1995 Chevrolet Tracker Owners Manual

wrench (C).

2. Attach the jack handle to the jack. Turn the jack

handle to the right to raise the lift head.

3. The spare tire is mounted on your tailgate. Pull the

cover off of the spare tire.

4. Insert your key into the wheel lock on the spare tire

and pull the wheel lock off.

5. Remove wheel nuts with the wheel wrench. 6. Remove the spare tire from the mounting bracket

and place it near your flat tire.

7. Attach the jack handle to the jack bolt. Turn the jack

handle clockwise (to the right). That will raise the lift head a little.

8. Using the wheel wrench, loosen all the wheel nuts.

Don’t remove them yet.

5-25

NOTICE: Raising your vehicle with the jack improperly positioned will damage the vehicle or may allow the vehicle to fall off the jack. Be sure to fit the jack lift head into the proper location before raising your vehicle.

9. Position the jack and raise the jack lift head until it

fits firmly onto the bosses nearest the flat tire. (Under the vehicle near each wheel, there are bosses in the vehicle’s rocker flange.)

5-26

10. Raise the vehicle by turning the jack handle clockwise. Raise the vehicle far enough off the ground so there is enough room for the spare tire to fit.

11. Remove all the wheel nuts and take off the flat tire.

12. Remove any rust or dirt from the wheel bolts,

mounting surfaces and spare wheel. Place the spare on the wheel mounting surface.

13. Replace the wheel nuts with the rounded end of the

nuts toward the wheel. Tighten each nut by hand until the wheel is held against the hub.

14. Lower the vehicle by turning the jack handle counterclockwise. Lower the jack completely.

15. Tighten the wheel nuts firmly in a criss-cross

sequence as shown.

Front Passenger 's Seat Jack Clamp Wrench Jack Handle Driver's Seat

1. 2. 3. 4. 5. 6. Replace the jack, jack handle, flat tire, and wheel wrench.

If You’re Stuck: In Sand, Mud, Ice or Snow What you don’t want to do when your vehicle is stuck is to spin your wheels too fast. The method known as “rocking” can help you get out when you’re stuck, but you must use caution.

I NOTICE:

Spinning your wheels can destroy parts of your vehicle as well as the tires. If you spin the wheels too fast while shifting your transmission back and forth, you can destroy your transmission.

For information about using tire chains on your vehicle, see ‘“Tire Chains” in the Index.

Using the Recovery Hooks

Rocking your vehicle to get it out: First, turn your steering wheel left and right. That will clear the area around your front wheels. Then shift back and forth between REVERSE (R) and a forward gear (or with a manual transmission, between FIRST (1) or SECOND (2) and REVERSE (R)), spinning the wheels as little as possible. Release the accelerator pedal while you shift, and press lightly on the accelerator pedal when the transmission is in gear. If that doesn’t get you out after a few tries, you may need to be towed out. Or, you can use your recovery hooks, if your vehicle has them. If you do need to be towed out, see “Towing Your Vehicle” in the Index.

Your vehicle is equipped with recovery hooks. The recovery hooks are provided at the front and rear of your vehicle. You may need to use them if you’re stuck off-road and need to be pulled to some place where you can continue driving.

NOTICE: Never use the recovery hooks to tow the vehicle. Your vehicle could be damaged and it would not be covered by warranty.

NOTES

Gem Section 6 Service and Appearance Care

Doing Your Own Service Work If you want to do some of your own service work, you’ll want to get the proper Geo Service Manual. It tells you much more about how to service your Geo than this manual can. To order the proper service manual, see “Service Publications” in the Index. You should keep a record with all parts receipts and list the mileage and the date of any service work you perform. See “Maintenance Record” in the Index.

Here you will find information about the care of your Geo. This section begins with service and fuel information, and then it shows how to check important fluid and lubricant levels. There is also technical information about your vehicle, and a part devoted to its amearance care. Service Your Chevrolet/Geo dealer knows your vehicle best and wants you to be happy with it. We hope you’ll go to your dealer for all your service needs. You’ll get genuine GM parts and GM-trained and supported service people. We hope you’ll want to keep your GM vehicle all GM.

Genuine GM parts have one of these marks: n

Delco

NOTICE: If you try to do your own service work without knowing enough about it, your vehicle could be damaged.

Fuel Use regular unleaded gasoline rated at 87 octane or higher. It should meet specifications ASTM D4814 in the United States and CGSB 3.5-92 in Canada. These fuels should have the proper additives, so you should not have to add anything to the fuel. In the United States and Canada, it’s easy to be sure you get the right kind of gasoline (unleaded). You’ll see UNLEADED right on the pump. And only unleaded nozzles will fit into your vehicle’s filler neck. Be sure the posted octane is at least 87. If the octane is less than 87, you may get a heavy knocking noise when you drive. If it’s bad enough, it can damage your engine. If you’re using fuel rated at 87 octane or higher and you still hear heavy knocking, your engine needs service. But don’t worry if you hear a little pinging noise when you’re accelerating or driving up a hill. That’s normal, and you don’t have to buy a higher octane fuel to get rid of pinging. It’s the heavy, constant knock that means you have a problem.

What about gasoline with blending materials that contain oxygen (oxygenates), such as MTBE or alcohol? MTBE is “methyl tertiary-butyl ether.” Fuel that is no more than 15% MTBE is fine for your vehicle. Ethanol is ethyl or grain alcohol. Properly-blended fuel that is no more than 10% ethanol is fine for your vehicle. Methanol is methyl or wood alcohol.

NOTICE: Fuel that is more than 5% methanol is bad for your vehicle. Don’t use it. It can corrode metal parts in your fuel system and also damage plastic and rubber parts. That damage wouldn’t be covered under your warranty. And even at 5% or less, there must be “cosolvents” and corrosion preventers in this fuel to help avoid these problems.

Gasolines for Cleaner Air Your use of gasoline with deposit control additives will help prevent deposits from forming in your engine and fuel system. That helps keep your engine in tune and your emission control system working properly. It’s good for your vehicle, and you’ll be doing your part for cleaner air. Many gasolines are now blended with oxygenates. General Motors recommends that you use gasolines with these blending materials, such as MTBE and ethanol. By doing so, you can help clean the air, especially in those parts of the country that have high carbon monoxide levels. In addition, some gasoline suppliers are now producing reformulated gasolines. These gasolines are specially designed to reduce vehicle emissions. General Motors recommends that you use reformulated gasoline. By doing so, you can help clean the air, especially in those parts of the country that have high ozone levels. You should ask your service station operators if their gasolines contain deposit control additives and oxygenates, and if they have been reformulated to reduce vehicle emissions.

Fuels in Foreign Countries If you plan on driving in another country outside the U.S. or Canada, unleaded fuel may be hard to find. Do not use leaded gasoline. If you use even one tankful, your emission controls won’t work well or at all. With continuous use, spark plugs can get fouled, the exhaust system can corrode, and your engine oil can deteriorate quickly. Your vehicle’s oxygen sensor will be damaged. All of that means costly repairs that wouldn’t be covered by your warranty. To check on fuel availability, ask an auto club, or contact a major oil company that does business in the country where you’ll be driving. You can also write us at the following address for advice. Just tell us where you’re going and give your Vehicle Identification Number (VIN).

