2003 CHEVROLET CAVALIER Owners Manual

How to Inspect the Engine Air
Cleaner/Filter
To inspect the air cleaner/®lter remove the ®lter from the
vehicle and lightly shake the ®lter to release loose
dust and dirt. If the ®lter remains ªcakedº with dirt, a new
®lter is required.
To inspect or replace the ®lter, remove the screws that
hold the cover on and lift off the cover. Be sure to
reinstall the cover tightly.
{CAUTION:
Operating the engine with the air cleaner/®lter
off can cause you or others to be burned. The
air cleaner not only cleans the air, it helps to
stop ¯ame if the engine back®res. If it isn't
there and the engine back®res, you could be
burned. Don't drive with it off, and be careful
working on the engine with the air
cleaner/®lter off.
Notice:If the air cleaner/®lter is off, a back®re can
cause a damaging engine ®re. And, dirt can
easily get into your engine, which will damage it.
Always have the air cleaner/®lter in place when
you're driving.
5-19

Automatic Transaxle Fluid
It is not necessary to check the transaxle ¯uid level. A
transaxle ¯uid leak is the only reason for ¯uid loss.
If a leak occurs, take the vehicle to the dealership
service department and have it repaired as soon as
possible. You may also have your ¯uid level checked by
your dealer or service center when you have your oil
changed.
Change both the ¯uid and ®lter every 50,000 miles
(83 000 km) if the vehicle is mainly driven under one or
more of these conditions:
·In heavy city traffic where the outside temperature
regularly reaches 90ÉF (32ÉC) or higher.
·In hilly or mountainous terrain.
·When doing frequent trailer towing.
·Uses such as found in taxi, police or delivery
service.
If you do not use your vehicle under any of these
conditions, the ¯uid and ®lter do not require changing.
Notice:We recommend you use only ¯uid labeled
DEXRONž±III, because ¯uid with that label is
made especially for your automatic transaxle.
Damage caused by ¯uid other than DEXRON
ž±III is
not covered by your new vehicle warranty.
Manual Transaxle Fluid
It is not necessary to check the transaxle ¯uid level. A
transaxle ¯uid leak is the only reason for ¯uid loss.
If a leak occurs, take the vehicle to the dealership
service department and have it repaired as soon as
possible. You may also have your ¯uid level checked by
your dealer or service center when you have your oil
changed. See
Part D: Recommended Fluids and
Lubricants on page 6-25for the proper ¯uid to use.
5-20

Hydraulic Clutch
The hydraulic clutch linkage in your vehicle is
self-adjusting. The master cylinder reservoir is ®lled with
hydraulic ¯uid.
It is not necessary to regularly check the ¯uid unless
you suspect there is a leak in the system. Adding ¯uid
won't correct a leak.
A ¯uid loss in this system could indicate a problem.
Have the system inspected and repaired.
When to Check and What to Use
Refer to the Maintenance
Schedule to determine
how often you should
check the ¯uid level in your
master cylinder reservoir
and for the proper
¯uid. See
Part B: Owner
Checks and Services
on page 6-19
andPart D:
Recommended Fluids
and Lubricants on
page 6-25
.
How to Check and Add Fluid
You do not need to check the ¯uid level unless you
suspect a clutch problem. To check the ¯uid level, take
the cap off. If the ¯uid reaches the step inside the
reservoir, the ¯uid level is correct. See
Engine
Compartment Overview on page 5-12for more
information on location.
5-21

Engine Coolant
The cooling system in your vehicle is ®lled with
DEX-COOLžengine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs ®rst, if you add
only DEX-COOL
žextended life coolant.
The following explains your cooling system and how to
add coolant when it is low. If you have a problem
with engine overheating, see
Engine Overheating on
page 5-25.
A 50/50 mixture of clean, drinkable water and
DEX-COOL
žcoolant will:
·Give freezing protection down to-34ÉF (-37ÉC).
·Give boiling protection up to 265ÉF (129ÉC).
·Protect against rust and corrosion.
·Help keep the proper engine temperature.
·Let the warning lights and gages work as they
should.
Notice:When adding coolant, it is important that
you use only DEX-COOLž(silicate-free) coolant.
If coolant other than DEX-COOLžis added to
the system, premature engine, heater core or
radiator corrosion may result. In addition, the engine
coolant will require change sooner Ð at 30,000 miles
(50,000 km) or 24 months, whichever occurs ®rst.
Damage caused by the use of coolant other
than DEX-COOL
žis not covered by your new vehicle
warranty.
What to Use
Use a mixture of one-halfclean, drinkable waterand
one-half DEX-COOLžcoolant which won't damage
aluminum parts. If you use this coolant mixture,
you don't need to add anything else.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will.
CAUTION: (Continued)
5-22

