brake CHEVROLET TRACKER 2003 2.G Workshop Manual

Service............................................................5-3
Doing Your Own Service Work.........................5-3
Adding Equipment to the Outside
of Your Vehicle...........................................5-4
Fuel................................................................5-4
Gasoline Octane............................................5-4
Gasoline Speci®cations....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-5
Fuels in Foreign Countries...............................5-6
Filling Your Tank............................................5-6
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood.....................5-9
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-16
Engine Air Cleaner/Filter................................5-20
Automatic Transmission Fluid.........................5-23
Manual Transmission Fluid.............................5-26
Hydraulic Clutch...........................................5-27
Engine Coolant.............................................5-28
Radiator Pressure Cap..................................5-30
Engine Overheating.......................................5-31
Cooling System............................................5-33
Power Steering Fluid.....................................5-40Windshield Washer Fluid................................5-41
Brakes........................................................5-42
Battery........................................................5-45
Jump Starting...............................................5-46
Rear Axle.......................................................5-52
Four-Wheel Drive............................................5-53
Bulb Replacement..........................................5-55
Halogen Bulbs..............................................5-55
Headlamps..................................................5-55
Front Turn Signal and Parking Lamps..............5-57
Sidemarker Lamps........................................5-57
Rear Combination Lamps...............................5-58
Replacement Bulbs.......................................5-59
Tires..............................................................5-59
In¯ation - Tire Pressure.................................5-60
Tire Inspection and Rotation...........................5-60
When It Is Time for New Tires.......................5-62
Buying New Tires.........................................5-62
Uniform Tire Quality Grading..........................5-63
Wheel Alignment and Tire Balance..................5-64
Wheel Replacement......................................5-64
Tire Chains..................................................5-66
If a Tire Goes Flat........................................5-66
Changing a Flat Tire.....................................5-67
Section 5 Service and Appearance Care
5-1

Filling a Portable Fuel Container
{CAUTION:
Never ®ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
damaged if this occurs. To help avoid injury
to you and others:
·Dispense gasoline only into approved
containers.
·Do not ®ll a container while it is inside a
vehicle, in a vehicle's trunk, pickup bed or
on any surface other than the ground.
·Bring the ®ll nozzle in contact with the
inside of the ®ll opening before operating
the nozzle. Contact should be maintained
until the ®lling is complete.
·Do not smoke while pumping gasoline.
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. Don't reach through the
grille to release the underhood lever.
{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.
5-9

A. Engine Compartment Fuse Block. See ªEngine
Compartment Fuse Blockº underFuses and Circuit
Breakers on page 5-89.
B. Engine Air Cleaner/Filter. See
Engine Air
Cleaner/Filter on page 5-20.
C. Battery. See
Battery on page 5-45.
D. Power Steering Fluid Reservoir. See
Power Steering
Fluid on page 5-40.
E. Automatic Transmission Dipstick (If Equipped).
See
Automatic Transmission Fluid on page 5-23.F. Radiator Pressure Cap. See
Radiator Pressure Cap
on page 5-30.
G. Engine Oil Dipstick. See
Engine Oil on page 5-16.
H. Engine Oil Fill Cap. See
Engine Oil on page 5-16.
I. Brake Fluid Reservoir. See
Brakes on page 5-42.
J. Engine Coolant Recovery Tank. See
Engine Coolant
on page 5-28.
K. Windshield Washer Reservoir. See
Windshield
Washer Fluid on page 5-41.
5-13

A. Engine Compartment Fuse Block. See ªEngine
Compartment Fuse Blockº underFuses and Circuit
Breakers on page 5-89.
B. Engine Air Cleaner/Filter. See
Engine Air
Cleaner/Filter on page 5-20.
C. Battery. See
Battery on page 5-45.
D. Radiator Pressure Cap. See
Radiator Pressure Cap
on page 5-30.
E. Engine Oil Fill Cap. See
Engine Oil on page 5-16.
F. Automatic Transmission Dipstick. See
Automatic
Transmission Fluid on page 5-23.G. Engine Oil Dipstick. See
Engine Oil on page 5-16.
H. Power Steering Fluid Reservoir. See
Power Steering
Fluid on page 5-40.
I. Brake Fluid Reservoir. See
Brakes on page 5-42.
J. Engine Coolant Recovery Tank. See
Engine Coolant
on page 5-28.
K. Windshield Washer Reservoir. See
Windshield
Washer Fluid on page 5-41.
5-15