General Motors Overseas Distribution Corporation, North American Export Sales (NAES) 1908 Colonel Sam Drive Oshawa, Ontario L1H 8P7

Filling Your Tank

~~~

The cap is behind a hinged door on the passenger’s side of your vehicle.

To take off the cap, turn it slowly to the left (counterclockwise).

..lecking Things Under the Hood

Then go to the front of the vehicle, push down lightly on the hood, and push the hood release lever to your left.

open the hood, first pull the release handle inside the we box.

Lift the hood, release the hood prop from its retainer and put the hood prop into the slot in the hood.

6-7

When you open the hood, you’ll see the following on the 8-valve engine:

1. Battery 2. Automatic Transmission Dipstick (if equipped) 3. Oil Fill Cap 4. Brake Fluid Reservoir 5. Air Cleaner 6. Engine Coolant Reservoir 7. Power Steering Reservoir 8. Radiator Pressure Cap 9. Electric Engine Fan 10. Engine Oil Dipstick 1 1. Windshield Washer Reservoir 12. Main Fuse Box

Before closing the hood, be sure all the filler caps are on.

6-9

When you open the hood, you’ll see the following on the 16-valve engine: 1. Battery 2. Automatic Transmission Dipstick (if equipped) 3. Oil Fill Cap 4. Brake muid Reservoir 5. Air Cleaner 6. Engine Coolant Reservoir 7. Power Steering Reservoir 8. Radiator Pressure Cap 9. Electric Engine Fan 10. Windshield Washer Reservoir 11. Main Fuse Box

Before closing the hood, be sure all the filler caps are on. Then lift the hood to relieve pressure on the hood prop. Remove the hood prop from the slot in the hood and return the prop to its retainer. Then just let the hood down and close it firmly.

6-11

Engine Oil It’s a good idea to check your engine oil level every time you get fuel. In order to get an accurate reading, the oil must be warm and the vehicle must be on level ground.

To Check Engine Oil Pull out the dipstick and clean it with a paper towel or a cloth, then push it back in all the way. Remove it again, keeping the tip down.

Turn off the engine and give the oil a few minutes to drain back into the oil pan. If you don’t, the oil dipstick might not show the actual level.

When to Add Oil If the oil is at or below the ADD mark, you’ll need to add some oil. But you must use the right kind. This part explains what kind of oil to use. For crankcase capacity, see “Capacities and Specifications” in the Index.

Don’t add too much oil. If your engine has so much oil that the oil level gets above the upper mark that shows the proper operating range, your engine could be damaged.

8-Valve Engine

16-Valve Engine

Just fill it enough to put the level somewhere in the proper operating range. Push the dipstick all the way back in when you’re through.

6-13

What Kind of Oil to Use Oils of the proper quality for your vehicle can be identified by looking for the “Starburst” symbol. The “Starburst” symbol indicates that the oil has been certified by the American Petroleum Institute (API), and is preferred for use in your gasoline engine.

If you change your own o i l , be sure t o use oil that has the “Starburst” symbol on the front of the oil container. If you have your oil changed for you, be sure the o i l put into your engine is American Petroleum Institute certified for gasoline engines. You should also use the proper viscosity oil for your vehicle, as shown in the following chart:

6-14

RECOMMENDED SAE VISCOSITY GRADE ENGINE OILS

FOR BEST FUEL ECONOMY AND COLD STARTING, SAE VISCOSITY GRADE OIL FOR THE EXPECTED TEMPERATURE RANGE.

SELECT THE LOWEST

__

.~

LOOK

FOR THIS SYMBOL

HOT

WEATHER - -

+ 80

+ 60

t 20

SAE ZW-30 PREFERRED

./

-.

\..

,.,’

-.

COLD

WEATHER

DO NOT USE SAE 2OW-50 OR ANY OTHER GRADE OIL NOT RECOMMENDED

As shown in the chart, SAE 5W-30 is best for your vehicle. However, you can use SAE 10W-30 if it's going to be 0°F (-18°C) or above. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils, such as SAE 20W-50.

NOTICE: Use only engine oil with the American Petroleum Institute Certified For Gasoline Engines "Starburst" symbol. Failure to use the proper oil can result in engine damage not covered by your warranty.

GM Goodwrench@ oil (in Canada, GM Engine Oil) meets all the requirements for your vehicle. Engine Oil Additives Don't add anything to your oil. Your Chevrolet/Geo dealer is ready to advise if you think something should be added.

When to Change Engine Oil See if any one of these is true for you:

Most trips are less than 5 to 10 miles (8 to 16 krn). This is particularly important when outside temperatures are below freezing. Most trips include extensive idling (such as frequent driving in stop and go traffic). You operate your vehicle in dusty areas or off-road frequently. You frequently tow a trailer or use a carrier on top of your vehicle.

If any one of these is true for your vehicle, then you need to change your oil and filter every 3,000 miles (5 000 km) or 3 months -- whichever comes first. If none of them is true, change oil and filter every 7,500 miles (12 500 km) or 7.5 months -- whichever comes first.

What to Do with Used Oil Did you know that used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer? Don’t let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly throw away clothing or rags containing used engine oil. (See the manufacturer’s warnings about the use and disposal of oil products.) Used oil can be a real threat to the environment. If you change your own oil, be sure to drain all free-flowing oil from the filter before disposal. Don’t ever dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a service station or a local recycling center for help.

Air Cleaner

8-Valve Engine

Refer to the Maintenance Schedule to determine when to replace the air filter and the crankcase ventilation filter. See “Scheduled Maintenance Services” in the Index.

NOTICE: If the air cleaner is off, a backfire can cause a damaging engine fire. And, dirt can easily get into your engine, which will damage it. Always have the air cleaner in place when you’re driving.

16-Valve Engine

6-17

Air Filter Replacement (8-Valve Engine)

Air Filter Replacement (16-Valve Engine)

To check or replace the filter: 1. Remove the screws on the cover. 2. Lift up the cover. 3. Pull out the filter.

To check or replace the filter: 1. Remove the screws on the cover. 2. Lift the cover up. 3. Pull out the filter.

6-18

y__.._.

Automatic Transmission Fluid When to Check and Change A good time to check your automatic transmission fluid level is when the engine oil is changed. Refer to the Maintenance Schedule to determine when to change your fluid. See “Scheduled Maintenance Services” in the Index. How to Check Because this operation can be a little difficult, you may choose to have this done at your Chevrolet/Geo dealer Service Department. If you do it yourself, be sure to follow all the instructions here, or you could get a false reading on the dipstick.

NOTICE: Too much or too little fluid can damage your transmission. Too much can mean that some of the fluid could come out and fall on hot engine parts or exhaust system parts, starting a fire. Be sure to get an accurate reading if you check your transmission fluid.

Wait at least 30 minutes before checking the transmission fluid level if you have been driving: 0 When outside temperatures are above 90°F (32°C).

At high speed for quite a while.

0 In heavy traffic -- especially in hot weather. 0 While pulling a trailer. To get the right reading, the fluid should be at normal operating temperature, which is 180” F to 200” F (82°C to 93°C).

To check transmission fluid hot: Get the vehicle warmed up by driving about 15 miles (24 km) when outside temperatures are above 50°F (10°C). If it's colder than 50°F ( 10°C), drive the vehicle in DRIVE (D) until the engine temperature gage moves and then remains steady for ten minutes. Then follow the hot check procedures. To check transmission fluid cold: A cold check is made after the vehicle has been sitting for eight hours or more with the engine off and is used only as a reference. Let the engine run at idle for five minutes if outside temperatures are 50 OF ( 10 " C) or more. If it's colder than 50°F (10°C)' you may have to idle the engine longer. Should the fluid level be low during a cold check, you must perform a hot check before adding fluid. This will give you a more accurate reading of the fluid level.

To check the fluid hot or cold:

Park your vehicle on a level place. Keep the engine running. With the parking brake applied, place the shift lever in PARK (P). With your foot on the brake pedal, move the shift lever through each gear range, pausing for about three seconds in each range. Then, position the shift lever in PARK (P).

0 Let the engine run at idle for three minutes or more.

Then, without shutting off the engine, follow these steps:

1. Pull out the dipstick and wipe it with a clean rag or

paper towel.

2. Push it back in all the way, wait three seconds and

then pull it back out again.

3. Check both sides of the dipstick, and read the lower level. The fluid level must be in the COLD area for a cold check or in the HOT area or cross-hatched area for a hot check.

