cooling CHEVROLET CLASSIC 2005 User Guide

Cooling System
When you decide it is safe to lift the hood, here is what
you will see:
A. Coolant Surge Tank with Pressure Cap
B. Electric Engine Cooling Fans{CAUTION:
An electric engine cooling fan under the hood
can start up even when the engine is not
running and can injure you. Keep hands,
clothing and tools away from any underhood
electric fan.
If the coolant inside the coolant surge tank is boiling,
do not do anything else until it cools down. The vehicle
should be parked on a level surface.
5-24

The coolant level should be at or above the FULL COLD
mark. If it is not, you may have a leak at the pressure cap
or in the radiator hoses, heater hoses, radiator, water
pump or somewhere else in the cooling system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them.
If you do, you can be burned.
CAUTION: (Continued)
CAUTION: (Continued)
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine re, and you could be
burned. Get any leak xed before you drive
the vehicle.
If there seems to be no leak, with the engine on, check
to see if the electric engine cooling fans are running.
If the engine is overheating, the fans should be running.
If they are not, your vehicle needs service.
Notice:If you operate the engine without coolant
or fail to maintain the cooling system properly,
you could damage the engine. The repairs would not
be covered by your warranty. Always follow the
maintenance schedule in this manual for
maintaining your cooling system. SeeCooling
System on page 5-24for more information.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
5-25

How to Add Coolant to the Coolant
Surge Tank
Notice:This vehicle has a specic coolant ll
procedure. Failure to follow this procedure could
cause your engine to overheat and be severely
damaged.
If you have not found a problem yet, check to see if
coolant is visible in the surge tank. If coolant is visible
but the coolant level is not at or above the FULL COLD
mark, add a 50/50 mixture ofclean, drinkable water
and DEX-COOL
®coolant at the coolant surge tank,
but be sure the cooling system, including the coolant
surge tank pressure cap, is cool before you do it.
SeeEngine Coolant on page 5-18.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and DEX-COOL
®coolant.
Notice:In cold weather, water can freeze and crack
the engine, radiator, heater core and other parts.
Use the recommended coolant and the proper
coolant mixture.
5-26

{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.
If no coolant is visible in the surge tank, add coolant as
follows:
{CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They
are under pressure, and if you turn the radiator
pressure cap — even a little — they can come
out at high speed. Never turn the cap when the
cooling system, including the radiator pressure
cap, is hot. Wait for the cooling system and
radiator pressure cap to cool if you ever have
to turn the pressure cap.1. You can remove the coolant surge tank pressure
cap when the cooling system, including the coolant
surge tank pressure cap and upper radiator
hose, is no longer hot. Turn the pressure cap slowly
counterclockwise (left) about two or two and
one-half turns.
If you hear a hiss, wait for that to stop. This will
allow any pressure still left to be vented out
the discharge hose.
2. Then keep turning the pressure cap slowly, and
remove it.
5-27

3. Fill the coolant surge tank with the proper mixture, to
the hash mark on the label. Wait about five minutes,
then check to see if the level is below the hash mark.
If the level is below the hash mark, add additional
coolant to bring the level up to the hash mark.
Repeat this procedure until the level remains
constant at the hash mark for at least five minutes.4. With the coolant surge tank pressure cap off, start
the engine and let it run until you can feel the upper
radiator hose getting hot. Watch out for the
engine cooling fans.
By this time, the coolant level inside the coolant
surge tank may be lower. If the level is lower than
the FULL COLD mark, add more of the proper
mixture to the coolant surge tank until the level
reaches the FULL COLD mark.
5. Replace the pressure cap. Be sure the pressure
cap is hand-tight and fully seated.
See your dealer, if necessary.
5-28

{CAUTION:
Using the wrong replacement wheels, wheel
bolts or wheel nuts on your vehicle can be
dangerous. It could affect the braking and
handling of your vehicle, make your tires lose
air and make you lose control. You could have
a collision in which you or others could be
injured. Always use the correct wheel, wheel
bolts and wheel nuts for replacement.
Notice:The wrong wheel can also cause problems
with bearing life, brake cooling, speedometer or
odometer calibration, headlamp aim, bumper height,
vehicle ground clearance and tire or tire chain
clearance to the body and chassis.
SeeChanging a Flat Tire on page 5-60for more
information.
Used Replacement Wheels
{CAUTION:
Putting a used wheel on your vehicle is
dangerous. You can’t know how it’s been used
or how far it’s been driven. It could fail suddenly
and cause a crash. If you have to replace a
wheel, use a new GM original equipment wheel.
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 front tires and 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.
5-59