Get the vehicle warmed up by driving about 15 miles
(24 km) when outside temperatures are above 50ÉF
(10ÉC). If it's colder than 50ÉF (10ÉC), drive the vehicle
in DRIVE (D) until the engine temperature gage
moves and then remains steady for 10 minutes.
A cold ¯uid check can be made after the vehicle has
been sitting for eight hours or more with the engine off,
but this is used only as a reference. Let the engine
run at idle for ®ve minutes if outside temperatures are
50ÉF (10ÉC) or more. If it's colder than 50ÉF (10ÉC), you
may have to idle the engine longer. Should the ¯uid
level be low during this cold check, you
mustcheck the
¯uid hot before adding ¯uid. Checking the ¯uid hot
will give you a more accurate reading of the ¯uid level.
Checking the Fluid Level
Prepare your vehicle as follows:
·Park your vehicle on a level place. Keep the engine
running.
·With the parking brake applied, place the shift lever
in PARK (P).
·With your foot on the brake pedal, move the shift
lever through each gear range, pausing for about
three seconds in each range. Then, position the shift
lever in PARK (P).
·Let the engine run at idle for three minutes or more.Then, without shutting off the engine, follow these steps:
The automatic
transmission dipstick has
a red ring handle located in
the rear of the engine
compartment toward the
center of the vehicle.
See
Engine Compartment
Overview on page 5-12
for more information
on location.
1. Pull out the dipstick and wipe it with a clean rag or
paper towel.
2. Push it back in all the way, wait three seconds and
then pull it back out again. 2.0L Engine shown,
2.5L Engine similar
5-24

Brakes
Brake Fluid
Your brake master cylinder reservoir is ®lled with DOT-3
brake ¯uid. SeeEngine Compartment Overview on
page 5-12for the location of the reservoir.
There are only two reasons why the brake ¯uid level
in the reservoir might go down. The ®rst is that the brake
¯uid goes down to an acceptable level during normal
brake lining wear. When new linings are put in, the ¯uid
level goes back up. The other reason is that ¯uid isleaking out of the brake system. If it is, you should have
your brake system ®xed, since a leak means that
sooner or later your brakes will not work well, or will not
work at all.
So, it is not a good idea to ªtop offº your brake ¯uid.
Adding brake ¯uid will not correct a leak. If you add ¯uid
when your linings are worn, then you will have too
much ¯uid when you get new brake linings. You should
add (or remove) brake ¯uid, as necessary, only when
work is done on the brake hydraulic system.
{CAUTION:
If you have too much brake ¯uid, it can spill on
the engine. The ¯uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
¯uid only when work is done on the brake
hydraulic system. See ªChecking Brake Fluidº
in this section.
Refer to the Maintenance Schedule to determine when
to check your brake ¯uid. See
Part C: Periodic
MaintenanceInspections on page 6-28.
5-42

Checking Brake Fluid
You can check the brake
¯uid without taking off
the cap.
Just look at the brake ¯uid reservoir. The ¯uid level
should be above MIN. If it is not, have your brake
system checked to see if there is a leak.
After work is done on the brake hydraulic system,
make sure the level is above the MIN but not over the
MAX mark.
What to Add
When you do need brake ¯uid, use only DOT-3 brake
¯uid. Use new brake ¯uid from a sealed container
only. See
Part D: Recommended Fluids and Lubricants
on page 6-30.Always clean the brake ¯uid 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.
See
Appearance Care on page 5-79.
5-43

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 ®rmly).
{CAUTION:
The brake wear warning sound means that soon
your brakes will not work well. That could lead
to an accident. When you hear the brake wear
warning sound, have your vehicle serviced.
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 ®rst applied or lightly
applied. This does not mean something is wrong with
your brakes.Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to GM torque speci®cations.
Your rear drum brakes do not have wear indicators,
but if you ever hear a rear brake rubbing noise, have the
rear brake linings inspected immediately. 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 brake pads replaced, have
the rear brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.
See
Brake System Inspection on page 6-29.
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.
5-44

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 Ð for
example, when your brake linings wear down and you
need new ones put in Ð 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 Ð 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's time for a new battery, get one that
has the replacement number shown on the original
battery's label. We recommend an ACDelco
žbattery.
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.
5-45

1. Check the other vehicle. It must have a 12-volt
battery with a negative ground system.
Notice:If the other vehicle's system is not a 12-volt
system with a negative ground, both vehicles can
be damaged. Only use vehicles with 12-volt systems
with negative grounds to jump start your vehicle.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles aren't touching
each other. If they are, it could cause a ground
connection you don't want. You wouldn't be able to
start your vehicle, and the bad grounding could
damage the electrical systems.
To avoid the possibility of the vehicles rolling, set
the parking brake ®rmly on both vehicles involved in
the jump start procedure. Put an automatic
transmission in PARK (P) or a manual transmission
in NEUTRAL before setting the parking brake.
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. Turn off the radio and all lamps that aren't
needed. This will help reduce 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 battery. See
Engine Compartment Overview
on page 5-12for more information on battery
location.
{CAUTION:
If your vehicle has air conditioning, the
auxiliary electric fan under the hood 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.
5-47