2004 CHEVROLET OPTRA service

What can you do about highway hypnosis? First, be
aware that it can happen.
Then here are some tips:
•Make sure your vehicle is well ventilated, with a
comfortably cool interior.
•Keep your eyes moving. Scan the road ahead and
to the sides. Check your rearview mirrors and your
instruments frequently.
•If you get sleepy, pull off the road into a rest,
service or parking area and take a nap, get some
exercise, or both. For safety, treat drowsiness
on the highway as an emergency.
Hill and Mountain Roads
Driving on steep hills or mountains is different from
driving in flat or rolling terrain.
4-23

Towing
Towing Your Vehicle
Consult your dealer or a professional towing service if
you need to have your disabled vehicle towed. See
Roadside Assistance Program on page 7-6.
If you want to tow your vehicle behind another vehicle
for recreational purposes (such as behind a motorhome),
see “Recreational Vehicle Towing” following.
Recreational Vehicle Towing
Recreational vehicle towing means towing your vehicle
behind another vehicle, such as behind a motorhome.
The two most common types of recreational vehicle
towing are known as “dinghy towing” (towing your vehicle
with all four wheels on the ground) and “dolly towing”
(towing your vehicle with two wheels on the ground and
two wheels up on a device known as a “dolly”).With the proper preparation and equipment, many
vehicles can be towed in these ways. See “Dinghy
Towing” and “Dolly Towing,” following.
Here are some important things to consider before you
do recreational vehicle towing:
•What is the towing capacity of the towing vehicle?
Be sure you read the tow vehicle manufacturer’s
recommendations.
•How far will you tow? Some vehicles have
restrictions on how far and how long they can tow.
•Do you have the proper towing equipment?
See your dealer or trailering professional for
additional advice and equipment recommendations.
•Is your vehicle ready to be towed? Just as you
would prepare your vehicle for a long trip, you
will want to make sure your vehicle is prepared to
be towed. SeeBefore Leaving on a Long Trip
on page 4-22.
4-31

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

Service
Your dealer knows your vehicle best and wants you to
be happy with it. We hope you will go to your dealer
for all your service needs. You will get genuine GM parts
and GM-trained and supported service people.
We hope you will want to keep your GM vehicle all GM.
Genuine GM parts have one of these marks:
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many fluids, and
some component wear by-products contain and/or emit
these chemicals.
5-3

Doing Your Own Service Work
If you want to do some of your own service work, you
will want to use the proper service manual. It tells
you much more about how to service your vehicle than
this manual can. To order the proper service manual,
seeService Publications Ordering Information on
page 7-12.
Your vehicle has an air bag system. Before attempting
to do your own service work, seeServicing Your Air
Bag-Equipped Vehicle on page 1-60.
You should keep a record with all parts receipts and list
the mileage and the date of any service work you
perform. SeePart E: Maintenance Record on page 6-26.{CAUTION:
You can be injured and your vehicle could be
damaged if you try to do service work on a
vehicle without knowing enough about it.
Be sure you have sufficient knowledge,
experience, the proper replacement parts
and tools before you attempt any vehicle
maintenance task.
Be sure to use the proper nuts, bolts and
other fasteners. “English” and “metric”
fasteners can be easily confused. If you
use the wrong fasteners, parts can later
break or fall off. You could be hurt.
5-4

Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle can
affect the airflow around it. This may cause wind
noise and affect windshield washer performance. Check
with your dealer before adding equipment to the
outside of your vehicle.
Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
Use regular unleaded gasoline with a posted octane of
87 or higher. If the octane is less than 87, you may get a
heavy knocking noise when you drive. If this occurs, use
a gasoline rated at 87 octane or higher as soon as
possible. Otherwise, you might damage your engine. A
little pinging noise when you accelerate or drive uphill is
considered normal. This does not indicate a problem
exists or that a higher-octane fuel is necessary. If you are
using 87 octane or higher-octane fuel and hear heavy
knocking, your engine needs service.
Gasoline Specications
It is recommended that gasoline meet specifications
which were developed by automobile manufacturers
around the world and contained in the World-Wide Fuel
Charter which is available from the Alliance of
Automobile Manufacturers at www.autoalliance.org.
Gasoline meeting these specifications could provide
improved driveability and emission control system
performance compared to other gasoline.
In Canada, look for the
“Auto Makers’ Choice”
label on the pump.
Canada Only
5-5

California Fuel
If your vehicle is certified to meet California Emission
Standards (see the underhood emission control label), it
is designed to operate on fuels that meet California
specifications. If this fuel is not available in states
adopting California emissions standards, your vehicle
will operate satisfactorily on fuels meeting federal
specifications, but emission control system performance
may be affected. The malfunction indicator lamp may
turn on (seeMalfunction Indicator Lamp on page 3-33)
and your vehicle may fail a smog-check test. If this
occurs, return to your authorized GM dealer for
diagnosis. If it is determined that the condition is caused
by the type of fuel used, repairs may not be covered
by your warranty.
Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work properly.
You should not have to add anything to your fuel.
However, some gasolines contain only the minimum
amount of additive required to meet U.S. Environmental
Protection Agency regulations. General Motors
recommends that you buy gasolines that are advertisedto help keep fuel injectors and intake valves clean. If your
vehicle experiences problems due to dirty injectors or
valves, try a different brand of gasoline.
Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines may be available in
your area to contribute to clean air. General Motors
recommends that you use these gasolines, particularly if
they comply with the specifications described earlier.
Notice:Your vehicle was not designed for fuel that
contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in your fuel
system and also damage the plastic and rubber
parts. That damage would not be covered under
your warranty.
Some gasolines that are not reformulated for low
emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese tricarbonyl
(MMT); ask the attendant where you buy gasoline
whether the fuel contains MMT. General Motors does
not recommend the use of such gasolines. Fuels
containing MMT can reduce the life of spark plugs and
the performance of the emission control system may
be affected. The malfunction indicator lamp may turn on.
If this occurs, return to your authorized GM dealer for
service.
5-6