brake CHEVROLET TRACKER 1994 Service Manual

When you open the hood, you’ll see on
the 16-valve engine:
1. Battery
2. Automatic Transmission Dipstick
3. Oil Fill Cap
4. Brake Fluid Reservoir
5. Air Cleaner
6. Engine Coolant Reservoir (if equipped)
7. Power Steering Reservoir
8. Radiator Pressure Cap
9. Electric Engine Fan
IO. Engine Oil Dipstick
11. Windshield Washer Reservoir
12. Main Fuse Box
A CAUTION:
Things that bm can get on hot engiae
parts and start a fxe. These include
liquids like gasoline, oil, coolant,
brake fluid, windshield
washer and
other fluids, and plastic or rubber.
You
or others could be burned. Be
careful not to drop or spill things that
will bum onto a hot engine.
Before closing the hood, be sure all
the filler caps are on.
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I A utomatic Transmission FIuid
When to Check and Change
A good time to check your automatic
transmission fluid level
is when the
engine
oil is changed. Refer to the
Maintenance Schedule to determine when
to change your fluid. See “Scheduled
Maintenance Services”
in the Index.
How to Check
Because this operation can be a little
difficult, you may choose to have
this
done at your Geo dealership Service
Department.
If you do
it yourself, be sure to follow all
the instructions here, or you could get a
false reading on the dipstick.
NOTICE:
Too much or too little tluid can
damage your transmission.
Too much
can mean that some of the fluid could
come out and fall on hot engine parts
or exhaust system parts, starting
a fire.
Be sure to get an accurate reading
if
you check your transmission tluid. Wait
at least 30 minutes before checking
the transmission fluid level
if you have
been driving:
0 When outside temperatures are above
0 At high speed for quite a while.
0 In heavy traffic - especially in hot
While pulling a trailer.
To get the right reading, the fluid should
be at normal operating temperature,
which is 180°F to 200°F
(82°C to 93°C).
To check transmission fluid hot: Get the
vehicle warmed
up by driving about IS
miles (24 km) when outside temperatures
are above 50°F
( 10°C). If it’s colder than
50°F (IOOC), drive the vehicle in “D”
(Third Gear) until the engine temperature
gage moves
and then remains steady for
ten minutes. Then follow the hot check
procedures.
To check transmission fluid cold: A cold
check is made after the vehicle has been
sitting for eight hours or more
with the
engine off
and is used only as a reference.
Let
the engine run at idle for five minutes
if outside temperatures are 50°F (10°C)
or more. If it’s colder than 50°F (IO’C),
you
may have to idle the engine longer.
90°F (32°C).
weather. Should
the
fluid level be low during a
cold check, you must perform a hot check
before adding fluid. This will give you a
more accurate reading
of the fluid level.
To check the fluid hot or cold
0 Park your vehicle on a level place.
0 With the parking brake applied, place
0 With your foot on the brake pedal,
Keep the
engine running.
the shift lever
in “P’ (Park).
move the shift lever through each gear
range, pausing for about three seconds
in each range. Then, position the shift
lever
in “P” (Park).
minutes or more.
0 Let the engine run at idle for three
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Service and Appearance Care
Windshield Washer Fluid
To Add:
Open the cap with the washer symbol on
it. Add washer fluid until the bottle is full.
NOTICE:
When using concentrated washer
tluid, follow the manuficturer’s
instructions for adding water.
Don’t mix water with
ready-to-use washer fluid. Water
can cause the solution to freeze
and damage
your washer fluid
tank and other parts
of the washer
system. Also, water doesn’t clean
as well
as washer tluid.
Fill your washer tluid tank only
3/4 full when it’s very cold. This
allows for expansion, which could
damage the
tank if it is completely
full.
Don’t use radiator antifreeze in
your windshield washer. It can
damage your washer system and
paint.
Brake Master Cylinder
Your brake master cylinder is here. It is
‘illed with
DOT-3 brake fluid.
I‘here are
only two reasons why the brake
fluid level
in your master cylinder might
go down. The first is that the brake fluid
goes down
to an acceptable level during
lormal brake lining wear. When new
iinings are put
in, the fluid level goes
mck
up. The other reason is that tluid is
leaking out of the brake system.
If it is,
you should have your brake system fixed,
;ince a leak means that sooner or later
your brakes won’t work well,
or won’t
work
at all.
So, it isn‘t a good idea to “top off’ your
brake fluid. Adding brake tluid won’t
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correct a leak. If you add fluid when your
linings are worn, then you’ll have too
much fluid when you get new brake
linings. You should add (or remove)
brake fluid, as necessary, only when work
is done on the brake hydraulic system.
Refer to the Maintenance Schedple to
determine when to check
yoqr drake
fluid. See “Periodic Maintenance
Inspections” in the Index.
To Check Brake Fluid:
You can check the brake fluid without
taking
off the cap. Just look at the
windows on the brake fluid reservoir. The
fluid levels should be above “MIN.” If
they aren’t, have your brake system
checked to see if there is a leak.
After work is done
on the brake hydraulic
system, make sure the levels are above
“MIN’ and below the top
of each
window.