4. If the fluid level is in the acceptable range, push the

dipstick back in all the way.

6-21

How to Add Fluid Refer to the Maintenance Schedule to determine what kind of transmission fluid to use. See “Recommended Fluids and Lubricants” in the Index. Add fluid only after checking the transmission fluid HOT. (A COLD check is used only as a reference.) If the fluid level is low, add only enough of the proper fluid to bring the level up to the HOT area for a hot check. It doesn’t take much fluid, generally less than a pint. Don ’t ove$ZZ. We recommend you use only fluid labeled DEXRON@-111, because fluid with that label is made especially for your automatic transmission. Damage caused by fluid other than DEXRON@-I11 is not covered by your new vehicle warranty.

After adding fluid, recheck the fluid level as described under “How to Check.’’ When the correct fluid level is obtained, push the dipstick back in all the way.

Manual Transmission Fluid When to Check and Change A good time to have it checked is when the engine oil is changed. Refer to the Maintenance Schedule to determine when to change your transmission fluid. See “Scheduled Maintenance Services” in the Index. How to Check Because this operation can be a little difficult, you may choose to have this done at your Chevrolet/Geo dealer Service Department. If you do it yourself, be sure to follow all the instructions here, or you could get a false reading.

NOTICE: Too much or too little fluid can damage your transmission. Too much can mean that some of the fluid could come out and fall on hot engine parts or exhaust system parts, starting a fire. Be sure to get an accurate reading if you check your transmission fluid.

Check the fluid level only when your engine is off, the vehicle is parked on a level place and the transmission is cool enough for you to rest your fingers on the transmission case. Then, follow these steps: Remove the filler plug. 1. 2. Check that the lubricant level is up to the bottom of the filler plug hole. If the fluid level is good, install the plug and be sure it is fully seated. If the fluid level is low, add more fluid as described in the next steps.

3.

How to Add Fluid Here’s how to add fluid. Refer to the Maintenance Schedule to determine what kind of fluid to use. See “Recommended Fluids and Lubricants” in the Index. I . Remove the filler plug. 2. Add fluid at the filler plug hole. Add only enough fluid to bring the fluid level up to the bottom of the filler plug hole.

3. Install the filler plug. Be sure the plug is fully seated. Clutch Adjustment The clutch linkage in your vehicle should be checked as recommended in your Maintenance Schedule. To check, push the clutch pedal down with your hand until you feel some resistance to movement of the pedal. If the pedal moves freely up to an inch (25 mm) or so before you feel resistance to the travel, adjustment isn’t needed. If there is no free travel or very little (less than 5/23 of an inch (16 mm)), see your dealer for adjustment.

Rear Axle When to Check and Change Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant and when to change it. See “Periodic Maintenance Inspections” and “Scheduled Maintenance Services” in the Index. How to Check Lubricant If the level is below the bottom of the filler plug hole, you’ll need to add some lubricant. Add enough lubricant to raise the level to the bottom of the filler plug hole. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See “Recommended Fluids and Lubricants” in the Index.

Four- Wheel Drive Most lubricant checks in this section also apply to four-wheel-drive vehicles. However, they have two additional systems that need lubrication. Transfer Case When to Check and Change Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant and when to change it. See “Scheduled Maintenance Services” in the Index. How to Check Lubricant If the level is below the bottom of the filler plug hole, you’ll need to add some lubricant. Add enough lubricant to raise the level to the bottom of the filler plug hole. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See “Recommended Fluids and Lubricants” in the Index.

Front Axle When to Check and Change Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant and when to change it. See “Periodic Maintenance Inspections” and “Scheduled Maintenance Services” in the Index. How to Check Lubricant If the level is below the bottom of the filler plug hole, you’ll need to add some lubricant. If the differential is at operating temperature (warm), add enough lubricant to raise the level to the bottom of the filler plug hole. If the differential is cold, add enough lubricant to raise the level to 1/2 inch (12 mm) below the filler plug hole. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See “Recommended Fluids and Lubricants” in the Index.

Engine Coolant The following explains your cooling system and how to add coolant when it is low. If you have a problem with engine overheating, see “Engine Overheating’’ in the Index. The proper coolant for your Geo will: 0 Give freezing protection down to -33°F (-36°C).

Give boiling protection up to 258°F (125°C). Protect against rust and corrosion. Help keep the proper engine temperature. Let the warning lights work as they should.

What to Use Use a mixture of one-half clean water (preferably distilled) and one-half antifreeze that meets “GM Specification 1825M,” which won’t damage aluminum parts. You can also use a recycled coolant conforming to GM Specification 1825M with a complete coolant flush and refill. If you use this mixture, you don’t need to add anything else.

Adding Coolant

I NOTICE:

If you use an improper coolant mix, your engine could overheat and be badly damaged. The repair cost wouldn’t be covered by your warranty. Too much water in the mix can freeze and crack the engine, radiator, heater core and other parts.

6-26

8-Valve Engine

To Check Coolant When your engine is cold, the coolant level should be at LOW, or a little higher. When your engine is warm, the level should be up to FULL, or a little higher.

Add coolant mix at the recovery tank, but be careful not to spill it.

16-Valve Engine

To Add Coolant If you need more coolant, add the proper mix ut the coolant recovery tank.

Radiator Pressure Cap

I NOTICE:

Your radiator cap is a 13 psi (90 kPa) pressure-type cap and must be tightly installed to prevent coolant loss and possible engine damage from overheating. Be sure the arrows on the cap line up with the overflow tube on the radiator filler neck.

When you replace your radiator pressure cap, an AC@ cap is recommended. Thermostat Engine coolant temperature is controlled by a thermostat in the engine coolant system. The thermostat stops the flow of coolant through the radiator until the coolant reaches a preset temperature. When you replace your thermostat, an AC@ thermostat is recommended.

Power Steering Fluid

How To Check Power Steering Fluid When the engine compartment is cool, unscrew the cap and wipe the dipstick with a clean rag. Replace the cap and completely tighten it. Then remove the cap again and look at the fluid level on the dipstick.

When the engine compartment is hot, the level should be at the MAX mark. When the engine compartment is cool, the level should be at the MIN mark.

A fluid loss in this system could indicate a problem. Have the system inspected and repaired.

What to Add Refer to the Maintenance Schedule to determine what kind of fluid to use. See “Recommended Fluids and Lubricants” in the Index.

NOTICE: When adding power steering fluid or making a complete fluid change, always use the proper fluid. Failure to use the proper fluid can cause leaks and damage hoses and seals.

3

Windshield Washer Fluid What to Use When you need windshield washer fluid, be sure to read the manufacturer’s instructions before use. If you will be operating your vehicle in an area where the temperature may fall below freezing, use a fluid that has sufficient protection against freezing. To Add

Open the cap with the washer symbol on it. Add washer fluid until the tank is full. 6-30

NOTICE:

When using concentrated washer fluid, follow the manufacturer’s instructions for adding water. Don’t mix water with ready-to-use washer fluid. Water can cause the solution to freeze and damage your washer fluid tank and other parts of the washer system. Also, water doesn’t clean as well as washer fluid. Fill your washer fluid tank only 3/4 full when it’s very cold. This allows for expansion, which could damage the tank if it is completely full. Don’t use radiator antifreeze in your windshield washer. It can damage your washer system and paint.

Brakes Brake Master Cylinder YOLK brake master cylinder is here. It is filled with DOT-3 brake fluid.

fluid is leaking out of the brake system. If it is, you should have your brake system fixed, since a leak means that sooner or later your brakes won’t work well, or won’t work at all. So, it isn’t a good idea to “top off” your brake fluid. Adding brake fluid won’t correct a leak. If you add fluid when your linings are worn, then you’ll have too much fluid when you get new brake linings. You should add (or remove) brake fluid, as necessary, only when work is done on the brake hydraulic system.

