2004 CHEVROLET OPTRA service

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 48232-5170In 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 specifications for GM
transmissions, transaxles, and transfer cases.
RETAIL SELL PRICE: $50.00
7-12

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).
Owner’s Information
Owner publications are written specifically for owners
and intended to provide basic operational information
about the vehicle. The owner’s manual will include
the Maintenance Schedule for all models.
In-Portfolio: Includes a Portfolio, Owner’s Manual, and
Warranty Booklet.
RETAIL SELL PRICE: $35.00
Without Portfolio: Owner’s Manual only.
RETAIL SELL PRICE: $25.00
Current and Past Model Order Forms
Service Publications are available for current and
past model GM vehicles. To request an order form,
please specify year and model name of the vehicle.
ORDER TOLL FREE: 1-800-551-4123
Monday-Friday 8:00 AM - 6:00 PM
Eastern Time
For Credit Card Orders Only
(VISA-MasterCard-Discover), visit Helm, Inc. on the
World Wide Web at: www.helminc.com
Or you can write to:
Helm, Incorporated
P. O. Box 07130
Detroit, MI 48207
Prices are subject to change without notice and without
incurring obligation. Allow ample time for delivery.
Note to Canadian Customers: All listed prices are
quoted in U.S. funds. Canadian residents are to make
checks payable in U.S. funds.
7-13

A
Accessory Power Outlets.................................3-16
Adding Washer Fluid.......................................5-34
Additional Program Information........................... 7-9
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment............................5-82
Adjusting the Speakers (Balance/Fade)......3-42, 3-46
Air Bag
Readiness Light..........................................3-28
Air Bag Systems.............................................1-51
How Does an Air Bag Restrain?....................1-57
Servicing Your Air Bag-Equipped Vehicle.........1-60
What Makes an Air Bag Inflate?....................1-57
What Will You See After an Air Bag Inflates?......1-58
When Should an Air Bag Inflate?...................1-56
Where Are the Air Bags?..............................1-54
Air Cleaner/Filter, Engine.................................5-18
Airbag Sensing and Diagnostic Module (SDM).......7-10
AM ...............................................................3-51
Antenna, Backglass.........................................3-52
Anti-lock Brake System (ABS)............................ 4-6
Anti-Lock Brake, System Warning Light..............3-31
Appearance Care............................................5-73
Care of Safety Belts....................................5-76
Chemical Paint Spotting...............................5-79
Cleaning the Inside of Your Vehicle................5-73
Cleaning the Outside of Your Vehicle..............5-76
Finish Damage............................................5-78Appearance Care (cont.)
Sheet Metal Damage...................................5-78
Underbody Maintenance...............................5-79
Vehicle Care/Appearance Materials................5-79
Weatherstrips..............................................5-76
Arming the System.........................................2-16
Ashtrays........................................................3-17
Audio System(s).............................................3-40
Backglass Antenna......................................3-52
Care of Your CD Player...............................3-52
Care of Your CDs........................................3-52
Radio with CD....................................3-40, 3-44
Theft-Deterrent Feature................................3-51
Understanding Radio Reception.....................3-51
Automatic Transaxle........................................2-19
Fluid..........................................................5-20
Operation...................................................2-23
Automatic Transaxle Check..............................6-19
Automatic Transaxle Shift Lock Control
System Check.............................................6-21
B
Backglass Antenna..........................................3-52
Battery..........................................................5-38
Battery Replacement......................................... 2-6
Before Leaving on a Long Trip.........................4-22
Body Lubrication Service..................................6-20
1