CAUTION: (Continued)
Your vehicle's coolant warning system is set
for the proper coolant mixture. With plain
water or the wrong mixture, your engine could
get too hot but you wouldn't get the overheat
warning. Your engine could catch ®re and you
or others could be burned. Use a 50/50 mixture
of clean, drinkable water and DEX-COOL
ž
coolant.
Notice:If you use an improper coolant mixture,
your engine could overheat and be badly damaged.
The repair cost wouldn't be covered by your
warranty. Too much water in the mixture can freeze
and crack the engine, radiator, heater core and
other parts.
If you have to add coolant more than four times a year,
have your dealer check your cooling system.
Notice:If you use the proper coolant, you don't
have to add extra inhibitors or additives which claim
to improve the system. These can be harmful.
Checking Coolant
The surge tank is located
on the passenger's side of
the engine compartment.
See
Engine Compartment
Overview on page 5-12
for more information
on location.
{CAUTION:
Turning the surge tank pressure cap when the
engine and radiator are hot can allow steam
and scalding liquids to blow out and burn you
badly. Never turn the surge tank pressure
cap Ð even a little Ð when the engine and
radiator are hot.
5-23

The vehicle must be on a level surface. When your
engine is cold, the coolant level should be at the FULL
COLD mark.
If the low coolant light
comes on and stays on, it
means you're low on
engine coolant. See
Low
Coolant Warning Light
on page 3-30
.
Adding Coolant
If you need more coolant, add the proper DEX-COOLž
coolant mixtureat the surge tank, but only when the
engine is cool. If the surge tank is empty, a special ®ll
procedure is necessary. See
Engine Overheating
on page 5-25for instructions on ªHow to Add Coolant to
the Coolant Surge Tank.º
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol,
and it will burn if the engine parts are hot
enough. Don't spill coolant on a hot engine.
When replacing the pressure cap, make sure it is
hand-tight.
Coolant Surge Tank Pressure Cap
Notice:Your pressure cap is a pressure-type
cap and must be tightly installed to prevent coolant
loss and possible engine damage from overheating.
See ªCapacities and Speci®cationsº for more
information.
5-24

Engine Overheating
You will ®nd a coolant temperature gage and a low
coolant warning light on your vehicle's instrument panel.
See
Engine Coolant Temperature Gage on page 3-29andLow Coolant Warning Light on page 3-30.
If Steam Is Coming From Your Engine
{CAUTION:
Steam from an overheated engine can burn
you badly, even if you just open the hood. Stay
away from the engine if you see or hear steam
coming from it. Just turn it off and get
everyone away from the vehicle until it cools
down. Wait until there is no sign of steam or
coolant before you open the hood.
If you keep driving when your engine is
overheated, the liquids in it can catch ®re. You
or others could be badly burned. Stop your
engine if it overheats, and get out of the
vehicle until the engine is cool.
Notice:If your engine catches ®re because you
keep driving with no coolant, your vehicle can
be badly damaged. The costly repairs would not be
covered by your warranty.
5-25

If No Steam Is Coming From Your
Engine
An overheat warning, along with a low coolant light, can
indicate a serious problem. SeeLow Coolant Warning
Light on page 3-30.
If you get an engine overheat warning with no low
coolant light, but see or hear no steam, the problem may
not be too serious. Sometimes the engine can get a
little too hot when you:
·Climb a long hill on a hot day.
·Stop after high-speed driving.
·Idle for long periods in traffic.
·Tow a trailer.If you get the overheat warning with no sign of steam,
try this for a minute or so:
1. In heavy traffic, let the engine idle in NEUTRAL (N)
while stopped. If it is safe to do so, pull off the road,
shift to PARK (P) or NEUTRAL (N) and let the
engine idle.
2. Turn on your heater to full hot at the highest fan
speed and open the window as necessary.
If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning doesn't come back on, you can drive
normally.
If the warning continues and you have not stopped, pull
over, stop, and park your vehicle right away.
If there's still no sign of steam, you can idle the engine
for three minutes while you're parked. If you still
have the warning,
turn off the engine and get everyone
out of the vehicleuntil it cools down.
You may decide not to lift the hood but to get service
help right away.
5-26