There are only two reasons why the brake fluid level in your master cylinder might go down. The first is that the brake fluid goes down to an acceptable level during normal brake lining wear. When new linings are put in, the fluid level goes back up. The other reason is that

Refer to the Maintenance Schedule to determine when to check your brake fluid. See “Periodic Maintenance Inspections” in the Index.

6-31

To Check Brake Fluid

You can check the brake fluid without taking off the cap. Just look at the windows on the brake fluid reservoir. The fluid levels should be above MIN. If they aren’t, have your brake system checked to see if there is a leak.

After work is done on the brake hydraulic system, make sure the levels are above MIN and below the top of each window.

What to Add When you do need brake fluid, use only DOT-3 brake fluid -- such as Delco Supreme 1 l@ (GM Part No. 1052535). Use new brake fluid from a sealed container only, and always clean the brake fluid reservoir cap before removing it.

I NOTICE:

Don’t let someone put in the wrong kind of fluid, For example, just a few drops of mineral-based oil, such as engine oil, in your brake system can damage brake system parts so badly that they’ll have to be replaced.

0 Brake fluid can damage paint, so be careful

not to spill brake fluid on your vehicle. If you do, wash it off immediately. See “Appearance Care” in the Index.

Brake Wear Your Geo has front disc brakes and rear drum brakes. Disc brake pads have built-in wear indicators that make a high-pitched warning sound when the brake pads are worn and new pads are needed. The sound may come and go or be heard all the time your velvcle is moving (except when you are pushing on the brake pedal firmly).

NOTICE: Continuing to drive with worn-out brake pads could result in costly brake repair.

rSray C2iQSg si brake

Some driving conditions or climates squeal when the brakes are first applied or lightly applied. This does not mean something is wrong with your brakes. Your rear drum brakes don’t have wear indicators, but if you ever hear a rear brake rubbing noise, have the rear brake linings inspected. Also, the rear brake drums should be removed and inspected each time the tires are removed for rotation or changing. When you have the front brakes replaced, have the rear brakes inspected, too. Brake linings should always be replaced as complete axle sets. Brake Pedal Travel See your dealer if the brake pedal does not return to normal height, or if there is a rapid increase in pedal travel. This could be a sign of brake trouble. Brake Adjustment Every time you make a brake stop, your disc brakes adjust for wear. If your brake pedal goes down farther than normal, your rear drum brakes may need adjustment. Adjust them by backing up and firmly applying the brakes a few times.

Replacing Brake System Parts The braking system on a modern vehicle is complex. Its many parts have to be of top quality and work well together if the vehicle is to have really good braking. Vehicles we design and test have top-quality GM brake parts in them, as your Geo does when it is new. When you replace parts of your braking system -- for example, when your brake linings wear down and you have to have new ones put in -- be sure you get new genuine GM replacement parts. If you don’t, your brakes may no longer work properly. For example, if someone puts in brake linings that are wrong for your vehicle, the balance between your front and rear brakes can change -- for the worse. The braking performance you’ve come to expect can change in many other ways if someone puts in the wrong replacement brake parts. Battery Every new Geo has a Delco Freedom@ battery. You never have to add water to one of these. When it’s time for a new battery, we recommend a Delco Freedom@ battery. Get one that has the replacement number shown on the original battery’s label.

Vehicle Storage If you’re not going to drive your vehicle for 25 days or more, take off the black, negative (-) cable from the battery. This will help keep your battery from running down.

Contact your dealer to learn how to prepare your vehicle for longer storage periods.

Halogen Bulbs

Headlamps

Bulb Replacement See “Replacement Bulbs” in the Index to check the size and type of bulb you need to use.

To replace the headlamp bulb: 1. Open the hood. 2. Push in on both sides of the electrical connector.

Then pull up and rearward, to disconnect it from the bulb. The plastic clip on the electrical connector may need to be lifted gently with a screwdriver.

6-35

4. Pull the lock ring and the headlamp bulb straight out.

Save the lock ring to use with the new bulb.

3. Turn the lock ring counterclockwise to release the

bulb.

5. Reverse the steps with a new bulb.

Front Parking and Turn Signal Lamps

To replace the parking and turn signal bulb: 1. Open the hood. 2. Turn the bulb socket counterclockwise and pull it out

of the lamp housing.

3. Push the bulb in, turn it to counterclockwise and pull

it out.

4. Reverse the steps with a new bulb.

6-37

Sidemarker Lamps To replace the sidemarker bulb: 1. Push the sidemarker housing toward the back of the vehicle to release the clip and pull out the front edge. The housing should pull away from the vehicle.

3. Pull the bulb out of the socket. 4. Reverse the steps with a new bulb.

2. Turn the socket counterclockwise and pull it out of

the housing.

6-38 -

Rear Sidemarker Lamps To replace the rear sidemarker bulb: 1. Remove the screw (hardtop only). 2. Pull the sidemarker lamp housing out at the back edge. Turn the socket toward the rear of the vehicle and pull it out. Pull the bulb out of the socket. Reverse the steps with a new bulb.

4. 5.

3.

Rear Combination Lamps

To remove the rear combination bulbs: 1 . Remove the two screws from the combination lamps.

A

2. Place two fingers into the slots where the screws

were removed and pull up to remove the rear combination lamp assembly. Pull the assembly out far enough to reach the bulb socket.

3. Turn the socket counterclockwise and pull it out. 4. Disconnect the bulb from its socket by twisting and

then pulling the bulb out.

5. Reverse the steps with a new bulb.

6-40

Tires We don’t make tires. Your new vehicle comes with high-quality tires made by a leading tire manufacturer. These tires are warranted by the tire manufacturers, and their warranties are delivered with every new Geo. If your spare tire is a different brand than your road tires, you will have a tire warranty folder from each of these manufacturers.

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Inflation - Tire Pressure

The Tire-Loading Information label which is on the driver’s door shows the correct inflation pressures for your tires, when they’re cold. “Cold” means your vehicle has been sitting for at least three hours or driven no more than a mile.

I ’ NOTICE: Don’t let anyone tell you that underidation or overinflation is all right. It’s not. If your tires don’t have enough air (underinflation) you can get:

Too much flexing Too much heat Tire overloading Bad wear Bad handling Bad fuel economy.

If your tires have too much air (overinflation), you can get:

Unusual wear 0 Bad handling

Rough ride Needless damage from road hazards.

When to Check Check your tires once a month or more. Also, check the tire pressure of the spare tire. How to Check Use a good quality pocket-type gage to check tire pressure. Simply looking at the tires will not tell you the pressure, especially if you have radial tires -- which may look properly inflated even if they’re underinflated. If your tires have valve caps, be sure to put them back on. They help prevent leaks by keeping out dirt and moisture. Tire Inspection and Rotation Tires should be inspected every 6,000 to 8,000 miles (10 000 to 13 000 km) for any signs of unusual wear. If unusual wear is present, rotate your tires as soon as possible and check wheel alignment. Also check for damaged tires or wheels. See “When It’s Time for New Tires” and “Wheel Replacement” later in this section for more information. The purpose of regular rotation is to achieve more uniform wear for all tires on the vehicle. The first rotation is the most important. See “Scheduled Maintenance Services” in the Index for scheduled rotation intervals.

When rotating your tires, always use one of the correct rotation patterns shown here. ,

After the tires have Deen rotated, adjust the front and rear inflation pressures as shown on the Tire-Loading Information label. Make certain that all wheel nuts are properly tightened. See “Wheel Nut Torque” in the Index.

r i .

6-43

