2004 CHEVROLET OPTRA Section 3

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specifications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
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...................................................5-14
Engine Air Cleaner/Filter................................5-18
Automatic Transaxle Fluid..............................5-20
Manual Transaxle Fluid..................................5-20
Hydraulic Clutch...........................................5-20
Engine Coolant.............................................5-21
Coolant Surge Tank Pressure Cap..................5-24
Engine Overheating.......................................5-24
Cooling System............................................5-27
Power Steering Fluid.....................................5-33Windshield Washer Fluid................................5-34
Brakes........................................................5-35
Battery........................................................5-38
Jump Starting...............................................5-39
Headlamp Aiming...........................................5-44
Bulb Replacement..........................................5-44
Halogen Bulbs..............................................5-44
Headlamps..................................................5-44
Front Turn Signal and Parking Lamps..............5-45
Turn Signal Lamps (Side)..............................5-46
Fog Lamps..................................................5-46
Sidemarker Lamps (Front)..............................5-47
Sidemarker Lamps (Rear)..............................5-47
Center High-Mounted Stoplamp (CHMSL).........5-48
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-48
Replacement Bulbs.......................................5-49
Windshield Wiper Blade Replacement..............5-50
Tires..............................................................5-51
Inflation - Tire Pressure.................................5-57
Tire Inspection and Rotation...........................5-58
When It Is Time for New Tires.......................5-59
Buying New Tires.........................................5-60
Uniform Tire Quality Grading..........................5-60
Section 5 Service and Appearance Care
5-1

Wheel Alignment and Tire Balance..................5-62
Wheel Replacement......................................5-62
Tire Chains..................................................5-63
If a Tire Goes Flat........................................5-63
Changing a Flat Tire.....................................5-64
Compact Spare Tire......................................5-72
Appearance Care............................................5-73
Cleaning the Inside of Your Vehicle.................5-73
Care of Safety Belts......................................5-76
Weatherstrips...............................................5-76
Cleaning the Outside of Your Vehicle.................5-76
Sheet Metal Damage.....................................5-78
Finish Damage.............................................5-78
Underbody Maintenance................................5-79Chemical Paint Spotting.................................5-79
Vehicle Care/Appearance Materials..................5-79
Vehicle Identication......................................5-81
Vehicle Identification Number (VIN).................5-81
Service Parts Identification Label.....................5-81
Electrical System............................................5-82
Add-On Electrical Equipment..........................5-82
Headlamp Wiring..........................................5-82
Windshield Wiper Fuses................................5-82
Power Windows and Other Power Options.......5-82
Fuses and Circuit Breakers............................5-83
Capacities and Specications..........................5-90
Normal Maintenance Replacement Parts..........5-91
Section 5 Service and Appearance Care
5-2

When to Add Engine Oil
If the oil is at or below the lower hole at the tip of the
dipstick (B), then you will need to add at least one quart
of oil. But you must use the right kind. This section
explains what kind of oil to use. For engine oil crankcase
capacity, seeCapacities and Specifications on
page 5-90.
Notice:Do not add too much oil. If your engine has
so much oil that the oil level gets above the upper
hole (A) that shows the proper operating range, your
engine could be damaged.
SeeEngine Compartment Overview on page 5-12for
the location of the engine oil fill cap.
Be sure to add enough oil to put the level somewhere in
the proper operating range. Push the dipstick all the
way back in when you are through.
What Kind of Engine Oil to Use
Look for two things:
•GM6094M
Your vehicle’s engine requires oil meeting GM
Standard GM6094M. You should look for and use
only an oil that meets GM Standard GM6094M.
5-15

Headlamp Aiming
If your vehicle is damaged in an accident, the headlamp
aim may be affected. Aim adjustment to the low beam
may be necessary if it is difficult to see lane markers
(for horizontal aim), or if oncoming drivers flash
their high beams at you (for vertical aim). If you believe
your headlamps need to be re-aimed, we recommend
that you take your vehicle to the dealer for service.
However, it is possible for you to re-aim your headlamps
by following the procedure in the service manual for
your vehicle.
Notice:To make sure your headlamps are aimed
properly, read all the instructions before beginning.
Failure to follow these instructions could cause
damage to headlamp parts.
Bulb Replacement
For bulb types, seeReplacement Bulbs on page 5-49.
For any bulb changing procedures not listed in this
section, contact your dealer.
Halogen Bulbs
{CAUTION:
Halogen bulbs have pressurized gas inside and
can burst if you drop or scratch the bulb. You or
others could be injured. Be sure to read and
follow the instructions on the bulb package.
Headlamps
1. Open the hood.
2. Remove the two bolts and the one nut that retain
the headlamp assembly.
3. Disconnect the wiring harness connector from the
rear of the bulb.
5-44

