2004 CHEVROLET CAVALIER brake

Brake System Inspection
Inspect the complete system. Inspect brake lines and
hoses for proper hook-up, binding, leaks, cracks,
chang, etc. Inspect disc brake pads for wear and rotors
for surface condition. Also inspect drum brake linings
for wear and cracks. Inspect other brake parts, including
drums, wheel cylinders, calipers, parking brake, etc.
Check parking brake adjustment. You may need to have
your brakes inspected more often if your driving
habits or conditions result in frequent braking.
Caliper/Knuckle Maintenance
Inspection
If you operate your vehicle in a highly corrosive
environment, as indicated by the shaded areas on the
map following this text, your vehicle may require
additional brake service. Refer to the appropriate GM
service bulletin for the proper caliper inspection
procedure. As necessary, caliper pins and knuckle
brake pad abutments should be lubricated at every other
tire rotation. Also, see your GM dealer’s service
department or qualied service center for additional
information.
6-24

Part D: Recommended Fluids and
Lubricants
Fluids and lubricants identied below by name, part
number or specication may be obtained from your
dealer.
Usage Fluid/Lubricant
Engine OilEngine oil which meets GM
Standard GM6094M and displays
the American Petroleum Institute
Certied for Gasoline Engines
starburst symbol. To determine the
proper viscosity for your vehicle’s
engine, seeEngine Oil on
page 5-13.
Engine Coolant50/50 mixture of clean, drinkable
water and use only
DEX-COOL
®Coolant. SeeEngine
Coolant on page 5-20.
Usage Fluid/Lubricant
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake uid.
Windshield
Washer SolventGM Optikleen
®Washer Solvent.
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. 89021184, in Canada
89021186).
Manual
TransaxleDEXRON
®-III Automatic
Transmission Fluid.
6-25

Courtesy Transportation is available only at participating
dealers and all program options, such as shuttle
service, may not be available at every dealer. Please
contact you dealer for specic information about
availability. All Courtesy Transportation arrangements
will be administered by appropriate dealer personnel.
Canadian Vehicles:For warranty repairs during
the Complete Vehicle Coverage period of the General
Motors of Canada New Vehicle Limited Warranty,
alternative transportation may be available under the
Courtesy Transportation Program. Please consult
your dealer for details.
General Motors reserves the right to unilaterally modify,
change or discontinue Courtesy Transportation at
any time and to resolve all questions of claim eligibility
pursuant to the terms and conditions described
herein at its sole discretion.Vehicle Data Collection and Event
Data Recorders
Your vehicle, like other modern motor vehicles, has a
number of sophisticated computer systems that monitor
and control several aspects of the vehicle’s
performance. Your vehicle uses on-board vehicle
computers to monitor emission control components to
optimize fuel economy, to monitor conditions for air bag
deployment and, if so equipped, to provide anti-lock
braking and to help the driver control the vehicle
in difficult driving situations. Some information may be
stored during regular operations to facilitate repair
of detected malfunctions; other information is stored only
in a crash or near crash event by computer systems
commonly called event data recorders (EDR).
In a crash or near crash event, computer systems, such
as the Air Bag Sensing and Diagnostic Module (SDM)
in your vehicle may record information about the
condition of the vehicle and how it was operated, such
as engine speed, brake applications, throttle position,
vehicle speed, safety belt usage, air bag readiness, air
bag performance data, and the severity of a collision.
This information has been used to improve vehicle crash
performance and may be used to improve crash
performance of future vehicles and driving safety. Unlike
the data recorders on many airplanes, these on-board
systems do not record sounds, such as conversation of
vehicle occupants.
7-9

To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 366-0123 in
the Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation
Washington, D.C. 20590
You can also obtain other information about motor
vehicle safety from the hotline.
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
7-11

A
Accessory Power Outlets.................................3-15
Adding Washer Fluid.......................................5-32
Additional Program Information........................... 7-8
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment............................5-80
Adjusting the Speakers
(Balance/Fade)....................3-38, 3-40, 3-45, 3-55
Air Bag
Readiness Light..........................................3-23
Air Bag Systems.............................................1-47
How Does an Air Bag Restrain?....................1-54
Servicing Your Air Bag-Equipped Vehicle.........1-56
What Makes an Air Bag Inate?....................1-53
What Will You See After an
Air Bag Inates?......................................1-54
When Should an Air Bag Inate?...................1-52
Where Are the Air Bags?..............................1-50
Air Cleaner/Filter, Engine.................................5-17
Airbag Sensing and Diagnostic Module (SDM)...... 7-9
AM ...............................................................3-67
AM-FM Radio.................................................3-36
Antenna, Fixed Mast.......................................3-68Antenna, XM™ Satellite Radio
Antenna System..........................................3-68
Anti-lock Brake System (ABS)............................ 4-6
Anti-Lock Brake, System Warning Light..............3-26
Appearance Care............................................5-72
Care of Safety Belts....................................5-75
Chemical Paint Spotting...............................5-78
Cleaning the Inside of Your Vehicle................5-73
Cleaning the Outside of Your Vehicle..............5-75
Finish Damage............................................5-77
Sheet Metal Damage...................................5-77
Underbody Maintenance...............................5-78
Vehicle Care/Appearance Materials................5-78
Weatherstrips..............................................5-75
Arming the System.........................................2-14
Ashtrays........................................................3-16
Audio System(s).............................................3-35
AM-FM Radio.............................................3-36
Care of Your CD Player...............................3-68
Care of Your CDs........................................3-68
Chime Level Adjustment...............................3-68
Fixed Mast Antenna.....................................3-68
Personal Choice Radio Controls....................3-66
1

