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Maintenance Information Chevrolet Cavalier I

Procedures 11 illustrations ~1417 words

MODEL IDENTIFICATION

Note. For scheduled maintenance intervals and the related fluid capacities, fluid specifications and labor times for major service intervals, see SCHEDULED SERVICES article in this section. Warranty information and specifications for fluid capacities, lubrication specifications, wheel and tire size, and battery type are covered in this article.

VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN Code ID Explanation (1 Of 2). Scheme 1

Scheme 1: VIN Code ID Explanation (1 Of 2)
Scheme 1: VIN Code ID Explanation (1 Of 2)

VIN Code ID Explanation (2 Of 2). Scheme 2

Scheme 2: VIN Code ID Explanation (2 Of 2)
Scheme 2: VIN Code ID Explanation (2 Of 2)

SEVERE & NORMAL SERVICE DEFINITIONS

Note. Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating conditions

Severe Service

  1. Short Trips (4 Miles Or Less)
  2. Most Trips Are Less Than 10 Miles When Outside Temperatures Are Below Freezing
  3. Towing Or Heavily Loaded
  4. Severe Dust Conditions
  5. Hot Weather, Engine Is At Low Speed Most Of The Time (Stop-And-Go Driving)
  6. Extensive Idling Conditions (Taxi Or Delivery Type Service)

Normal Service

  1. Driven More Than 10 Miles Daily
  2. No Severe Service Operating Conditions

Scheme 3

Scheme 3: SERVICE POINT LOCATIONS
Scheme 3: SERVICE POINT LOCATIONS

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

SERVICE LABOR TIMES

Note. For 1990 and newer vehicles, labor times are provided, where available, within appropriate SERVICE INTERVAL table in SCHEDULED SERVICES article.

TIRE INFLATION

The tire specification decal is located on rear of the driver's door.

WHEEL TIGHTENING

Tighten aluminum wheel lug nuts to 100 ft. lbs. (136 N.m). Tighten steel wheel lug nuts to 80 ft. lbs. (110 N.m).

BATTERY SPECIFICATIONS

CAUTIONWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section.

All models use Group 75 batteries. See original battery's label for specific replacement number.

AIR CONDITIONING SERVICING (1994 MODELS)

CAUTIONAvoid breathing R-134a refrigerant and PAG lubricant vapors, exposure may irritate eyes, nose and throat. To remove R-134a from system use R-134a recycling equipment that meets SAE J2210 specifications. If accidental system discharge occurs, ventilate work area before resuming service.
WARNINGR-134a service equipment or vehicle A/C systems SHOULD NOT be pressure tested or leak tested with compressed air. Some mixtures of air/R134a have shown to be combustible at elevated pressures. These mixtures are dangerous and may cause fire and/or explosions. See the appropriate A/C SYSTEM GENERAL SERVICING article in the AIR CONDITIONING & HEAT section.

ANTI-LOCK BRAKE SYSTEM

The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions

  1. DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES Section.
  2. DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
  3. Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

BATTERY WARNING

WARNINGWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION section.

REPLACING BLOWN FUSES

CAUTIONBefore replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BRAKE PAD WEAR INDICATOR

CAUTIONIndicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

CAUTIONContinued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and vehicle.

COOLANT (PROPYLENE-GLYCOL FORMULATIONS)

CAUTIONTo avoid possible damage to vehicle use only ethylene-glycol based coolants with a mixture ratio from 44-68% anti-freeze. DO NOT use 100% anti-freeze as it will cause the formation of cooling system deposits. This results in coolant temperatures of over 300° F (149°C) which can melt plastics. 100% anti-freeze has a freeze point of only -8° F (-22°C).
CAUTIONPropylene-Glycol Mixtures has a smaller temperature range than Ethylene-Glycol. The temperature range (freeze-boil) of a 50/50 Anti-Freeze/Water Mix is as follows: Propylene-Glycol -26° F (-32°C) - 257° F (125°C) Ethylene-Glycol -35° F (-37°C) - 263° F (128°C)
CAUTIONPropylene-Glycol/Ethylene-Glycol Mixtures can cause the destabilization of various corrosion inhibitors. Also Propylene-Glycol/Ethylene-Glycol has a different specific gravity than Ethylene-Glycol coolant, which will result in inaccurate freeze point calculations.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

WARNINGMany solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not. Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.