Buying New Tires To find out what kind and size of tires you need, look at the Tire-Loading Information label. The tires installed on your vehicle when it was new had a Tire Performance Criteria Specification (TPC Spec) number on each tire’s sidewall. When you get new tires, get ones with that same TPC Spec number. That way, your vehicle will continue to have tires that are designed to give proper endurance, handling, speed rating, traction, ride and other things during norrnal service on your vehicle. If your tires have an all-season tread design, the TPC number will be followed by an “MS” (for mud and snow). If you ever replace your tires with those not having a TPC Spec number, make sure they are the same size, load range, speed rating and construction type (bias, bias-belted or radial) as your original tires.

When It’s Time for New Tires

One way to tell when it’s time for new tires is to check the treadwear indicators, which will appear when your tires have only 1/16 inch (1.6 rnm) or less of tread remaining.

You need a new tire if 0 You can see the indicators at three or more places

around the tire.

0 You can see cord or fabric showing through the tire’s

rubber.

0 The tread or sidewall is cracked, cut or snagged deep

enough to show cord or fabric.

0 The tire has a bump, bulge or split. 0 The tire has a puncture, cut, or other damage that

can’t be repaired well because of the size or location of the damage.

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Uniform Tire Quality Grading 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.)

Treadwear The treadwear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions on a specified government test course. For example, a tire graded 150 would wear one and a half (1 1/2) times as well on the government course as a tire graded 100. The relative performance of tires depends upon the actual conditions of their use, however, and may depart significantly from the norm due to variations in driving habits, service practices and differences in road characteristics and climate. Traction - A, B, C The traction grades, from highest to lowest are: A, B, and C. They represent the tire’s ability to stop on wet pavement as measured under controlled conditions on specified government test surfaces of asphalt and concrete. A tire marked C may have poor traction performance. Warning: The traction grade assigned to this tire is basea on braking (straight-ahead) traction tests and does not include cornering (turning) traction.

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Temperature - A, B, C

The temperature grades are A (the highest), B, and C, representing the tire’s resistance to the generation of heat and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel. Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive temperature can lead to sudden tire failure. The grade C corresponds to a level of performance which all passenger car tires must meet under the Federal Motor Vehicle Safety Standard No. 109. Grades B and A represent higher levels of performance on the laboratory test wheel than the minimum required by law. Warning: The temperature grade for this tire is established for a tire that is properly inflated and not overloaded. Excessive speed, underinflation, or excessive loading, either separately or in combination, can cause heat buildup and possible tire failure.

These grades are molded on the sidewalls of passenger car tires. While the tires available as standard or optional equipment on General Motors vehicles may vary with respect to these grades, all such tires meet General Motors performance standards and have been approved for use on General Motors vehicles. All passenger type (P Metric) tires must conform to Federal safety requirements in addition to these grades. Wheel Alignment and Tire Balance The wheels on your vehicle were aligned and balanced carefully at the factory to give you the longest tire life and best overall performance. In most cases, you will not need to have your wheels aligned again. However, if you notice unusual tire wear or your vehicle pulling one way or the other, the alignment may need to be reset. If you notice your vehicle vibrating when driving on a smooth road, your wheels may need to be rebalanced.

Wheel Replacement Replace any wheel that is bent, cracked, or badly rusted or corroded. If wheel nuts keep coming loose, the wheel, wheel bolts, and wheel nuts should be replaced. If the wheel leaks air, replace it (except some aluminum wheels, which can sometimes be repaired). See your Chevrolet/Geo dealer if any of these conditions exist. Your dealer will know the kind of wheel you need. Each new wheel should have the same load carrying capacity, diameter, width, offset, and be mounted the same way as the one it replaces. If you need to replace any of your wheels, wheel bolts, or wheel nuts, replace them only with new GM original equipment parts. This way, you will be sure to have the right wheel, wheel bolts, and wheel nuts for your Geo model.

I NOTICE:

The wrong wheel can also cause problems with bearing life, brake cooling, speedometer/odometer calibration, headlamp aim, bumper height, vehicle ground clearance, and tire or tire chain clearance to the body and chassis.

Used Replacement Wheels

Tire Chains

NOTICE: 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 tires of the drive axle (four-wheel drive vehicles can use chains on both axles). 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.

6-48

Appearance Care Remember, cleaning products can be hazardous. Some are toxic. Others can burst into flame if you strike a match or get them on a hot part of the vehicle. Some are dangerous if you breathe their fumes in a closed space. When you use anything from a container to clean your Geo, be sure to follow the manufacturer’s warnings and instructions. And always open your doors or windows when you’re cleaning the inside. Never use these to clean your vehicle:

Gasoline Benzene Naphtha Carbon Tetrachloride Acetone Paint Thinner Turpentine Lacquer Thinner Nail Polish Remover

They can all be hazardous -- some more than others -- and they can all damage your vehicle, too.

of these unless this manual says you can. these will damage your vehicle:

Don’t use any In many uses, 0 Alcohol 0 Laundry Soap 0 Bleach 0 Reducing Agents Cleaning the Inside of Your Geo Use a vacuum cleaner often to get rid of dust and loose dirt. Wipe vinyl or leather with a clean, damp cloth. Your ChevroletlGeo dealer has two GM cleaners, a solvent-type spot lifter and a foam-type powdered cleaner. They will clean normal spots and stains very well. Do not use them on vinyl or leather. Here are some cleaning tips:

Always read the instructions on the cleaner label. Clean up stains as soon as you can -- before they set. Use a clean cloth or sponge, and change to a clean area often. A soft brush may be used if stains are stubborn. Use solvent-type cleaners in a well-ventilated area only. If you use them, don’t saturate the stained area. If a ring forms after spot cleaning, clean the entire area immediately or it will set.

Using Foam-Qpe Cleaner on Fabric

Vacuum and brush the area to remove any loose dirt. Always clean a whole trim panel or section. Mask surrounding trim along stitch or welt lines. Mix multi-purpose powdered cleaner following the directions on the container label. Use suds only and apply with a clean sponge. Don’t saturate the material. Don’t rub it roughly. As soon as you’ve cleaned the section, use a sponge to remove the suds. Rinse the section with a clean, wet sponge. ’wipe off what’s left with a slightly damp paper towel or cloth. Then dry it immediately with a blow dryer or a heat lamp.

I NOTICE:

Be careful. A blow dryer or a heat lamp may scorch the fabric.

Wipe with a clean cloth.

Using Solvent-Qpe Cleaner on Fabric First, see if you have to use solvent-type cleaner at all. Some spots and stains will clean off better with just water and mild soap. If you need to use a solvent: 0 Gently scrape excess soil from the trim material with a clean, dull knife or scraper. Use very little cleaner, light pressure and clean cloths (preferably cheesecloth). Cleaning should start at the outside of the stain, “feathering” toward the center. Keep changing to a clean section of the cloth.

0 When you clean a stain from fabric, immediately dry

the area with a blow dryer or a heat lamp to help prevent a cleaning ring. (See the previous NOTICE.)

Fabric Protection Your Geo has upholstery that has been treated with Scotchgard TM Fabric Protector, a 3M product. Scotchgard’“ protects fabrics by repelling oil and water, which are the carriers of most stains. Even with this protection, you still need to clean your upholstery often to keep it looking new.

Further information on cleaning is available by calling 1-800-433-3296 (in Minnesota, 1-800-642-6167). Special Cleaning Problems Greasy or Oily Stains Stains caused by grease, oil, butter, margarine, shoe polish, coffee with cream, chewing gum, cosmetic creams, vegetable oils, wax crayon, tar and asphalt can be removed as follows:

Carefully scrape off excess stain. Follow the solvent-type instructions described earlier. Shoe polish, wax crayon, tar and asphalt will stain if left on a vehicle seat fabric. They should be removed as soon as possible. Be careful, because the cleaner will dissolve them and may cause them to spread.