Brake
Parking......................................................2-28
System Inspection.......................................6-24
System Warning Light..................................3-30
Brake Fluid....................................................5-35
Brake Wear...................................................5-36
Brakes..........................................................5-35
Braking........................................................... 4-6
Braking in Emergencies..................................... 4-8
Break-In, New Vehicle.....................................2-18
Bulb Replacement...........................................5-44
Center High-Mounted Stoplamp (CHMSL)........5-48
Fog Lamps.................................................5-46
Front Turn Signal and Parking Lamps.............5-45
Halogen Bulbs............................................5-44
Headlamp Aiming........................................5-44
Headlamps.................................................5-44
Replacement Bulbs......................................5-49
Sidemarker Lamps.......................................5-47
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps........................................5-48
Turn Signal Lamps......................................5-46
Buying New Tires...........................................5-60
C
California Fuel.................................................. 5-6
Canada – Customer Assistance.......................... 7-4
Canadian Owners................................................ iiCanadian Roadside Assistance........................... 7-7
Canceling the Rear Door Security Lock..............2-10
Capacities and Specifications............................5-90
Carbon Monoxide...........4-25, 4-37, 2-11, 2-13, 2-33
Care of
Safety Belts................................................5-76
Your CD Player...........................................3-52
Your CDs ...................................................3-52
Cassette Tape Player Service...........................6-18
CD Messages........................................3-44, 3-50
Center High-Mounted Stoplamp (CHMSL)...........5-48
Center Rear Passenger Position, Safety Belts.....1-28
Chains, Tires..................................................5-63
Charging System Light....................................3-29
Check
Engine Light...............................................3-33
Check Engine Light.........................................3-33
Checking Coolant............................................5-23
Checking Engine Oil........................................5-14
Checking Things Under the Hood......................5-10
Chemical Paint Spotting...................................5-79
Child Restraints
Child Restraint Systems...............................1-35
Infants and Young Children...........................1-31
Lower Anchorages and Top Tethers for
Children (LATCH System)..........................1-42
Older Children.............................................1-29
Securing a Child Restraint Designed for the
LATCH System........................................1-45
2

Child Restraints (cont.)
Securing a Child Restraint in a Rear Seat
Position..................................................1-45
Securing a Child Restraint in the Right Front
Seat Position...........................................1-48
Top Strap...................................................1-39
Top Strap Anchor Location............................1-41
Where to Put the Restraint...........................1-38
Cigarette Lighter.............................................3-17
Cleaning
Inside of Your Vehicle..................................5-73
Outside of Your Vehicle................................5-76
Underbody Maintenance...............................5-79
Weatherstrips..............................................5-76
Cleaning Aluminum Wheels..............................5-78
Cleaning Exterior Lamps/Lenses.......................5-77
Cleaning Fabric/Carpet....................................5-73
Cleaning Glass Surfaces..................................5-75
Cleaning Interior Plastic Components.................5-75
Cleaning Leather............................................5-75
Cleaning the Top of the Instrument Panel...........5-75
Cleaning Tires................................................5-78
Cleaning Vinyl................................................5-75
Cleaning Windshield and Wiper Blades..............5-77
Climate Control System...................................3-19
Air Filter, Passenger Compartment.................3-23
Outlet Adjustment........................................3-22
Clock............................................................3-18Clutch and Brake Pedal Free Play Check...........6-19
Clutch, Hydraulic.............................................5-20
Compact Spare Tire........................................5-72
Control of a Vehicle.......................................... 4-5
Coolant
Engine Temperature Gage............................3-32
Heater, Engine............................................2-21
Surge Tank Pressure Cap.............................5-24
Cooling System..............................................5-27
Cruise Control.................................................. 3-9
Cruise Control Light........................................3-37
Cupholder(s)..................................................2-37
Current and Past Model Order Forms................7-13
Customer Assistance Information
Courtesy Transportation.................................. 7-7
Customer Assistance for Text Telephone (TTY)
Users....................................................... 7-4
Customer Assistance Offices........................... 7-4
Customer Satisfaction Procedure..................... 7-2
GM Mobility Program for Persons with
Disabilities................................................ 7-5
Reporting Safety Defects to General Motors.......7-12
Reporting Safety Defects to the Canadian
Government............................................7-12
Reporting Safety Defects to the United States
Government............................................7-11
Roadside Assistance Program......................... 7-6
Service Publications Ordering Information........7-12
3