Engine Compartment Fuse Block
The engine compartment fuse block is located on the
driver’s side of the vehicle, near the engine air
cleaner/filter. SeeEngine Compartment Overview on
page 5-12for more information on location.
Fuses Usage
1 Ignition Switch
2Right Electrical Center-Fog Lamps
(If Equipped), Radio, Body Function
Control Module, Interior Lamps
Fuses Usage
3Left Electrical Center-Stoplamps,
Hazard Lamps, Body Function
Control Module, Cluster, Climate
Control System
4 Anti-Lock Brakes
5 Ignition Switch
6 Not Used
7Left Electrical Center-Power Seats,
Power Mirrors, Door Locks, Trunk
Release and Remote Lock Control
8 Cooling Fan #1
Relays Usage
9 Rear Defogger
10 Not Used
11 Not Used
12 Cooling Fan #1
13 HVAC Blower (Climate Control)
14 Not Used
15 Cooling Fan
16 Air Conditioning Compressor
17 Not Used
5-83

Relays Usage
18 Fuel Pump
19 Automatic Headlamp System
20 Automatic Headlamp System
21 Horn
22 Daytime Running Lamps (DRL)
Fuses Usage
23–32 Spare Fuse Holder
33 Rear Defogger
34Accessory Power Outlets,
Cigar Lighter
35 Not Used
36 Not Used
37Air Conditioning Compressor,
Body Function Control Module
38 Automatic Transaxle
39Powertrain Control Module (PCM),
Ignition
40 Anti-Lock Brakes (ABS)
41 Ignition System
Fuses Usage
42Back-Up Lamps, Shift Lock
Control System
43 Horn
44 PCM
45 Parking Lamps
46 Climate Control System
47Canister Purge Valve, PCM,
Exhaust Gas Recirculation,
Heated Oxygen Sensor
48 Fuel Pump Injectors
49 Not Used
50 Right Headlamp
51 Left Headlamp
52 Cooling Fan
53 HVAC Blower (Climate Control)
54 Not Used
55 Not Used
56 Fuse Puller
57 Not Used
5-84

Capacities and Specications
The following approximate capacities are given in English and metric conversions. SeePart D: Recommended Fluids
and Lubricants on page 6-22for more information.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a 1.4 lbs 0.6 kg
Automatic Transaxle Complete Overhaul 9.5 qt 9.0 L
Cooling System 8.6 qt 8.2 L
Engine Oil with Filter 5.0 qt 4.7 L
Fuel Tank 14.1 gal 53.4 L
Wheel Nut Torque 100 ft lb 140Y
All capacities are approximate. When adding, be sure to fill to the appropriate level, as recommended in this
manual.
Engine Specications
Engine VIN Code Transaxle Spark Plug Gap
2.2L L4 ECOTEC
®™ F Automatic 0.042 inch (1.06 mm)
5-85

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
How This Section is Organized.........................6-3
Part A: Scheduled Maintenance Services...........6-4
Using the Maintenance Schedule......................6-4
Selecting the Right Schedule...........................6-5
Short Trip/City Scheduled Maintenance..............6-6
Long Trip/Highway Scheduled Maintenance......6-12
Part B: Owner Checks and Services................6-16
At Each Fuel Fill..........................................6-16
At Least Once a Month.................................6-16At Least Twice a Year...................................6-17
At Least Once a Year...................................6-17
Part C: Periodic Maintenance Inspections.........6-20
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection............................6-20
Exhaust System Inspection............................6-20
Fuel System Inspection..................................6-20
Engine Cooling System Inspection...................6-21
Throttle System Inspection.............................6-21
Brake System Inspection................................6-21
Part D: Recommended Fluids and Lubricants. . . .6-22
Part E: Maintenance Record...........................6-23
Section 6 Maintenance Schedule
6-1