2003 CHEVROLET CAVALIER engine

Part C: Periodic
MaintenanceInspections
Listed in this part are inspections and services which
should be performed at least twice a year (for instance,
each spring and fall).
You should let your dealer's
service department do these jobs. Make sure any
necessary repairs are completed at once.
Proper procedures to perform these services may be
found in a service manual. SeeService Publications
Ordering Information on page 7-10.
Steering, Suspension and Front
Drive Axle Boot and Seal Inspection
Inspect the front and rear suspension and steering
system for damaged, loose or missing parts, signs of
wear or lack of lubrication. Inspect the power steering
lines and hoses for proper hook-up, binding, leaks,
cracks, cha®ng, etc. Clean and then inspect the drive
axle boot seals for damage, tears or leakage. Replace
seals if necessary.
Exhaust System Inspection
Inspect the complete exhaust system. Inspect the body
near the exhaust system. Look for broken, damaged,
missing or out-of-position parts as well as open seams,
holes, loose connections or other conditions which
could cause a heat build-up in the ¯oor pan or could let
exhaust fumes into the vehicle. See
Engine Exhaust
on page 2-30.
Fuel System Inspection
Inspect the complete fuel system for damage or leaks.
Engine Cooling System Inspection
Inspect the hoses and have them replaced if they
are cracked, swollen or deteriorated. Inspect all pipes,
®ttings and clamps; replace as needed. Clean the
outside of the radiator and air conditioning condenser.
To help ensure proper operation, a pressure test of
the cooling system and pressure cap is recommended
at least once a year.
Throttle System Inspection
Inspect the throttle system for interference or binding,
and for damaged or missing parts. Replace parts
as needed. Replace any components that have high
effort or excessive wear. Do not lubricate accelerator
and cruise control cables.
6-23

Part D: Recommended Fluids and
Lubricants
Fluids and lubricants identi®ed below by name, part
number or speci®cation may be obtained from your
dealer.
Usage Fluid/Lubricant
Engine OilEngine oil with the American
Petroleum Institute Certi®ed for
Gasoline Engines starburst symbol
of the proper viscosity. To determine
the preferred viscosity for your
vehicle's engine, see
Engine Oil on
page 5-14.
Engine Coolant50/50 mixture of clean, drinkable
water and use only
DEX-COOL
žCoolant. SeeEngine
Coolant on page 5-22.
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake ¯uid.
Windshield
Washer SolventGM Optikleen
žWasher Solvent or
equivalent.
Usage Fluid/Lubricant
Hydraulic
Clutch SystemHydraulic Clutch Fluid (GM Part No.
U.S. 12345347, in Canada
10953517, or equivalent DOT-3
brake ¯uid).
Power Steering
SystemGM Power Steering Fluid (GM Part
No. U.S. 1052884, in Canada
993294, or equivalent).
Manual
TransaxleDEXRON
ž-III Automatic
Transmission Fluid.
Automatic
TransaxleDEXRON
ž-III Automatic
Transmission Fluid.
Key Lock
CylindersMulit-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474, or equivalent).
Manual
Transaxle Shift
LinkageChassis Lubricant (GM Part No.
U.S. 12377985, in Canada
88901242, or equivalent) or lubricant
meeting requirements of NLGI #2,
Category LB or GC-LB.
Clutch Linkage
Pivot PointsEngine oil.
6-25

Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to General
Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you'll notify us.
Please call us at 1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
Transmission, Transaxle, Transfer
Case Unit Repair Manual
This manual provides information on unit repair service
procedures, adjustments, and speci®cations for GM
transmissions, transaxles, and transfer cases.
RETAIL SELL PRICE: $50.00
Service Bulletins
Service Bulletins give technical service information
needed to knowledgeably service General Motors cars
and trucks. Each bulletin contains instructions to
assist in the diagnosis and service of your vehicle.
In Canada, information pertaining to Product Service
Bulletins can be obtained by contacting your General
Motors dealer or by calling 1-800-GM-DRIVE
(1-800-463-7483).
7-10