Non-Greasy Stains Stains caused by catsup, coffee (black), egg, fruit, fruit juice, milk, soft drinks, wine, vomit, urine and blood can be removed as follows:

Carefully scrape off excess stain, then sponge the soiled area with cool water.

0 If a stain remains, follow the foam-type instructions

described earlier.

0 If an odor lingers after cleaning vomit or urine, treat the area with a waterbaking soda solution: 1 teaspoon (5 ml) of baking soda to 1 cup (250 ml) of lukewarm water.

0 If needed, clean lightly with solvent-type cleaner. Combination Stains Stains caused by candy, ice cream, mayonnaise, chili sauce and unknown stains can be removed as follows:

Carefully scrape off excess stain, then clean with cool water and allow to dry.

0 If a stain remains, clean it with solvent-type cleaner. Cleaning Vinyl Use warm water and a clean cloth. 0 Rub with a clean, damp cloth to remove dirt. You

may have to do it more than once. Things like tar, asphalt and shoe polish will stain if you don’t get them off quickly. Use a clean cloth and a GM Vinylkeather Cleaner or equivalent product.

Cleaning the Top of the Instrument Panel Use only mild soap and water to clean the top surfaces of the instrument panel. Sprays containing silicones or waxes may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. Care of Safety Belts Keep belts clean and dry.

Glass Glass should be cleaned often. GM Glass Cleaner (GM Part No. 1050427) or a liquid household glass cleaner will remove normal tobacco smoke and dust films. Don’t use abrasive cleaners on glass, because they may cause scratches. Avoid placing decals on the inside rear window, since they may have to be scraped off later. If abrasive cleaners are used on the inside of the rear window, an electric defogger element may be damaged. Any temporary license should not be attached across the defogger grid.

Cleaning the Outside of the Windshield and Wiper Blades If the windshield is not clear after using the windshield washer, or if the wiper blade chatters when running, wax or other material may be on the blade or windshield. Clean the outside of the windshield with GM Windshield Cleaner, Bon-Ami Powder@ (GM Part No. 1050011). The windshield is clean if beads do not form when you rinse it with water. Clean the blade by wiping vigorously with a cloth soaked in full strength windshield washer solvent. Then rinse the blade with water. Wiper blades should be checked on a regular basis and replaced when worn.

Weatherstrips Silicone grease on weatherstrips will make them last longer, seal better, and not stick or squeak. Apply silicone grease with a clean cloth at least every six months. During very cold, damp weather more frequent application may be required. (See “Recommended Fluids and Lubricants” in the Index.) Cleaning the Outside of Your Geo The paint finish on your vehicle provides beauty, depth of color, gloss retention and durability. Washing Your Vehicle The best way to preserve your vehicle’s finish is to keep it clean by washing it often with lukewarm or cold water. Don’t wash your vehicle in the direct rays of the sun. Don’t use strong soaps or chemical detergents. Use liquid hand, dish or car washing (mild detergent) soaps. Don’t use cleaning agents that are petroleum based, or that contain acid or abrasives. All cleaning agents should be flushed promptly and not allowed to dry on the surface, or they could stain. Dry the finish with a soft, clean chamois or a 100% cotton towel to avoid surface scratches and water spotting. High pressure car washes may cause water to enter your vehicle.

6-53

Finish Care Occasional waxing or mild polishing of your Geo by hand may be necessary to remove residue from the paint finish. You can get GM approved cleaning products from your dealer. (See “Appearance Care and Materials” in the Index.) Your Geo has a “basecoatlclearcoat” paint finish. The clearcoat gives more depth and gloss to the colored basecoat. Always use waxes and polishes that are non-abrasive and made for a basecoatlclearcoat paint finish.

I NOTICE:

Machine compounding or aggressive polishing on a basecoat/clearcoat paint finish may dull the finish or leave swirl marks.

Foreign materials such as calcium chloride and other salts, ice melting agents, road oil and tar, tree sap, bird droppings, chemicals from industrial chimneys, etc. can

damage your vehicle’s finish if they remain on painted surfaces. Wash the vehicle as soon as possible. If necessary, use non-abrasive cleaners that are marked safe for painted surfaces to remove foreign matter. Exterior painted surfaces are subject to aging, weather and chemical fallout that can take their toll over a period of years. You can help to keep the paint finish looking new by keeping your Geo garaged or covered whenever possible. Protecting Exterior Bright Metal Parts Bright metal parts should be cleaned regularly to keep their luster. Washing with water is all that is usually needed. However, you may use GM Chrome Polish on chrome or stainless steel trim, if necessary. Use special care with aluminum trim. To avoid damaging protective trim, never use auto or chrome polish, steam or caustic soap to clean aluminum. A coating of wax, rubbed to high polish, is recommended for all bright metal parts.

Special Care for Canvas Top and Plastic Windows To protect the canvas top: 0 After you wash the vehicle, make sure the top is

completely dry before you open or remove it. Don’t get any vinyl cleaner on the vehicle’s painted finish; it could leave streaks.

0 Don’t go through automatic car washes; the canvas

top could be damaged.

The plastic windows are pliable and can be scratched if you don’t take these precautions when you clean them: 0 Wipe off dust with a soft cotton cloth moistened with

clean, cool or lukewarm water. Don’t use a “dry” cloth. Wipe in one direction only, not back and forth.

To remove frost, snow or ice, use lukewarm water. Don’t use a scraper or any de-icing fluids. Wash the windows with a soft cloth and clean, cool or lukewarm water. Never use a dry cloth, hot water, strong soap or detergent, solvents or harsh cleaning agents. Rinse thoroughly and wipe with a slightly moist soft, clean cloth. Don’t put any labels, stickers or tape on windows. It’s hard to remove adhesives left on the window when such items are removed. If a sticker or label must be removed, remove any adhesive left on the window while the adhesive is still soft and sticky. Press on a new sticker or piece of tape and then lift it off again; keep doing this until all the adhesive lifts off with the sticker or tape.

Aluminum Wheels (If So Equipped) Your aluminum wheels have a protective coating similar to the painted surface of your vehicle. Don’t use strong soaps, chemicals, chrome polish, abrasive cleaners or abrasive cleaning brushes on them because you could damage this coating. After rinsing thoroughly, a wax may be applied.

I NOTICE:

If you have aluminum wheels, don’t use an automatic vehicle wash that has hard silicon carbide cleaning brushes. These brushes can take the protective coating off your aluminum wheels.

Tires To clean your tires, use a stiff brush with a tire cleaner. When applying a tire dressing always take care to wipe off any overspray or splash from painted surfaces. Petroleum-based products may damage the paint finish. Sheet Metal Damage If your vehicle is damaged and requires sheet metal repair or replacement, make sure the body repair shop applies anti-corrosion material to the parts repaired or replaced to restore corrosion protection. Finish Damage Any stone chips, fractures or deep scratches in the finish should be repaired right away. Bare metal will corrode quickly and may develop into a major repair expense. Minor chips and scratches can be repaired with touch-up materials available from your dealer or other service outlets. Larger areas of finish damage can be corrected in your dealer’s body and paint shop.

Underbody Maintenance Chemicals used for ice and snow removal and dust control can collect on the underbody. If these are not removed, accelerated corrosion (rust) can occur on the underbody parts such as fuel lines, frame, floor pan, and exhaust system even though they have corrosion protection. At least every spring, flush these materials from the underbody with plain water. Clean any areas where mud and other debris can collect. Dirt packed in closed areas of the frame should be loosened before being flushed. Your dealer or an underbody vehicle washing system can do this for you.

Chemical Paint Spotting Some weather and atmospheric conditions can create a chemical fallout. Airborne pollutants can fall upon and attack painted surfaces on your vehicle. This damage can take two forms: blotchy, ringlet-shaped discolorations, and small irregular dark spots etched into the paint surface. Although no defect in the paint job causes this, Geo will repair, at no charge to the owner, the surfaces of new vehicles damaged by this fallout condition within 12 months or 12,000 miles (20 000 km) of purchase, whichever comes first.