What to Add:
When you do need brake fluid, use only
DOT-3 brake fluid
- such as Delco-
Supreme 11s (GM Part
No. 1052535).
Use new brake fluid from a sealed container
only, and always clean the brakl
fluid reservoir cap before removing it.
NOTICE:
Don’t let someone put in the
wrong kind of fluid. 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’ll
have to be replaced.
Brake fluid can damage paint, so
be careful not to spill brake fluid
on your vehicle. If
you do, wash it
off immediately. See “Appearance
Care” in the Index.
Brake Wear
Your Geo 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).
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~ Service and Appearance Care
r
NOTICE:
Continuing to drive
with worn-out
brake pads could result in costly
brake repair.
Some driving conditions or climates may
cause a brake squeal when the brakes are
first applied or lightly applied. This does
not mean something is wrong with your
brakes.
Your rear drum brakes don’t have wear
indicators, but if you ever hear a rear
brake rubbing noise, have the rear brake linings inspected. Also, the rear brake
drums should be removed and inspected
each time the tires are removed for
rotation or changing. When you have the front brakes replaced, have
the rear
brakes inspected, too.
Brake linings should always be replaced
as complete axle sets.
Brake Pedal Travel
See your dealer if the brake pedal does
not return to normal height, or if there is a
rapid increase in pedal travel. This could
be a sign
of brake trouble.
Brake Adjustment
Every time you make a brake stop, your
disc brakes adjust for wear.
If your brake pedal goes down farther
than normal, your rear drum brakes may
need adjustment. Adjust them by backing
up and firmly applying the brakes a few
times.
Replacing Brake System Parts
The braking system on a modern 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.
Vehicles we design and test have
top-quality GM brake parts in them, as
your Geo does when it is new. When you replace parts
of your braking system -
for example,
when your brake linings
wear down and you have to have new
ones put in
- be sure you get new
genuine
GM replacement parts. If you
don’t, 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’ve come to
expect can change in many other ways if
someone puts in the wrong replacement
brake parts.
Battery
Every new Geo has a Delco Freedoms
battery.
You never have to add water to
one
of these. When it’s time for a new
battery, we recommend a Delco
Freedoma battery. Get one that has the
catalog number shown on the original
battery’s label.
Vehicle Storage
If you’re not going to drive your vehicle
for
25 days or more, take off the black,
negative
(-) cable from the battery. This
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Service and Appearance Care
If you need to replace any of your wheels,
wheel bolts, or wheel nuts, replace them
only
with new GM original equipment
parts. This way, you
will be sure to have
the right wheel, wheel bolts, and wheel
nuts for your Geo model.
NOTICE:
The wrong wheel can also cause
problems
with bearing life, brake
cooling, speedometer/odometer
calibration, headlight aim, bumper
height, vehicle ground clearance,
and
tire or tire chain clearance to the
body and chassis.
Used Replacement Wheels
A CAUTION:
Putting a used wheel on your vehicle
is dangerous. You can’t know how
it’s been used or how many miles it’s
been driven. It could
fail suddenly
and cause an accident.
If you have
to replace a wheel
use a new GM
original equipment wheel.
Tire Chains
NOTICE:
Use tire chains only where legal and
only when you must. Use only SAE
Class “S” type chains that are the
proper size for your tires. Install them
on the tires of the drive axle (four-
wheel drive vehicles can use chains
on both axles). Tighten them
as
tightly as possible with the ends
securely fastened. Drive slowly and
follow the chain manufacturer’s
instructions.
If you can hear the
chains contacting your vehicle, stop
and retighten them.
If the contact
continues, slow down until
it stops.
Driving too fast with chains
on will
damage your vehicle.
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Replacement Bulbs
Back-up ........................................................ 1156
Dome
...................................................... 96051559
Center High-Mounted Stop
........................................... 921
Front Parking and
Turn Signal .................................... 1157 NA
Headlight (Halogen) ............................................... 9004
Heater
or Air Conditioning Control ............................... 96052599
Charging System
............................................ 9433 184
Engine Oil Pressure
.......................................... 9433 184
4WD
...................................................... 9433184
Headlight High Beam
......................................... 9433 184
Instrument Cluster
............................................. 9605 156
Rear Defogger Switch ......................................... 9606 1736
Rear Hazard and
Turn Signal ........................................ 1156
Rear Wipermasher Switch
..................................... 9606 1736
Indicator and Warning
Brake
..................................................... 9433184
CheckEngine
............................................... 9433184
SafetyBelt
................................................. 9433184
Turnsignal
................................................. 9433184
Licenseplate
..................................................... 194
Lighter
...................................................... 9433184
Rearparkingandstop
............................................. 1157
Sidemarker ......................................... ............ 194
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Maintenance Schedule
Section A: Scheduled Maintenance Services (cont.)
Schedule / (Cont.)
* An Emission Control Service.
t The US. 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 vehicle useful life. General
Motors, however, urges that all recommended
maintenance services be performed at the
indicated intervals and the maintenance be
recorded in “Section E: Maintenance Record.”
