2004 CHEVROLET CAVALIER suspension

Tire Chains
{CAUTION:
If your vehicle has P195/65R15 or P205/55R16
size tires, don’t use tire chains, there’s not
enough clearance.
Tire chains used on a vehicle without the
proper amount of clearance can cause damage
to the brakes, suspension or other vehicle
parts. The area damaged by the tire chains
could cause you to lose control of your vehicle
and you or others may be injured in a crash.
Use another type of traction device only if its
manufacturer recommends it for use on your
vehicle and tire size combination and road
CAUTION: (Continued)
CAUTION: (Continued)
conditions. Follow that manufacturer’s
instructions. To help avoid damage to your
vehicle, drive slowly, readjust or remove the
device if it’s contacting your vehicle, and don’t
spin your wheels.
If you do nd traction devices that will t,
install them on the front tires.
Notice:If your vehicle has a tire size other than
P195/65R15 or P205/55R16 size tires, use tire chains
only where legal and only when you must. Use
only SAE Class “S” type chains that are the proper
size for your tires. Install them on the front tires
and tighten them as tightly as possible with the ends
securely fastened. Drive slowly and follow the
chain manufacturer’s instructions. If you can hear
the chains contacting your vehicle, stop and
retighten them. If the contact continues, slow down
until it stops. Driving too fast or spinning the
wheels with chains on will damage your vehicle.
5-60

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
How This Section is Organized.........................6-3
Part A: Scheduled Maintenance Services...........6-4
Using Your Maintenance Schedule....................6-4
Selecting the Right Schedule...........................6-5
Short Trip/City Scheduled Maintenance..............6-6
Long Trip/Highway Scheduled Maintenance......6-13
Part B: Owner Checks and Services................6-18
At Each Fuel Fill..........................................6-18
At Least Once a Month.................................6-18At Least Twice a Year...................................6-18
At Least Once a Year...................................6-19
Part C: Periodic Maintenance Inspections.........6-23
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection............................6-23
Exhaust System Inspection............................6-23
Fuel System Inspection..................................6-23
Engine Cooling System Inspection...................6-23
Throttle System Inspection.............................6-23
Brake System Inspection................................6-24
Caliper/Knuckle Maintenance Inspection...........6-24
Part D: Recommended Fluids and Lubricants. . . .6-25
Part E: Maintenance Record...........................6-27
Section 6 Maintenance Schedule
6-1

Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
#Lubricate the suspension, steering linkage and the
transaxle shift linkage.
+A good time to check your brakes is during tire
rotation. See Brake System Inspection on page 6-24.
++If you drive in a highly corrosive environment,
your brake calipers may require additional inspection
and service, at every other tire rotation. See
Caliper/Knuckle Maintenance Inspection on page 6-24.
3,000 Miles (5 000 km)
❑Change engine oil and lter (or every 3 months,
whichever occurs rst).An Emission Control Service.
6,000 Miles (10 000 km)
❑Change engine oil and lter (or every 3 months,
whichever occurs rst).An Emission Control Service.
❑Lubricate chassis components (or every 6 months,
whichever occurs rst).(See footnote #.)
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-54for proper rotation pattern and additional
information.(See footnote +.)
9,000 Miles (15 000 km)
❑Change engine oil and lter (or every 3 months,
whichever occurs rst).An Emission Control Service.
12,000 Miles (20 000 km)
❑Change engine oil and lter (or every 3 months,
whichever occurs rst).An Emission Control Service.
❑Lubricate chassis components (or every 6 months,
whichever occurs rst).(See footnote #.)
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-54for proper rotation pattern and additional
information.(See footnote +.) (Also see footnote ++.)
6-7

Long Trip/Highway Scheduled
Maintenance
The services shown in this schedule up to 100,000 miles
(166 000 km) should be repeated after 100,000 miles
(166 000 km) at the same intervals for the life of
this vehicle. The services shown at 150,000 miles
(240 000 km) should be repeated at the same interval
after 150,000 miles (240 000 km) for the life of this
vehicle.
SeePart B: Owner Checks and Services on page 6-18
andPart C: Periodic Maintenance Inspections on
page 6-23.
Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
#Lubricate the suspension, steering linkage and the
transaxle shift linkage.
+A good time to check your brakes is during tire
rotation. See Brake System Inspection on page 6-24.++If you drive in a highly corrosive environment, your
brake calipers may require additional inspection and
service at every other tire rotation. See Caliper/Knuckle
Maintenance Inspection on page 6-24.
7,500 Miles (12 500 km)
❑Change engine oil and lter (or every 12 months,
whichever occurs rst).An Emission Control
Service.
❑Lubricate chassis components (or every 12 months,
whichever occurs rst).(See footnote #.)
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-54for proper rotation pattern and additional
information.(See footnote +.)
15,000 Miles (25 000 km)
❑Change engine oil and lter (or every 12 months,
whichever occurs rst).An Emission Control
Service.
❑Lubricate chassis components (or every 12 months,
whichever occurs rst).(See footnote #.)
❑Inspect engine air cleaner lter. SeeEngine Air
Cleaner/Filter on page 5-17for more information.An
Emission Control Service. (See footnote †.)
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-54for proper rotation pattern and additional
information.(See footnote +.) (Also see footnote ++.)
6-13

Part C: Periodic Maintenance
Inspections
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 7-11.
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, chang, 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. SeeEngine Exhaust
on page 2-28.
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

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

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

Locks
Door........................................................... 2-7
Leaving Your Vehicle....................................2-10
Lockout Protection.......................................2-10
Power Door.................................................. 2-8
Rear Door Security Locks............................... 2-9
Long Trip/Highway Denition.............................. 6-6
Long Trip/Highway Intervals............................... 6-6
Long Trip/Highway Scheduled Maintenance........6-13
Loss of Control...............................................4-13
Low Coolant Warning Light..............................3-29
M
Maintenance, Normal Replacement Parts............5-86
Maintenance Schedule
At Each Fuel Fill.........................................6-18
At Least Once a Month................................6-18
At Least Once a Year..................................6-19
At Least Twice a Year..................................6-18
Brake System Inspection..............................6-24
Caliper/Knuckle Maintenance Inspection..........6-24
Engine Cooling System Inspection.................6-23
Exhaust System Inspection...........................6-23
Fuel System Inspection................................6-23Maintenance Schedule (cont.)
How This Section is Organized....................... 6-3
Introduction.................................................. 6-2
Long Trip/Highway Scheduled Maintenance.....6-13
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4
Part B - Owner Checks and Services.............6-18
Part C - Periodic Maintenance Inspections......6-23
Part D - Recommended Fluids and
Lubricants...............................................6-25
Part E - Maintenance Record........................6-27
Selecting the Right Schedule.......................... 6-5
Short Trip/City Scheduled Maintenance............. 6-6
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection..........................6-23
Throttle System Inspection............................6-23
Using Your................................................... 6-4
Your Vehicle and the Environment................... 6-2
Maintenance When Trailer Towing.....................4-43
Making Turns.................................................4-41
Malfunction Indicator Light................................3-29
Manual Seats................................................... 1-2
Manual Transaxle............................................2-18
Fluid..........................................................5-19
Operation...................................................2-23
9