Appearance Care and Maintenance Materials

You can get these from your GM Parts Department.

PART

NUMBER

SIZE

DESCRIPTION

USAGE

Spray-A-Squeak Silicone Grease

Weatherstrips,

Stops squeaks

* Not recommended for pigskin suede leather. See your General Motors Parts Departments for these products. See your Maintenance Schedule for other products.

Vehicle Identification Number (VIN)

(.

lli Iiilll Ill1 iilllllilll ENGINE / 1995 \ ASSEMBLY I

SAMPLE4UXSMJ72675

4 5 s -

CODE

YEAR MODEL PLANT

This is the legal identifier for your Geo. It appears on a plate in the front corner of the instrument panel, on the driver’s side. You can see it if you look through the windshield from outside your vehicle. The VIN also appears on the Vehicle Certification and Service Parts labels and the certificates of title and registration. Engine Identification The eighth character in your VIN is the engine code. This code will help you identify your engine, specifications, and replacement parts.

Service Parts Identification Label You’ll find this label inside the glove box on the door. It’s very helpful if you ever need to order parts. On this label is:

your VIN,

0 the model designation, paint information, and

0 a list of all production options and special

equipment.

Be sure that this label is not removed from the vehicle. Add-on Electrical Equipment

NOTICE: Don’t add anything electrical to your Geo unless you check with your dealer first. Some electrical equipment can damage your vehicle and the damage wouldn’t be covered by your warranty. Some add-on electrical equipment can keep other components from working as they should.

Fuses and Circuit Breakers

Another fuse box is under the left side of the instrument panel. The fuses here protect each separate circuit including headlamps. If you have electrical failure, check here first.

The wiring circuits in your vehicle are protected from short circuits by fuses, circuit breakers and thermal links in the wiring itself. This greatly reduces the chance of fires caused by electrical problems. The main fuse box in your engine compartment is on the right side. It protects all electrical loads. For access to the main fuses, pull off the cover. A spare fuse is also inside the fuse box.

Look at the silver-colored band inside the fuse. If the band is broken or melted, replace the fuse. Be sure you replace a bad fuse with a new one of the correct size.

If you ever have a problem on the road and don’t have a spare fuse, you can borrow one. Just pick some feature of your vehicle that you can get along without -- like the radio or cigarette lighter -- and use its fuse, if it is the size you need. Replace it as soon as you can. Before replacing a fuse, turn every vehicle electrical switch off.

Fuse Usage

Instrument Panel Fuse Block

Main Fuse Block Fuse

Usage Generator to Battery Circuit Circuits Only Active When Ignition Switch is in ACC, ON or START Circuits Always Active Circuits Always Active

Fuse

Usage Right Headlamp Left Headlamp; High Beam Indicator Light Taillamps; Interior Lamp; Sidemarker Lamps; Instrument Cluster Lights Stop Lamps; Horn Hazard Lamps Door Lock (Option)

7 10 11 12 13 14

Lighter; Radio Ignition System; Warning and Indicator Lights Turn Signal Lamps; Back-up Lamps WiperNasher Rear Defogger Heater Rear Wheel Anti-Lock Main Relay Electronic Fuel Injection Main Relay

Replacement Bulbs Back-up .................................... 1156 Center High-Mounted Stop ...................... 921 Dome ............ GM Part No. 9605 1559 or equivalent Front Parking and Turn Signal ............... 1157 NA Headlamp (Halogen) .......................... 9004 GM Part No. 944173 1 or equivalent Heater or Air Conditioning Control ................... GM Part No. 96052599 or equivalent

Indicator and Warning

Brake . . . . . . . . . . . GM Part No. 9433184 or equivalent Charging System . . GM Part No. 9433184 or equivalent Check Engine . . . . . GM Part No. 9433184 or equivalent Engine Oil Pressure GM Part No. 9433184 or equivalent 4WD ........... GM Part No. 9433184 or equivalent Headlamp High Beam . . . . . . . . . . . . . . . . GM Part No. 9433184 or equivalent Safety Belt ....... GM Part No. 9433184 or equivalent Turn Signal ...... GM Part No. 9433 184 or equivalent Instrument Cluster GM Part No. 9605 1561 or equivalent

6-63

Replacement Bulbs Continued License Plate ................................. 194 GM Part No. 96053203 or equivalent Lighter ............ GM Part No. 9433 184 or equivalent Rear Defogger Switch ............................. GM Part No. 96061736 or equivalent Rear Hazard and Turn Signal .................... 1156 GM Part No. 96051557 or equivalent Rear Parking and Stop ......................... 1157 GM Part No. 96051558 or equivalent Rear Wipermasher Switch ......................... GM Part No. 96061736 or equivalent Sidemarker ................................... 194 GM Part No. 96053293 or equivalent

Capacities and Specifications Engine Type ......................................... L4 Compression Ratio

8-Valve Engine ............................ 16-Valve Engine ...........................

8.9: 1 9.5: 1 Firing Order .............................. 1-3-4-2 Fuel Delivery ......................... Fuel Injection Piston Displacement ................... 97 CID (1.6L) Valve Arrangement . . . . . . . . . . . . . . . . In-Head “V” Type AC Belt Tension .............. Deflect Belt 0.24-0.3 in. (6-9 mm) @ 22 lbs. (10 kg.) Pressure

Fan Belt Tension

Inspection . . . . . . . . . . . . . . . Deflect Belt 0.24-0.32 in. (6-8 mm) 0 22 lbs. (10 kg.) Pressure Replacement ............. Deflect Belt 0.20-0.28 in. (5-7 mm) @ 22 lbs. (10 kg.) Pressure Thermostat Temperature Specification . . . . 180°F (82°C)

Replacement Parts Air Cleaner Filter

8-Valve Engine ....................

16-Valve Engine

13780-61AAO GM Part No. 96064348 or equivalent .................... 13780-58B20 GM Part No. 96068629 or equivalent

Battery ................................. 26-60s Engine Oil Filter . . . . . . . . . . . . . . GM Part No. 2501444 1 Fuel Filter ........................ AC Type GF57 1 GM Part No. 96058022 or equivalent PCV Valve . . . . . . . GM Part No. 96058079 or equivalent Radiator Cap .............................. 13 psi Spark Plug ................... (0.028”- 0.032” Gap)

Capacities (Approximate) The following approximate capacities are given in U.S. and metric conversions. Air Conditioning? . . . . . See the refrigerant information

label under hood and “Air Conditioning” later in this section.

Automatic Transmission

Drain and Refill . . . . . . . . . . . . . . . . . . . 3.0 qt. (2.8 L)** Overhaul ........................

5.4 qt. (5.1 L)

Cooling System

Automatic Transmission . . . . . . . . . . . . 5.5 qt. (5.2 L) Manual Transmission . . . . . . . . . . . . . . . 5.6 qt. (5.3 L)

Crankcase

With Filter Change . . . . . . . . . . . . . . . . 4.5 qt. (4.2 L)* Without Filter Change . . . . . . . . . . . . . . 4.2 qt. (4.0 L)

Capacities (Approximate) Continued Front Differential .................... 1.1 qt. (1 .O L) Fuel Tank .......................... 11.1 gal. (42 L) Manual Transmission

Four-wheel Drive ................. 1.6 qt. (1.5 L)** Two-Wheel Drive ................. 1.8 qt. (1.7 L)**

Rear Differential .................... 2.3 qt. (2.2 L) Transfer Case ....................... 1.8 qt. (1.7 L) * When changing the oil filter, additional oil may be needed. Recheck the oil level after filling. See “Engine Oil” in the Index.

** Recheck fluid level after filling. See “Automatic

Transmission Fluid” or “Manual Transmission Fluid” in the Index.

Wheel Nuts Wheel Nut Torque ................. 60 lb- ft (80 Nom)

Vehicle Dimensions Wheelbase ....................... 86.6” (2 200 mm) Tread

Front ......................... 54.9” (1 395 mm) Rear .......................... 55.1” (1 400 mm) Length ......................... 142.5” (3 620 mm) Width ........................... 64.2” (1 630 mm) Height ........................... 65.0” (1 65 1 mm)

Air Conditioning Refrigerants Not all air conditioning refrigerants are the same. If the air conditioning system in your vehicle needs refrigerant, be sure the proper refrigerant is used. If you’re not sure, ask your Chevrolet/Geo dealer. For additional information, see your “Warranty and Owner Assistance Information” booklet.

Gem Section 7 Maintenance Schedule

IMPORTANT: KEEP ENGINE OIL AT THE PROPER

RECOMMENDED

This section covers the maintenance required for your Geo. Your vehicle needs these services to retain its safety, dependability and emission control performance.

Introduction Your Vehicle and the Environment Proper vehicle maintenance not only helps to keep your vehicle in good working condition, but also helps the environment. All recommended maintenance procedures are important. Improper vehicle maintenance or the removal of important components can significantly affect the quality of the air we breathe. Improper fluid levels or even the wrong tire inflation can increase the level of emissions from your vehicle. To help protect our environment, and to help keep your vehicle in good condition, please maintain your vehicle properly.