(A) Tire Size:The tire size is a combination of letters
and numbers used to define a particular tire’s width,
height, aspect ratio, construction type and service
description. See the “Tire Size” illustration later in this
section for more detail.
(B) Department of Transportation (DOT):The
Department of Transportation (DOT) code indicates that
the tire is in compliance with the U.S. Department of
Transportation Motor Vehicle Safety Standards.
(C) Tire Identication Number (TIN):The letters and
numbers following DOT code are the Tire Identification
Number (TIN). The TIN shows the manufacturer and
plant code, tire size, and date the tire was manufactured.
The TIN is molded onto both sides of the tire, although
only one side may have the date of manufacture.
(D) Tire Ply Material:The type of cord and number of
plies in the sidewall and under the tread.
(E) Uniform Tire Quality Grading (UTQG):Tire
manufacturers are required to grade tires based on three
performance factors: treadwear, traction and
temperature resistance. For more information see
Uniform Tire Quality Grading on page 5-60.
(F) Maximum Cold Ination Load Limit:Maximum
load that can be carried and the maximum pressure
needed to support that load. For information on
recommended tire pressure seeInflation - Tire Pressure
on page 5-57andLoading Your Vehicle on page 4-33.
Passenger Car Tire Example
5-52

Tire Size
The following illustration shows an example of a typical
passenger car tire size.
(A) Passenger (P-Metric) Tire:The United States
version of a metric tire sizing system. The letter “P” as
the first character in the tire size means a passenger
vehicle tire engineered to standards set by the U.S. Tire
and Rim Association.
(B) Tire Width:The three-digit number indicates the
tire section width in millimeters from sidewall to sidewall.(C) Aspect Ratio:A two-digit number that indicates
the tire height-to-width measurements. For example,
if the tire size aspect ratio is “70,” as shown in item “C”
of the illustration, it would mean that the tire’s sidewall
is 70% as high as it is wide.
(D) Construction Code:A letter code is used to
indicate the type of ply construction in the tire. The letter
“R” means radial ply construction; the letter “D” means
diagonal or bias ply construction; and the letter “B”
means belted-bias ply construction.
(E) Rim Diameter:Diameter of the wheel in inches.
(F) Service Description:These characters represent
the load range and the speed rating of a tire. The
load range represents the load carry capacity a tire is
certified to carry. The speed rating is the maximum
speed a tire is certified to carry a load. Speed ratings
range from “A” to “Z”.
5-54

Buying New Tires
To find out what kind and size of tires you need, look at
the Tire-Loading Information label.
Make sure the replacements are the same size, load
range, speed rating and construction type (bias,
bias-belted or radial) as your original tires.
{CAUTION:
Mixing tires could cause you to lose control
while driving. If you mix tires of different sizes
or types (radial and bias-belted tires), the
vehicle may not handle properly, and you
could have a crash. Using tires of different
sizes may also cause damage to your vehicle.
Be sure to use the same size and type tires on
all wheels. It’s all right to drive with your
compact spare temporarily, it was developed
for use on your vehicle. See “Compact Spare
Tire” in the index.
{CAUTION:
If you use bias-ply tires on your vehicle, the
wheel rim anges could develop cracks after
many miles of driving. A tire and/or wheel
could fail suddenly, causing a crash. Use only
radial-ply tires with the wheels on your vehicle.
Uniform Tire Quality Grading
Quality grades can be found where applicable on the
tire sidewall between tread shoulder and maximum
section width. For example:
Treadwear 200 Traction AA Temperature A
The following information relates to the system
developed by the United States National Highway
Traffic Safety Administration, which grades tires by
treadwear, traction and temperature performance. (This
applies only to vehicles sold in the United States.)
The grades are molded on the sidewalls of most
passenger car tires. The Uniform Tire Quality Grading
system does not apply to deep tread, winter-type
snow tires, space-saver or temporary use spare tires,
tires with nominal rim diameters of 10 to 12 inches
(25 to 30 cm), or to some limited-production tires.
5-60

Here are some cleaning tips:
•Always read the instructions on the cleaner label.
•Clean up stains as soon as you can — before
they set.
•Carefully scrape off any excess stain.
•Use a clean cloth or sponge, and change to a clean
area often. A soft brush may be used if stains are
stubborn.
•If a ring forms on fabric after spot cleaning, clean
the entire area immediately or it will set.
Using Cleaner on Fabric
1. Vacuum and brush the area to remove any
loose dirt.
2. Always clean a whole trim panel or section. Mask
surrounding trim along stitch or welt lines.
3. Follow the directions on the container label.
4. Apply cleaner with a clean sponge. Do not saturate
the material and do not rub it roughly.
5. As soon as you have cleaned the section, use a
sponge to remove any excess cleaner.
6. Wipe cleaned area with a clean, water-dampened
towel or cloth.
7. Wipe with a clean cloth and let dry.
Special Fabric Cleaning Problems
Stains caused by such things as catsup, coffee (black),
egg, fruit, fruit juice, milk, soft drinks, vomit, urine
and blood can be removed as follows:
1. Carefully scrape off excess stain, then sponge the
soiled area with cool water.
2. If a stain remains, follow the cleaning instructions
described earlier.
3. If an odor lingers after cleaning vomit or urine, treat
the area with a water and baking soda solution:
1 teaspoon (5 ml) of baking soda to 1 cup (250 ml)
of lukewarm water.
4. Let dry.
Stains caused by candy, ice cream, mayonnaise, chili
sauce and unknown stains can be removed as follows:
1. Carefully scrape off excess stain.
2. Clean with cool water and allow to dry completely.
3. If a stain remains, follow the cleaner instructions
described earlier.
5-74