WHAT TO SERVICE
See “Explanation of Scheduled
Schedules
I and 11.
ITEM NO. Maintenance Services” following
WHEN TO PERFORM
Miles (kilometers) or Months
(whichever occurs first).
14
Air Cleaner Filter Replacement* See “Explanation of Scheduled
Maintenance
Services” following Schedules
I and 11.
15 I Fuel Tank, Cap and Lines Inspection*t I
See “Explanation of Scheduled Maintenance
Services” following Schedules
I and 11.
16
Every
80,000 miles (133 000 km). Heated
Oxygen Sensor Replacement*
18 Every
100,000 miles
(166 000 km).
Fuel Injector Inspection”
17 Every
30,000 miles (50 000 km)
or 30 months. Fuel Filter Replacement*
l9 I
Evaporative Emissions Canister
Replacement* I Every 100,000 miles (166 000 km).
Engine Control Module (ECM) and 2o Associated Sensors Inspection* Every 100,000 miles (1 66 000 km).
21 Every
100,000 miles (166 000 kml
Three Wav Catalvtic Converter Inspection* 22
Every 60,000 miles (100 000 km). Emission
System Hoses Inspection*
~~ I - \--- ~~
23 I Engine Timing and Distributor Check* I Every 60,000 miles (100 000 km).
24
Every 60,000 miles (100 000 km). Brake Fluid
Service 28
Every 60,000 miles (100 000 km) or 60 months.
Wiring Harness and Connectors Inspection* 27
Every 7,500 miles (12 500 km) or 7.5 months.
Power Steering System Inspection 26
Every 15,000 miles (25 000 km).
Valve Lash (Clearance) Inspection* 25
Every 15,000 miles (25 000 km).
Engine Idle Speed Check*?
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Maintenance Schedule
Section A: Scheduled Maintenance
Schedule /I (Cont.)
* An Emission Control Service.
t The US. 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 vehicle useful life. General
Motors, however, urges that all recommended
maintenance services be performed at the
indicated intervals and the maintenance be
recorded in “Section E: Maintenance Record.”
-
ITEM NO.
20
21
-
Services (Cont.)
WHAT TO SERVICE
See “Explanation of Scheduled
Maintenance Services” following
Schedules
I and 11.
Air Cleaner Filter Replacement*
Fuel Tank, Cap and Lines Inspection*?
Fuel Filter Replacement*
Fuel Injector Inspection* Heated Oxygen Sensor Replacement*
Evaporative Emissions Canister
Replacement*
Engine Control Module (ECM) and
Associated Sensors Inspection”
Emission System Hoses Inspection*
Three Way Catalytic Converter Inspection*
Engine Timing and Distributor Check*
Engine Idle Speed Check*?
Valve Lash (Clearance) Inspection*
Power Steering System Inspection
Wiring Harness and Connectors Inspection*
Brake Fluid Service
WHEN TO PERFORM
Miles (kilometers) or Months
(whichever occurs first).
See “Explanation of Scheduled Maintenance
Services” following Schedules
I and 11.
See “Explanation
of Scheduled Maintenance
Services” following Schedules I and
11.
Every 30,000 miles (50 000 km) or 30 months.
Every
100,000 miis (166 000 km).
Everv 80.000 miles (1 33 000 km).
Every
100,000 miles (166 000 km).
Every
100,000 miles (166 000 km).
Everv
60.000 miles (100 000 km). ~~
Every 100,000 miles (166 000 km).
Every
60,000 miles (100 000 km).
Every
15,000 miles (25 000 km).
Every
15,000 miles (25 000 km).
Every
7,500 miles (12 500 km) or 7.5 months.
Every
60,000 miles (100 000 km) or 60 months.
Every
60,000 miles (100 000 km).
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ITEM
NO. SERVICE
24 Engine Idle Speed-Check*t -
Check the idle speed and adjust
it to underhood label
specifications.
Inspection”
- Inspect the valve
lash and adjust if necessary.
Inspection
- Check the power
steering gear box, pump and
hose connections for leaks or
damage. Check the fluid level on
the dipstick. See “Power Steering
Fluid” in the Index. Check the
drive belt for cracks, fraying and
wear. Check belt tension. There
should be 0.24-0.35”
(6-9 mm)
deflection when you press your
thumb midway between the
pulleys. Adjust or replace belt
as needed.
25 Valve Lash (Clearance)
26 Power Steering System
ITEM
NO. SERVICE
27 Wiring Harness and Connectors
Inspection*
- Inspect the
underhood wiring harness for
loose connections, chafed wires
and damage.
refill and bleed the brake system
every
60,000 miles (100 000 km).
Use only new DOT-3 fluid from
a sealed container.
28 Brake Fluid Service - Drain,
* An Emission Control Service.
The
U.S. Environmental Protection Agency
or the California Air Resources Board has
determined that the failure to pe~orm this
maintenance item will not nullify the emission
warranty
or limit recall liability prior to the
completion
of vehicle useful life. General
Motors, however, urges that all recommended
maintenance services be performed at the
indicated intervals and the maintenance be
recorded in “Section
E: Maintenance
Record.”
r
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