D
Daytime Running Lamps (DRL).........................3-13
Daytime Running Lamps Indicator Light.............3-38
Defensive Driving............................................. 4-2
Defogging and Defrosting.................................3-21
Dinghy Towing................................................4-32
Disarming the System.....................................2-17
Doing Your Own Service Work........................... 5-4
Dolly Towing..................................................4-32
Dome Lamp...................................................3-15
Door
Ajar Light...................................................3-38
Central Door Unlocking System....................... 2-8
Door Ajar Reminder....................................... 2-9
Locks.......................................................... 2-7
Power Door Locks......................................... 2-9
Rear Door Security Locks............................... 2-9
Driver
Position, Safety Belt.....................................1-15
Seat Height Adjuster...................................... 1-4
Driving
At Night.....................................................4-14
City...........................................................4-19
Defensive..................................................... 4-2
Drunken....................................................... 4-2
Freeway.....................................................4-20Driving (cont.)
Hill and Mountain Roads..............................4-23
In Rain and on Wet Roads...........................4-16
Winter........................................................4-25
Driving on Snow or Ice....................................4-26
Driving Through Deep Standing Water...............4-18
Driving Through Flowing Water.........................4-18
E
Electrical System
Add-On Equipment......................................5-82
Fuses and Circuit Breakers...........................5-83
Headlamp Wiring.........................................5-82
Power Windows and Other Power Options......5-82
Windshield Wiper Fuses...............................5-82
Emergency Trunk Release Handle.....................2-12
Emissions Inspection and Maintenance
Programs...................................................3-35
Engine
Air Cleaner/Filter.........................................5-18
Battery.......................................................5-38
Check and Service Engine Soon Light............3-33
Coolant......................................................5-21
Coolant Heater............................................2-21
Coolant Temperature Gage...........................3-32
Cooling System Inspection............................6-23
4

If the Light Is On Steady.................................3-34
If You Are Caught in a Blizzard.........................4-27
If You Are Stuck in Sand, Mud, Ice or Snow.......4-30
Ignition Positions.............................................2-18
Ignition Transaxle Lock Check..........................6-21
Infants and Young Children, Restraints...............1-31
Inflation - Tire Pressure...................................5-57
Inspection
Brake System.............................................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...........................................6-24
Instrument Panel
Cluster.......................................................3-26
Overview..................................................... 3-2
Instrument Panel Brightness.............................3-14
Instrument Panel Fuse Block............................5-83
Interior Lamps................................................3-14
J
Jump Starting.................................................5-39
K
Key Lock Cylinders Service..............................6-20
Keyless Entry System....................................... 2-3
Keys............................................................... 2-2
L
Lamps
Exterior......................................................3-12
Fog Lamps.................................................5-46
Interior.......................................................3-14
Lamps On Reminder.......................................3-13
Lap-Shoulder Belt...................................1-16, 1-25
LATCH System
Child Restraints...........................................1-42
Securing a Child Restraint Designed for the
LATCH System........................................1-45
Leaving Your Vehicle.......................................2-10
Leaving Your Vehicle With the Engine Running......2-30
Liftgate..........................................................2-13
Light
Air Bag Readiness.......................................3-28
Anti-Lock Brake System Warning...................3-31
Brake System Warning.................................3-30
Charging System.........................................3-29
Cruise Control.............................................3-37
Daytime Running Lamps Indicator..................3-38
7

Light (cont.)
Door Ajar...................................................3-38
Fog Lamp..................................................3-37
Highbeam On.............................................3-38
Hold Mode.................................................3-32
Low Fuel Warning.......................................3-39
Malfunction Indicator....................................3-33
Oil Pressure...............................................3-36
Safety Belt Reminder...................................3-28
Safety Belt Reminder Tone...........................3-28
Speed Sensitive Power Steering (SSPS)
Warning Light..........................................3-31
Loading Your Vehicle.......................................4-33
Lockout Protection..........................................2-10
Locks
Central Door Unlocking System....................... 2-8
Door........................................................... 2-7
Leaving Your Vehicle....................................2-10
Lockout Protection.......................................2-10
Power Door.................................................. 2-9
Rear Door Security Locks............................... 2-9
Long Trip/Highway Definition.............................. 6-6
Long Trip/Highway Intervals............................... 6-6
Long Trip/Highway Scheduled Maintenance........6-13
Loss of Control...............................................4-13
Low Fuel Warning Light...................................3-39
Lumbar
Manual Controls............................................ 1-4M
Maintenance, Normal Replacement Parts............5-91
Maintenance Schedule
At Each Fuel Fill.........................................6-18
At Least Once a Month................................6-18
At Least Once a Year..................................6-20
At Least Twice a Year..................................6-19
Brake System Inspection..............................6-24
Engine Cooling System Inspection.................6-23
Exhaust System Inspection...........................6-23
Fuel System Inspection................................6-23
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...............................................6-24
Part E - Maintenance Record........................6-26
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............................6-24
Using Your................................................... 6-4
Your Vehicle and the Environment................... 6-2
8