engine CHEVROLET OPTRA 2005 1.G Repair Manual

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 between the MIN and
MAX marks, add a 50/50 mixture ofclean, drinkable
waterand proper 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. See
Engine Coolant on page 5-20for more information.
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 coolant
surge tank pressure cap — even a little — they
can come out at high speed. Never turn the
CAUTION: (Continued)
CAUTION: (Continued)
cap when the cooling system, including the
coolant surge tank pressure cap, is hot. Wait
for the cooling system and coolant surge tank
pressure cap to cool if you ever have to turn
the pressure cap.
{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 a proper coolant.
5-26

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.
{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.
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.
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3. Fill the coolant surge tank with the proper mixture
to the MAX mark on the coolant surge tank. Wait
about five minutes, then check to see if the level is
below the MAX mark. If the level is below the
MAX mark, add additional coolant to bring the level
up to the MAX mark. Repeat this procedure until
the level remains constant at the MAX 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 fan.
By this time, the coolant level inside the coolant
surge tank may be lower. If the level is lower than
the MAX mark, add more of the proper mixture
to the coolant surge tank until the level reaches the
MAX mark.
5. Then replace the pressure cap. Be sure the
pressure cap is hand-tight and fully seated.
See your dealer, if necessary.
Power Steering Fluid
When to Check Power Steering Fluid
The power steering fluid reservoir is located toward the
front of the engine compartment on the driver’s side
of the vehicle. SeeEngine Compartment Overview on
page 5-12for reservoir location.
It is not necessary to regularly check power steering
fluid unless you suspect there is a leak in the system or
you hear an unusual noise. A fluid loss in this system
could indicate a problem. Have the system inspected
and repaired.
5-28

How to Check Power Steering Fluid
Turn the key off and let the engine compartment cool
down. Then check the fluid level.
The level should be between the MIN (B) and MAX (A)
marks on the reservoir. If the level is below the
MIN (B) mark, add the power steering fluid to the
appropriate level. Replace the cap and completely
tighten it.
What to Use
To determine what kind of fluid to use, seePart D:
Recommended Fluids and Lubricants on page 6-24.
Always use the proper fluid. Failure to use the proper
fluid can cause leaks and damage hoses and seals.
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.
5-29

Adding Washer Fluid
Open the cap with the
washer symbol on it. Add
washer fluid until the
tank is full. SeeEngine
Compartment Overview on
page 5-12for reservoir
location.
Notice:
When using concentrated washer uid, follow
the manufacturer’s instructions for adding water.
Do not mix water with ready-to-use washer uid.
Water can cause the solution to freeze and
damage your washer uid tank and other parts of
the washer system. Also, water does not clean as
well as washer uid.
Fill your washer uid tank only three-quarters full
when it is very cold. This allows for expansion if
freezing occurs, which could damage the tank if
it is completely full.
Do not use engine coolant (antifreeze) in your
windshield washer. It can damage your washer
system and paint.
Brakes
Brake Fluid
Your master cylinder
reservoir is filled with
DOT-3 brake fluid. See
Engine Compartment
Overview on page 5-12for
the location of the
reservoir.
There are only two reasons why the brake fluid level in
the reservoir 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 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 will not work
well, or will not work at all.
5-30

So, it is not a good idea to top off your brake fluid.
Adding brake fluid will not correct a leak. If you add fluid
when your linings are worn, then you will 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
{CAUTION:
If you have too much brake uid, it can spill on
the engine. The uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
uid only when work is done on the brake
hydraulic system.
When your brake fluid falls to a low level, your brake
warning light will come on. SeeBrake System Warning
Light on page 3-32.
What to Add
When you do need brake fluid, use only DOT-3 brake
fluid. Use new brake fluid from a sealed container
only. SeePart D: Recommended Fluids and Lubricants
on page 6-24.Always clean the brake fluid reservoir cap and the area
around the cap before removing it. This will help
keep dirt from entering the reservoir.
{CAUTION:
With the wrong kind of uid in your brake
system, your brakes may not work well, or they
may not even work at all. This could cause a
crash. Always use the proper brake uid.
Notice:
Using the wrong uid can badly damage brake
system parts. 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 will have to be replaced. Do not
let someone put in the wrong kind of uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged. Be
careful not to spill brake uid on your vehicle. If
you do, wash it off immediately. SeeAppearance
Care on page 5-66.
5-31

Replacing Brake System Parts
The braking system on a 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. Your
vehicle was designed and tested with top-quality GM
brake parts. When you replace parts of your braking
system — for example, when your brake linings
wear down and you need new ones put in — be sure
you get new approved GM replacement parts. If you do
not, 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 have come to expect can change
in many other ways if someone puts in the wrong
replacement brake parts.
Battery
Your vehicle has a maintenance free battery. When it is
time for a new battery, get one that has the replacement
number shown on the original battery’s label. SeeEngine
Compartment Overview on page 5-12for battery location.
Warning:Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
Vehicle Storage
If you are not going to drive your vehicle for 25 days
or more, remove the black, negative (−) cable from
the battery. This will help keep your battery from
running down.
{CAUTION:
Batteries have acid that can burn you and gas
that can explode. You can be badly hurt if you
are not careful. SeeJump Starting on
page 5-34for tips on working around a battery
without getting hurt.
5-33

