2004 CHEVROLET CAVALIER fuel cap

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-2
Rear Seats
............................................... 1-7
Safety Belts
.............................................. 1-8
Child Restraints
.......................................1-29
Air Bag Systems
......................................1-47
Restraint System Check
............................1-56
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-12
Theft-Deterrent Systems
............................2-14
Starting and Operating Your Vehicle
...........2-16
Mirrors
....................................................2-30
OnStar
®System
......................................2-32
Storage Areas
.........................................2-33
Sunroof
..................................................2-34
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-2
Climate Controls
......................................3-16
Warning Lights, Gages, and Indicators
........3-20
Audio System(s)
.......................................3-35Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-29
Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-4
Checking Things Under the Hood
...............5-10
Bulb Replacement
....................................5-41
Windshield Wiper Blade Replacement
.........5-45
Tires
......................................................5-46
Appearance Care
.....................................5-72
Vehicle Identication
.................................5-79
Electrical System
......................................5-80
Capacities and Specications
.....................5-85
Normal Maintenance Replacement Parts
......5-86
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-10
Index.................................................................1
2004 Chevrolet Cavalier Owner ManualM

If the Light Is on Steady
You also may be able to correct the emission system
malfunction by considering the following:
Did you recently put fuel into your vehicle?
If so, reinstall the fuel cap, making sure to fully install
the cap. SeeFilling Your Tank on page 5-7. The
diagnostic system can determine if the fuel cap has
been left off or improperly installed. A loose or missing
fuel cap will allow fuel to evaporate into the atmosphere.
A few driving trips with the cap properly installed
should turn the light off.
Did you just drive through a deep puddle of water?
If so, your electrical system may be wet. The condition
will usually be corrected when the electrical system
dries out. A few driving trips should turn the light off.
Have you recently changed brands of fuel?
If so, be sure to fuel your vehicle with quality fuel. See
Gasoline Octane on page 5-5. Poor fuel quality will
cause your engine not to run as efficiently as designed.
You may notice this as stalling after start-up, stalling
when you put the vehicle into gear, misring, hesitation
on acceleration or stumbling on acceleration. (These
conditions may go away once the engine is warmed up.)
This will be detected by the system and cause the
light to turn on.If you experience one or more of these conditions,
change the fuel brand you use. It will require at least
one full tank of the proper fuel to turn the light off.
If none of the above steps have made the light turn off,
your dealer can check the vehicle. Your dealer has
the proper test equipment and diagnostic tools to x any
mechanical or electrical problems that may have
developed.
Emissions Inspection and Maintenance
Programs
Some state/provincial and local governments have or
may begin programs to inspect the emission control
equipment on your vehicle. Failure to pass this
inspection could prevent you from getting a vehicle
registration.
Here are some things you need to know to help your
vehicle pass an inspection:
Your vehicle will not pass this inspection if the Check
Engine light is on or not working properly.
3-31

Here are four things that some owners ask about. None
of these show a problem with your fuel gage:
At the service station, the gas pump shuts off
before the gage reads full.
It takes a little more or less fuel to ll up than the
gage indicated. For example, the gage may have
indicated the tank was half full, but it actually took a
little more or less than half the tank’s capacity to
ll the tank.
The gage moves a little when you turn a corner or
speed up.
The gage doesn’t go back to empty when you turn
off the ignition.
For your fuel tank capacity, seeCapacities and
Specications on page 5-85.
Audio System(s)
Notice:Before adding any sound equipment to
your vehicle, like a tape player, CB radio, mobile
telephone, or two-way radio, make sure that it can
be added by checking with your dealer. Also,
check federal rules covering mobile radio and
telephone units. If sound equipment can be added,
it is very important to do it properly.Added sound equipment may interfere with the
operation of your vehicle’s engine, radio, or other
systems, and even damage them. Your vehicle’s
systems may interfere with the operation of sound
equipment that has been added improperly.
Figure out which audio system is in your vehicle, nd
out what your audio system can do, and how to operate
all of its controls.
Your vehicle has a feature called Retained Accessory
Power (RAP). With RAP, the audio system can be
played even after the ignition is turned off. See
“Retained Accessory Power (RAP)” underIgnition
Positions on page 2-16.
Setting the Time for Radios without
Radio Data Systems (RDS)
Press and hold the HR or MIN arrow for two seconds.
Then press HR until the correct hour appears on
the display. Press and hold MIN until the correct minute
appears on the display. The time can be set with the
ignition on or off.
3-35