Have you purchased the GM Protection Plan .? The Plan supplements your new vehicle warranties. See your Chevrolet/Geo dealersfor details.

7-1

How This Section is Organized The remainder of this section is divided into five parts: “Part A: Scheduled Maintenance Services’’ shows what to have done and how often. Some of these services can be complex, so unless you are technically qualified and have the necessary equipment, you should let your dealer’s service department or another qualified service center do these jobs.

If you are skilled enough to do some work on your vehicle, you will probably want to get the service information GM publishes. See “Service Publications” in the Index.

“Part B: Owner Checks and Services” tells you what should be checked whenever you stop for fuel. It also explains what you can easily do to help keep your vehicle in good condition. “Part C: Periodic Maintenance Inspections” explains important inspections that your Chevrolet/Geo dealer’s service department or another qualified service center should perform. “Part D: Recommended Fluids and Lubricants” lists some products GM recommends to help keep your vehicle properly maintained. These products, or their equivalents, should be used whether you do the work yourself or have it done. “Part E: Maintenance Record” provides a place for you to record the maintenance performed on your vehicle. Whenever any maintenance is performed, be sure to write it down in this part. This will help you determine when your next maintenance should be done. In addition, it is a good idea to keep your maintenance receipts. They may be needed to qualify your vehicle for warranty repairs.

Part A: Scheduled Maintenance Services Using Your Maintenance Schedule We at General Motors want to help you keep your vehicle in good working condition. But we don’t know exactly how you’ll drive it. You may drive very short distances only a few times a week. Or you may drive long distances all the time in very hot, dusty weather. You may use your vehicle in making deliveries. Or you may drive it to work, to do errands or in many other ways. Because of all the different ways people use their GM vehicles, maintenance needs vary. You may even need more frequent checks and replacements than you’ll find in the schedules in this section. So please read this section and note how you drive. If you have any questions on how to keep your vehicle in good condition, see your Chevrolet/Geo dealer. This part tells you the maintenance services you should have done and when you should schedule them. If you go to your dealer for your service needs, you’ll know that GM-trained and supported service people will perform the work using genuine GM parts.

The proper fluids and lubricants to use are listed in Part D. Make sure whoever services your vehicle uses these. All parts should be replaced and all necessary repairs done before you or anyone else drives the vehicle. These schedules are for vehicles that: 0 carry passengers and cargo within recommended

limits. You will find these limits on your vehicle’s Tire-Loading Information label. See “Loading Your Vehicle’’ in the Index. are driven on reasonable road surfaces within legal driving limits. use the recommended unleaded fuel. See “Fuel” in the Index.

Selecting the Right Schedule First you’ll need to decide which of the two schedules is right for your vehicle. Here’s how to decide which schedule to follow:

Maintenance Schedule I Schedule I Definition Follow Maintenance Schedule I if any one of these is true for your vehicle:

Most trips are less than 5 to 10 miles (8 to 16 km). This is particularly important when outside temperatures are below freezing. Most trips include extensive idling (such as frequent driving in stop-and-go traffic).

0 You frequently tow a trailer or use a carrier on top of

your vehicle.

Schedule I should also be followed if the vehicle is used for delivery service, police, taxi, or other commercial application.

Schedule I Intervals

Every 3,000 Miles (5 000 km) or 3 Months, Whichever Occurs First

Engine Oil and Filter Change Free-Wheeling Hubs Inspection (If Equipped)

Every 6,000 Miles (10 000 km) or 6 Months, Whichever Occurs First

Tire Rotation

Every 15,000 Miles (25 000 km)

Air Cleaner Filter Inspection, if driving in dusty

conditions

Front Wheel Bearing Repack (or at each brake

relining, whichever occurs first)

Manual Transmission Fluid Change (or every

15 months, whichever occurs first)

Engine Idle Speed Check Valve Lash (Clearance) Adjustment Propeller Shafts and U-Joints Inspection (or every

15 months, whichever occurs first)

Maintenance Schedule

Every 30,000 Miles (50 000 km)

Every 60,000 Miles (100 000 km)

Air Cleaner Filter Replacement Spark Plug Replacement Engine Accessory Drive Belt Inspection (or every

24 months, whichever occurs first)

Fuel Filter Replacement (or every 30 months,

whichever occurs first)

Cooling System Service (or every 30 months,

whichever occurs first)

Every 50,000 Miles (83 000 lug)

Automatic Transmission Service (severe conditions

Positive Crankcase Ventilation (PCV) Valve

only)

Replacement

Exhaust Gas Recirculation (EGR) System Inspection

Engine Timing and Distributor Check Fuel Tank Cap Gasket Replacement Emission System Hoses Inspection Camshaft Timing Belt Replacement Brake Fluid Service Spark Plug Wire Replacement (or every 60 months,

whichever occurs first)

Wiring Harness and Connectors Inspection (or every

60 months, whichever occurs first)

Every 80,000 Miles (133 000 km)

Heated Oxygen Sensor Replacement

Every 90,000 Miles (150 000 km) Camshaft Timing Belt Inspection

Every 100,000 Miles (166 000 km)

Fuel Injector Inspection Evaporative Emissions Canister Replacement Engine Control Module (ECM) and Associated

Sensors Inspection

7-5

Maintenance Schedule 'I Schedule I1 Definition

Follow Schedule I1 only if none of the conditions from Schedule I is true.

Schedule I1 Intervals

Every 7,500 Miles (12 500 km)

Engine Oil and Filter Change (or every 7.5 months,

whichever occurs first)

Free-Wheeling Hubs Inspection (If Equipped) (or

every 3 months, whichever occurs first)

Tire Rotation

Every 15,000 Miles (25 000 km)

Front Wheel Bearing Repack (or at each brake

relining)

Engine Idle Speed Check Valve Lash (Clearance) Adjustment Propeller Shafts and U-Joints Inspec :ti 15 months, whichever occurs first)

on (or every

7-6

I-

Maintenance Schedule

Every 30,000 Miles (50 000 km)

Every 60,000 Miles (100 000 km)

Engine Accessory Drive Belt Inspection (or every

24 months, whichever occurs first)

Cooling System Service (or every 30 months,

whichever occurs first) Spark Plug Replacement Air Cleaner Filter Replacement Fuel Tank, Cap and Lines Inspection Manual Transmission Fluid Change (or every

30 months, whichever occurs first)

Fuel Filter Replacement (or every 30 months,

whichever occurs first)

Every 50,000 Miles (83 000 km)

Automatic Transmission Service (severe conditions

Positive Crankcase Ventilation (PCV) Valve

only)

Replacement

Exhaust Gas Recirculation (EGR) System Inspection

Engine Timing and Distributor Check Fuel Tank Cap Gasket Replacement Emission System Hoses Inspection Camshaft Timing Belt Replacement Spark Plug Wire Replacement (or every 60 months,

whichever occurs first)

Wiring Harness and Connectors Inspection (or every

60 months, whichever occurs first)

Brake Fluid Service

Every 90,000 Miles (150 000 km) Camshaft Timing Belt Inspection Every 100,000 Miles (166 000 km)

Fuel Injector Inspection Evaporative Emissions Canister Replacement Engine Control Module (ECM) and Associated

Sensors Inspection

I Maintenance Schedule I

The services shown in this schedule up to 100,000 miles (166 000 km) should be performed after 100,000 miles ( 166 000 km) at the same intervals. 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 vehicle useful life. We, however, urge that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded.

DATE

ACTUAL MILEAGE

SERVICED BY:

3,000 Miles (5 000 km) 0 Change engine oil and filter (or every

3 months, whichever occurs first). An Emission Control Service.

0 Inspect the locking front hubs (if equipped)

for correct operation (or every 3 months, whichever occurs first). Repair or replace if necessary.

DATE ACTUAL MILEAGE € SERVICED B Y

I Maintenance Schedule I 6,000 Miles (10 000 km) 0 Change engine oil and filter (or every

3 months, whichever occurs first). An Emission Control Service.

0 Rotate tires. See “Tire Inspection and

Rotation” in the Index for proper rotation pattern and additional information.

0 Inspect the locking front hubs (if equipped)

for correct operation (or every 3 months, whichever occurs first). Repair or replace if necessary.

9,000 Miles (15 000 km) 0 Change engine oil and filter (or every

3 months, whichever occurs first). An Emission Control Service.

0 Inspect the locking front hubs (if equipped)

for correct operation (or every 3 months, whichever occurs first). Repair or replace if