. SeeTire Inspection and Rotation
on page 316for proper rotation pattern and
additional information.(See footnote +.)
57,000 Miles (95 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
60,000 Miles (100 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
❑Replace passenger compartment air filter.
If you drive regularly under dusty conditions, the
filter may require replacement more often.❑Replace engine air cleaner filter. SeeEngine
Air Cleaner/Filter on page 264for more
information.
❑Rotate tires. SeeTire Inspection and Rotation
on page 316for proper rotation pattern and
additional information.(See footnote +.)
❑Replace spark plugs.An Emission Control
Service.
❑Replace spark plug wires.An Emission Control
Service.
❑Inspect drive belt(s).
❑Replace timing belt.
❑Inspect EVAP canister and vapor lines.
Replace EVAP vent solenoid valve.An
Emission Control Service. (See footnote †.)
❑Inspect PCV system.An Emission Control
Service. (See footnote †.)
❑Change brake/clutch fluid (or every 24 months,
whichever occurs first).
63,000 Miles (105 000 km)
❑Change engine oil and filter and replace engine
oil pan drain plug washer (or every 3 months,
whichever occurs first).An Emission Control
Service.
365