Audio System(s) (cont.)
Radio with CD............................3-39, 3-43, 3-52
Setting the Time for Radios with
Radio Data Systems (RDS).......................3-36
Setting the Time for Radios without
Radio Data Systems (RDS).......................3-35
Theft-Deterrent Feature................................3-67
Understanding Radio Reception.....................3-67
XM™ Satellite Radio Antenna System............3-68
Automatic Transaxle........................................2-18
Fluid..........................................................5-19
Operation...................................................2-20
Automatic Transaxle Inspection.........................6-19
Automatic Transaxle Shift Lock Control
System Check.............................................6-21
B
Backing Up....................................................4-41
Battery..........................................................5-36
Battery Replacement......................................... 2-6
Battery Run-Down Protection............................3-15
Before Leaving on a Long Trip.........................4-21
Body Lubrication Service..................................6-19
Brake
Parking......................................................2-25Brake (cont.)
System Inspection.......................................6-24
System Warning Light..................................3-25
Brake Fluid....................................................5-32
Brake Wear...................................................5-34
Brakes..........................................................5-32
Braking........................................................... 4-5
Braking in Emergencies..................................... 4-7
Break-In, New Vehicle.....................................2-16
Bulb Replacement...........................................5-41
Back-Up Lamps...........................................5-44
Front Turn Signal and Parking Lamps.............5-43
Halogen Bulbs............................................5-41
Headlamps.................................................5-41
Replacement Bulbs......................................5-44
Taillamps and Turn Signal Lamps..................5-44
Buying New Tires...........................................5-56C
California Fuel.................................................. 5-5
Caliper/Knuckle Maintenance Inspection.............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 Specications............................5-85
Carbon Monoxide...........2-10, 2-28, 4-24, 4-37, 4-43
2

H
Hazard Warning Flashers................................... 3-4
Head Restraints............................................... 1-5
Headlamp High/Low-Beam Changer.................... 3-7
Headlamp Wiring............................................5-80
Headlamps....................................................5-41
Bulb Replacement.......................................5-41
Front Turn Signal and Parking Lamps.............5-43
Halogen Bulbs............................................5-41
Highway Hypnosis...........................................4-22
Hill and Mountain Roads..................................4-22
Hitches..........................................................4-40
Hood
Checking Things Under................................5-10
Release.....................................................5-10
Horn............................................................... 3-5
How the System Alarm is Activated...................2-14
How to Add Coolant to the Coolant
Surge Tank.................................................5-27
How to Check................................................5-54
How to Check and Add Fluid............................5-20
How to Check Power Steering Fluid..................5-31
How to Detect a Tamper Condition....................2-15
How to Inspect the Engine Air Cleaner/Filter.......5-18
How to Turn Off the System Alarm....................2-15
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-13Hydraulic Clutch.............................................5-19
Hydraulic Clutch System Check........................6-19
Hydroplaning..................................................4-18
I
If No Steam Is Coming From Your Engine..........5-24
If Steam Is Coming From Your Engine...............5-23
If the Light Is Flashing.....................................3-30
If the Light Is on Steady..................................3-31
If You Are Caught in a Blizzard.........................4-26
If You Are Stuck in Sand, Mud, Ice or Snow.......4-28
If You Do Decide To Pull A Trailer.....................4-38
Ignition Positions.............................................2-16
Ignition Transaxle Lock Check..........................6-21
Infants and Young Children, Restraints...............1-31
Ination - Tire Pressure...................................5-53
Inspection
Brake System.............................................6-24
Caliper/Knuckle Maintenance.........................6-24
Engine Cooling System................................6-23
Exhaust System..........................................6-23
Fuel System...............................................6-23
Part C - Periodic Maintenance.......................6-23
Steering, Suspension and Front Drive Axle
Boot and Seal.........................................6-23
Throttle System...........................................6-23
7

Instrument Panel
Cluster.......................................................3-21
Overview..................................................... 3-2
Instrument Panel Brightness.............................3-14
Instrument Panel Fuse Block............................5-82
Interior Lamps................................................3-14
J
Jump Starting.................................................5-36
K
Key Lock Cylinders Service..............................6-19
Key Release Button (Manual Transaxle).............2-18
Keyless Entry System....................................... 2-3
Keys............................................................... 2-2
L
Lamps
Exterior......................................................3-11
Interior.......................................................3-14
Lamps On Reminder.......................................3-12
Lap-Shoulder Belt...................................1-14, 1-23LATCH System
Child Restraints...........................................1-40
Securing a Child Restraint Designed for the
LATCH System........................................1-42
Latches, Seatback............................................ 1-6
Leaving Your Vehicle.......................................2-10
Leaving Your Vehicle With the Engine
Running.....................................................2-26
Light
Air Bag Readiness.......................................3-23
Anti-Lock Brake System Warning...................3-26
Brake System Warning.................................3-25
Charging System.........................................3-24
Check Gages Warning.................................3-33
Enhanced Traction System (ETS)
Active Light.............................................3-28
Enhanced Traction System (ETS) Warning
Light......................................................3-27
Low Coolant Warning...................................3-29
Malfunction Indicator....................................3-29
Oil Pressure...............................................3-32
Passlock®Warning.......................................3-33
Safety Belt Reminder...................................3-23
Service Vehicle Soon...................................3-34
Up-Shift.....................................................3-25
Loading Your Vehicle.......................................4-31
Lockout Protection..........................................2-10
8