A
Accessory Power Outlets.................................3-16
Adding Washer Fluid.......................................5-34
Additional Program Information........................... 7-9
Additives, Fuel................................................. 5-5
Add-On Electrical Equipment............................5-80
Adjusting the Speakers
(Balance/Fade)....................3-38, 3-42, 3-52, 3-66
Air Bag Systems.............................................1-49
How Does an Air Bag Restrain?....................1-56
Servicing Your Air Bag-Equipped Vehicle.........1-58
What Makes an Air Bag In¯ate?....................1-55
What Will You See After an Air
Bag In¯ates?...........................................1-56
When Should an Air Bag In¯ate?...................1-55
Where Are the Air Bags?..............................1-52
Air Bag .........................................................3-24
Readiness Light..........................................3-24
Air Cleaner/Filter, Engine.................................5-18
AM-FM Radio.................................................3-37
AM ...............................................................3-76
Antenna, Fixed Mast.......................................3-78
Antenna, XMŸ Satellite Radio Antenna System . . 3-79
Anti-lock Brake System (ABS)............................ 4-6
Anti-Lock Brake, System Warning Light..............3-27
Appearance Care............................................5-71
Care of Safety Belts....................................5-74
Chemical Paint Spotting...............................5-77
Cleaning the Inside of Your Vehicle................5-71Appearance Care (cont.)
Cleaning the Outside of Your Vehicle..............5-74
Finish Damage............................................5-77
Sheet Metal Damage...................................5-77
Underbody Maintenance...............................5-77
Vehicle Care/Appearance Materials................5-78
Weatherstrips..............................................5-74
Arming the System.........................................2-15
Ashtrays........................................................3-16
Audio System(s).............................................3-36
AM-FM Radio.............................................3-37
Care of Your Cassette Tape Player................3-77
Care of Your CD Player...............................3-78
Care of Your CDs........................................3-78
Chime Level Adjustment...............................3-79
Fixed Mast Antenna.....................................3-78
Personal Choice Radio Controls....................3-75
Radio with Cassette and CD.........................3-63
Radio with CD....................................3-39, 3-49
Setting the Time for Radios with Radio
Data Systems (RDS)................................3-36
Setting the Time for Radios without
Radio Data Systems (RDS).......................3-36
Theft-Deterrent Feature................................3-76
Understanding Radio Reception.....................3-76
XMŸ Satellite Radio Antenna System............3-79
Automatic Transaxle Inspection.........................6-20
Automatic Transaxle Shift Lock Control
System Check.............................................6-21
1

Automatic Transaxle........................................2-19
Fluid..........................................................5-20
Operation...................................................2-22
B
Backing Up....................................................4-38
Battery Replacement......................................... 2-6
Battery Run-Down Protection............................3-15
Battery..........................................................5-39
Before Leaving on a Long Trip.........................4-21
Body Lubrication Service..................................6-20
Brake Fluid....................................................5-35
Brake Wear...................................................5-37
Brake............................................................2-26
Parking......................................................2-26
System Inspection.......................................6-24
System Warning Light..................................3-26
Brakes..........................................................5-35
Braking in Emergencies..................................... 4-8
Braking........................................................... 4-6
Break-In, New Vehicle.....................................2-17
Bulb Replacement...........................................5-45
Back-Up Lamps...........................................5-49
Front Turn Signal and Parking Lamps.............5-47
Halogen Bulbs............................................5-45
Headlamps.................................................5-45Bulb Replacement (cont.)
Replacement Bulbs......................................5-49
Taillamps and Turn Signal Lamps..................5-48
Buying New Tires...........................................5-55C
California Fuel.................................................. 5-5
Caliper/Knuckle MaintenanceInspection.............6-24
Canada ± Customer Assistance.......................... 7-4
Canadian Owners................................................ ii
Canadian Roadside Assistance........................... 7-7
Canceling the Rear Door Security Lock............... 2-9
Capacities and Speci®cations............................5-85
Carbon Monoxide...........4-24, 4-34, 4-40, 2-10, 2-30
Care of.........................................................5-74
Safety Belts................................................5-74
Your Cassette Tape Player............................3-77
Your CD Player...........................................3-78
Your CDs ...................................................3-78
Cassette Tape Messages.................................3-72
Cassette Tape Player Service...........................6-19
CD Adapter Kits.............................................3-73
Center Console Storage Area...........................2-35
Chains, Tires..................................................5-59
Charging System Light....................................3-25
Check Engine Light.........................................3-30
2

Checking Coolant............................................5-23
Checking Engine Oil........................................5-14
Checking Things Under the Hood......................5-10
Checking Your Restraint Systems......................1-58
Check...........................................................3-30
Engine Light...............................................3-30
Gages Warning Light...................................3-34
Chemical Paint Spotting...................................5-77
Child Restraints..............................................1-35
Child Restraint Systems...............................1-35
Infants and Young Children...........................1-32
Lower Anchorages and Top Tethers for
Children (LATCH System)..........................1-41
Older Children.............................................1-29
Securing a Child Restraint Designed for
the LATCH System...................................1-43
Securing a Child Restraint in a Rear
Seat Position...........................................1-43
Securing a Child Restraint in the Right
Front Seat Position...................................1-46
Top Strap Anchor Location............................1-40
Top Strap...................................................1-39
Where to Put the Restraint...........................1-38
Chime Level Adjustment..................................3-79
Cigarette Lighter.............................................3-16
Cleaning Aluminum or Chrome-Plated Wheels.....5-76
Cleaning Exterior Lamps/Lenses.......................5-75
Cleaning Fabric/Carpet....................................5-71
Cleaning Glass Surfaces..................................5-73Cleaning Interior Plastic Components.................5-73
Cleaning the Top of the
Instrument Panel.........................................5-73
Cleaning Tires................................................5-77
Cleaning Vinyl................................................5-73
Cleaning Windshield and Wiper Blades..............5-76
Cleaning........................................................5-71
Inside of Your Vehicle..................................5-71
Outside of Your Vehicle................................5-74
Underbody Maintenance...............................5-77
Weatherstrips..............................................5-74
Climate Control System...................................3-17
Outlet Adjustment........................................3-20
Clutch, Hydraulic.............................................5-21
Compact Disc Messages.................3-48, 3-63, 3-75
Compact Spare Tire........................................5-70
Content Theft-Deferrent....................................2-15
Control of a Vehicle.......................................... 4-5
Convenience Net............................................2-36
Coolant.........................................................3-29
Engine Temperature Gage............................3-29
Heater, Engine............................................2-21
Low Warning Light.......................................3-30
Surge Tank Pressure Cap.............................5-24
Cooling System..............................................5-27
Cruise Control.................................................. 3-8
Cupholder(s)..................................................2-35
Current and Past Model Order Forms................7-11
3