4. Open the hoods and locate the batteries. Find the
positive (+) and negative (−) terminal locations on
each vehicle. Your vehicle’s positive (+) terminal is
located under a red tethered cap on the battery.
The negative (–) terminal is located under a
black tethered cap on the battery. SeeEngine
Compartment Overview on page 5-12for more
information on location. Flip the caps up to access
the positive (+) and negative (–) terminals.
{CAUTION:
An electric fan 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.
{CAUTION:
Using a match near a battery can cause battery
gas to explode. People have been hurt doing
this, and some have been blinded. Use a
ashlight if you need more light.
CAUTION: (Continued)
CAUTION: (Continued)
Be sure the battery has enough water. You do
not need to add water to the battery installed
in your new vehicle. But if a battery has ller
caps, be sure the right amount of uid is there.
If it is low, add water to take care of that rst.
If you don’t, explosive gas could be present.
Battery uid contains acid that can burn you.
Do not get it on you. If you accidentally get it
in your eyes or on your skin, ush the place
with water and get medical help immediately.
{CAUTION:
Fans or other moving engine parts can injure
you badly. Keep your hands away from moving
parts once the engine is running.
5-35

5. Check that the jumper cables do not have loose or
missing insulation. If they do, you could get a
shock. The vehicles could be damaged too.
Before you connect the cables, here are some
things you should know. Positive (+) will go
to positive (+) or to a remote positive (+) terminal if
the vehicle has one. Negative (−) will go to a
heavy, unpainted metal engine part or to a remote
negative (−) terminal if the vehicle has one.
Do not connect positive (+) to negative (−)oryou
will get a short that would damage the battery
and maybe other parts too. And do not connect the
negative (−) cable to the negative (−) terminal on
the dead battery because this can cause sparks.
6. Connect the red positive (+) cable to the positive (+)
terminal of the dead battery. Use a remote
positive (+) terminal if the vehicle has one.
7. Do not let the other end touch metal. Connect it to
the positive (+) terminal of the good battery. Use a
remote positive (+) terminal if the vehicle has one.
8. Now connect the black negative (−) cable to the
negative (−) terminal of the good battery. Use a
remote negative (−) terminal if the vehicle has one.Do not let the other end touch anything until the
next step. The other end of the negative (−) cable
does notgo to the dead battery. It goes to a
heavy, unpainted metal engine part or to a remote
negative (−) terminal on the vehicle with the
dead battery.
9. Connect the other end
of the negative (−)
cable at least 18 inches
(45 cm) away from
the dead battery, but
not near engine
parts that move. The
electrical connection is
just as good there,
and the chance
of sparks getting back
to the battery is
much less.
10. Now start the vehicle with the good battery and run
the engine for a while.
11. Try to start the vehicle that had the dead battery. If
it will not start after a few tries, it probably needs
service.
5-36

Notice:If the jumper cables are connected or
removed in the wrong order, electrical shorting may
occur and damage the vehicle. The repairs would
not be covered by your warranty. Always connect
and remove the jumper cables in the correct
order, making sure that the cables do not touch
each other or other metal.
A. Heavy, Unpainted Metal Engine Part or Remote
Negative (–) Terminal
B. Good Battery or Remote Positive (+) and Remote
Negative (–) Terminals
C. Dead Battery or Remote Positive (+) TerminalTo disconnect the jumper cables from both vehicles, do
the following:
1. Disconnect the black negative (−) cable from the
vehicle that had the dead battery.
2. Disconnect the black negative (−) cable from the
vehicle with the good battery.
3. Disconnect the red positive (+) cable from the
vehicle with the good battery.
4. Disconnect the red positive (+) cable from the other
vehicle.
5. Return the caps over the positive (+) and
negative (–) terminals to their original positions.
Headlamp Aiming
If your vehicle is damaged in an accident, the headlamp
aim may be affected. Aim adjustment to the low beam
may be necessary if it is difficult to see lane markers (for
horizontal aim), or if oncoming drivers flash their high
beams at you (for vertical aim). If you believe your
headlamps need to be re-aimed, we recommend that you
take your vehicle to the dealer for service. However, it is
possible for you to re-aim your headlamps by following
the procedure in the service manual for your vehicle.
Notice:To make sure your headlamps are aimed
properly, read all the instructions before beginning.
Failure to follow these instructions could cause
damage to headlamp parts. Jumper Cable Removal
5-37