Certication Label
The Certication label, found on the rear edge of the
driver’s door, tells you the gross weight capacity of your
vehicle, called the Gross Vehicle Weight Rating
(GVWR). The GVWR includes the weight of the vehicle,
all occupants, fuel and cargo. Never exceed the
GVWR for your vehicle, or the Gross Axle Weight
Rating (GAWR) for either the front or rear axle.And, if you do have a heavy load, you should spread
it out. Do not carry more than 132 lbs (60 kg) in
your trunk.
{CAUTION:
Do not load your vehicle any heavier than the
GVWR, or either the maximum front or rear
GAWR. If you do, parts on your vehicle can
break, and it can change the way your vehicle
handles. These could cause you to lose
control and crash. Also, overloading can
shorten the life of your vehicle.
4-35

Towing a Trailer
(Automatic Transaxle)
{CAUTION:
If you do not use the correct equipment and
drive properly, you can lose control when you
pull a trailer. For example, if the trailer is too
heavy, the brakes may not work well — or even
at all. You and your passengers could be
seriously injured. You may also damage your
vehicle; the resulting repairs would not be
covered by your warranty. Pull a trailer only if
you have followed all the steps in this section.
Ask your dealer for advice and information
about towing a trailer with your vehicle.Your vehicle can tow a trailer if it is equipped with an
automatic transaxle and the proper trailer towing
equipment. If your vehicle is not equipped as stated
above, do not tow a trailer. To identify what the vehicle
trailering capacity is for your vehicle, you should
read the information in “Weight of the Trailer” that
appears later in this section. But trailering is different
than just driving your vehicle by itself. Trailering means
changes in handling, acceleration, braking, durability
and fuel economy. Successful, safe trailering takes
correct equipment, and it has to be used properly.
That is the reason for this part. In it are many
time-tested, important trailering tips and safety rules.
Many of these are important for your safety and that of
your passengers. So please read this section carefully
before you pull a trailer.
Load-pulling components such as the engine, transaxle,
wheel assemblies and tires are forced to work harder
against the drag of the added weight. The engine
is required to operate at relatively higher speeds and
under greater loads, generating extra heat. Also,
the trailer adds considerably to wind resistance,
increasing the pulling requirements.
4-37

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-4
Fuel................................................................5-4
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-6
Filling Your Tank............................................5-7
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood....................5-10
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Air Cleaner/Filter................................5-17
Automatic Transaxle Fluid..............................5-19
Manual Transaxle Fluid..................................5-19
Hydraulic Clutch...........................................5-19
Engine Coolant.............................................5-20
Coolant Surge Tank Pressure Cap..................5-23
Engine Overheating.......................................5-23
Cooling System............................................5-25
Power Steering Fluid.....................................5-30Windshield Washer Fluid................................5-31
Brakes........................................................5-32
Battery........................................................5-36
Jump Starting...............................................5-36
Bulb Replacement..........................................5-41
Halogen Bulbs..............................................5-41
Headlamps..................................................5-41
Front Turn Signal and Parking Lamps..............5-43
Taillamps and Turn Signal Lamps...................5-44
Back-Up Lamps............................................5-44
Replacement Bulbs.......................................5-44
Windshield Wiper Blade Replacement..............5-45
Tires..............................................................5-46
Ination - Tire Pressure.................................5-53
Tire Inspection and Rotation...........................5-54
When It Is Time for New Tires.......................5-55
Buying New Tires.........................................5-56
Uniform Tire Quality Grading..........................5-57
Wheel Alignment and Tire Balance..................5-58
Wheel Replacement......................................5-58
Tire Chains..................................................5-60
If a Tire Goes Flat........................................5-61
Changing a Flat Tire.....................................5-62
Compact Spare Tire......................................5-72
Section 5 Service and Appearance Care
5-1

Filling Your Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your
engine when you are refueling. Do not smoke
if you are near fuel or refueling your vehicle.
Keep sparks, ames and smoking materials
away from fuel. Do not leave the fuel pump
unattended when refueling your vehicle — this
is against the law in some places. Keep
children away from the fuel pump; never let
children pump fuel.The tethered fuel cap is located behind a hinged fuel
door on the passenger’s side of the vehicle.
5-7

While refueling, hang the tethered fuel cap from the
hook on the fuel door.
To remove the fuel cap, turn it slowly to the left
(counterclockwise). The fuel cap has a spring in it; if
you let go of the cap too soon, it will spring back to
the right.
{CAUTION:
If you spill fuel and then something ignites it,
you could be badly burned. Fuel can spray out
on you if you open the fuel cap too quickly.
This spray can happen if your tank is nearly
full, and is more likely in hot weather. Open
the fuel cap slowly and wait for any “hiss”
noise to stop. Then unscrew the cap all
the way.
Be careful not to spill fuel. Don’t top off or overll your
tank and wait a few seconds after you’ve nished
pumping before you remove the nozzle. Clean fuel from
painted surfaces as soon as possible. SeeCleaning
the Outside of Your Vehicle on page 5-75.
5-8