Emissions Inspection and Maintenance
Programs...................................................3-32
Engine Compartment Fuse Block......................5-84
Engine Coolant Level Check.............................6-19
Engine Cooling When Trailer Towing..................4-40
Engine Oil Additives........................................5-17
Engine Oil Level Check...................................6-19
Engine..........................................................5-18
Air Cleaner/Filter.........................................5-18
Battery.......................................................5-39
Check and Service Engine Soon Light............3-30
Compartment Overview................................5-12
Coolant Heater............................................2-21
Coolant Temperature Gage...........................3-29
Coolant......................................................5-22
Cooling System Inspection............................6-23
Exhaust.....................................................2-30
Oil .............................................................5-14
Overheating................................................5-25
Starting......................................................2-19
Enhanced Traction System (ETS)........................ 4-8
Active Light................................................3-29
Warning Light.............................................3-28
Entry Lighting.................................................3-15
Express-Down Window....................................2-14
Extender, Safety Belt.......................................1-28
Exterior Lamps...............................................3-12F
Filter.............................................................5-18
Engine Air Cleaner......................................5-18
Finding a PTY Station
(RDS and XMŸ).........................3-43, 3-53, 3-67
Finding a Station....................3-37, 3-41, 3-51, 3-65
Finish Care....................................................5-75
Finish Damage...............................................5-77
Five-Speed....................................................2-25
Fixed Mast Antenna........................................3-78
Flash-to-Pass................................................... 3-6
Flat Tire, Changing.........................................5-61
Flat Tire........................................................5-60
Fluid.............................................................5-20
Automatic Transaxle.....................................5-20
Manual Transaxle........................................5-20
Power Steering...........................................5-33
Windshield Washer......................................5-34
FM Stereo.....................................................3-76
Fog Lamps....................................................3-14
Folding the Seatback........................................ 1-8
Following Distance..........................................4-38
Forward Gears...............................................2-24
Front Reading Lamps......................................3-15
Fuel............................................................... 5-4
Additives...................................................... 5-5
California Fuel.............................................. 5-5
Filling a Portable Fuel Container..................... 5-9
Filling Your Tank........................................... 5-7
5

Fuel (cont.)
Fuels in Foreign Countries.............................. 5-6
Gage.........................................................3-35
Gasoline Octane........................................... 5-4
Gasoline Speci®cations.................................. 5-5
System Inspection.......................................6-23
Fuses...........................................................5-81
Fuses and Circuit Breakers...........................5-81
Windshield Wiper.........................................5-81
G
Gage............................................................3-34
Check Gages Warning Light..........................3-34
Engine Coolant Temperature.........................3-29
Fuel..........................................................3-35
Speedometer..............................................3-23
Tachometer.................................................3-23
Gasoline......................................................... 5-4
Octane........................................................ 5-4
Speci®cations............................................... 5-5
GM Mobility Program for Persons with
Disabilities.................................................... 7-5
H
Hazard Warning Flashers................................... 3-3
Head Restraints............................................... 1-5Headlamp High/Low-Beam Changer.................... 3-6
Headlamp Wiring............................................5-81
Headlamps....................................................5-45
Bulb Replacement.......................................5-45
Front Turn Signal and Parking Lamps.............5-47
Halogen Bulbs............................................5-45
Highway Hypnosis...........................................4-22
Hill and Mountain Roads..................................4-22
Hitches..........................................................4-37
Hood............................................................5-10
Checking Things Under................................5-10
Release.....................................................5-10
Horn............................................................... 3-4
How the System Alarm is Activated...................2-15
How to Add Coolant to the Coolant Surge Tank . . 5-29
How to Check and Add Fluid............................5-21
How to Check Power Steering Fluid..................5-33
How to Check................................................5-52
How to Detect a Tamper Condition....................2-16
How to Inspect the Engine Air Cleaner/Filter.......5-19
How to Turn Off the System Alarm....................2-16
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-14
Hydraulic Clutch System Check........................6-20
Hydraulic Clutch.............................................5-21
Hydroplaning..................................................4-18
6