ENGINE OIL

CAUTIONNever use non-detergent or straight mineral oil.

FUEL SYSTEM SERVICE

WARNINGRelieve fuel system pressure prior to servicing any fuel system component (fuel injection models).

HALOGEN BULBS

WARNINGHalogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

RADIATOR CAP

CAUTIONAlways disconnect the fan motor when working near the radiator fan. The fan is temperature controlled and could start at any time even when the ignition key is in the OFF position. DO NOT loosen or remove radiator cap when cooling system is hot.

RADIATOR FAN

WARNINGKeep hands away from radiator fan. Fan is controlled by a thermostatic switch which may come on or run for up to 15 minutes even after engine is turned off.

WARRANTY INFORMATION

CAUTIONDue to the different warranties offered in various regions and the variety of after-market extended warranties available, please refer to the warranty package that came with the vehicle to verify all warranty options.

BUMPER-TO-BUMPER PLUS LIMITED WARRANTY

Everything covered for 3 years or 50,000 miles, whichever occurs first. Covered by this warranty are any repairs to vehicle components which have proven defective in material and workmanship during normal use (tires excluded). Warranty repairs (parts and labor) will be made by the Dealer at no charge using new or remanufactured parts. This warranty is subject to a 100 deductible for each repair visit after the first year or 12,000 miles, whichever occurs first. Maintenance items are covered up to their first scheduled replacement interval only.

Note. 1992-93 vehicles are covered for 3 years or 36,000 miles, whichever occurs first, with no deductible.

CORROSION COVERAGE

Any body-sheet metal panel that is perforated due to corrosion is covered for 6 years or 100,000 miles whichever occurs first.

EMISSIONS "DEFECT" & "PERFORMANCE" WARRANTY (FEDERAL)

Defect Warranty ensures that vehicle meets applicable EPA regulations and that vehicle's emission control system is free from defects in materials and workmanship for a period of 5 years or 50,000 miles, whichever occurs first.

The Performance Warranty covers all costs of repairing or adjusting any components or parts as needed in order for the vehicle to pass a federally required state or local emissions test.

Other emission control parts related to these components are covered by the Performance Warranty, where applicable. If another part fails due to the failure of one of these components, both parts are covered. See customer's copy of warranty information for specific items covered.

EMISSION "PERFORMANCE" WARRANTY (CALIFORNIA)

If vehicle fails a Smog Check inspection, all necessary repairs and adjustments will be made by manufacturer to ensure that vehicle passes the inspection. Warranty begins at warranty start date and lasts for a period of 3 years or 50,000 miles, whichever occurs first.

EMISSION "DEFECTS" WARRANTY (CALIFORNIA)

If any emission-related part on the vehicle is defective, the part will be repaired or replaced by manufacturer. Warranty begins at warranty start date and lasts for a period of 3 years or 50,000 miles, whichever occurs first.

Some emission-related parts are warranted for 7 years or 70,000 miles whichever occurs first, and will be repaired or replaced by manufacturer if found to be defective in material or workmanship. See customer's copy of warranty information for specific items covered.

Scheme 9

Scheme 9: FUSE PANEL IDENTIFICATION (1983-90 MODELS)
Scheme 9: FUSE PANEL IDENTIFICATION (1983-90 MODELS)

Fuse & Circuit Breaker Identification

  1. 1 - 3 Amp - Crank Sensor
  2. 2 - 35 Amp - Power Accessories
  3. 3 - 10 Amp - Radio, Antenna, Cruise Control
  4. 4 - 5 Amp - Instrument Lights
  5. 5 - 35 Amp - Power Windows
  6. 6 - 20 Amp - Courtesy Lights, Cigarette Lighter
  7. 7 - 25 Amp - Wiper
  8. 8 - 20 Amp - Gauges, Chimes, Indicators, Defogger, Trunk Release
  9. 9 - 25 Amp - Ventilation System
  10. 10 - 20 Amp - Taillights
  11. 11 - 20 Amp - Foglights
  12. 12 - 20 Amp - Turn Signals, Back-Up Lights
  13. 13 - 20 Amp - Choke Heater, Coolant Fan, Alternator
  14. 14 - 20 Amp - Stoplights, Hazard Flashers
  15. 15 - 10 Amp - ECM, Fuel Pump, Oil Pressure Light
  16. 16 - 15 Amp - Computer Command Control Module

Scheme 10

Scheme 10: FUSE PANEL IDENTIFICATION (1991-93 MODELS)
Scheme 10: FUSE PANEL IDENTIFICATION (1991-93 MODELS)
  1. 1 - 5 Amp - Instrument Lights
  2. 2 - 10 Amp - ECM, Fuel Injectors (1993)
  3. 3 - 15 Amp - Cigarette Lighter, Glove Box Light (1993) Spare (1991)
  4. 4 - 10 Amp - Radio Power
  5. 5 - 10 Amp - Gauges, Audio Warning, Cluster Telltales, TCC, Rear Defogger Relay, Brake/Transaxle Shift Interlock (1993), Multi-Port Fuel Injection (1993)
  6. 6 - 15 Amp - Parking Lights, Turn Lights
  7. 7 - 25 Amp - HVAC, Heater & A/C Power, ABS, DRL Module (1993)
  8. 8 - 25 Amp - Wiper
  9. 9 - 10 Amp - Fuel Pump, Injectors
  10. 10 - 10 Amp - Radio Memory, Digital Clock (1993)
  11. 11 - 20 Amp - Interior Lights, Glove Box Light, Horn, Power Locks, Audible Warning (1993), Remote Liftgate Release (1993), Check Oil Light (1993)
  12. 12 - 30 Amp - Power Window Breaker, DRL Breaker (Canada)
  13. 13 - 10 Amp - Cruise Control
  14. 14 - 15 Amp - Back-Up Lights, Turn Signal
  15. 15 - 20 Amp - Stoplights, Hazard Flashers
  16. 16 - 20 Amp - Flash-To-Pass (Not in Canada)
  17. 17 - 30 Amp (Circuit Breaker) - Power Locks & Defogger Circuit Breaker
  18. 18 - 20 Amp (Circuit Breaker) - Headlight Circuit Breaker

Scheme 11

Scheme 11: FUSE PANEL IDENTIFICATION (1994 MODELS)
Scheme 11: FUSE PANEL IDENTIFICATION (1994 MODELS)
  1. 1 - 5 Amp - Interior Lights Dimming
  2. 2 - 10 Amp - ECM, Multiport Fuel Injection
  3. 3 - 10 Amp - Automatic Door Unlock
  4. 4 - 15 Amp - Cigarette Lighter, Interior Lights
  5. 5 - 10 Amp - Radio/Audio Systems
  6. 6 - 10 Amp - Gauges, Audio Warning, Brake/Transaxle Shift Interlock (BTSI), HVAC, Instrument Panel, Multi-Port Fuel Injection, Rear Defogger
  7. 7 - 15 Amp - Pk/Turn, Headlights
  8. 8 - 25 Amp - ABS, Coolant Fan, HVAC, Headlights: Daytime Runnin Lights (T61), Starter & Charging System
  9. 9 - 25 Amp - Wiper/Washer
  10. 10 - 10 Amp - Multiport Fuel Injection
  11. 11 - 10 Amp - Radio/Audio Systems
  12. 12 - 15 Amp - Audible Warning, Automatic Door Locks, Convertible Top, Horn, Instrument Panel, Interior Lights, Tailgate Release
  13. 13 - 30 Amp - Convertible Top Power Windows
  14. 14 - 10 Amp - Cruise Control
  15. 15 - 15 Amp - Back-Up Lights, Exterior Lights
  16. 16 - 20 Amp - Brake Transaxle Shift Interlock (BTSI), Exterior Lights: Stop/Hazard
  17. 17 - 20 Amp - Headlights
  18. 18 - 30 Amp (Circuit Breaker) - Automatic Door Locks, Rear Defogger
  19. 19 - 20 Amp (Circuit Breaker) - Headlight, Headlights: Daytime Running Lights (T61)

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