engine PONTIAC G3 2009 Repair Manual

How to Add Coolant to the Coolant
Surge Tank
{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.
Notice:This vehicle has a specic coolant ll
procedure. Failure to follow this procedure could
cause the engine to overheat and be severely
damaged.
{CAUTION:
An electric engine cooling fan under the hood can
start up even when the engine is not running and
can cause injury. Keep hands, clothing, and tools
away from any underhood electric fan.
{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 surge tank
pressure cap — even a little — they can come out
at high speed. Never turn the cap when the cooling
system, including the surge tank pressure cap, is
hot. Wait for the cooling system and surge tank
pressure cap to cool if you ever have to turn the
pressure cap.
If no coolant is visible in the surge tank, add coolant as
follows:
1. 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
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.
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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 Maximum mark, add more of the proper mixture
to the coolant surge tank until the level reaches
the mark.
5. Replace the pressure cap. Be sure the pressure
cap is hand-tight and fully seated.
Notice:If the pressure cap is not tightly installed,
coolant loss and possible engine damage may
occur. Be sure the cap is properly and tightly
secured.Engine Overheating
The vehicle has an indicator to warn of the engine
overheating.
There is a coolant temperature gage on the instrument
panel cluster. SeeEngine Coolant Temperature
Gage on page 3-30.
You may decide not to lift the hood when this warning
appears, but instead get service help right away.
SeeRoadside Assistance Program on page 7-7.
If you do decide to lift the hood, make sure the vehicle
is parked on a level surface.
Then check to see if the engine cooling fan is running.
If the engine is overheating, the fan should be running.
If it is not, do not continue to run the engine and have the
vehicle serviced.
Notice:Engine damage from running the engine
without coolant is not covered by the warranty.
Notice:If the engine catches re because of being
driven with no coolant, your vehicle can be badly
damaged. The costly repairs would not be covered
by the vehicle warranty.
5-28

If Steam Is Coming From The Engine
Compartment
{CAUTION:
Steam from an overheated engine can burn you
badly, even if you just open the hood. Stay away
from the engine if you see or hear steam coming
from it. Just turn it off and get everyone away from
the vehicle until it cools down. Wait until there is no
sign of steam or coolant before you open the hood.
If you keep driving when your engine is overheated,
the liquids in it can catch re. You or others could
be badly burned. Stop your engine if it overheats,
and get out of the vehicle until the engine is cool.
If No Steam Is Coming From The
Engine Compartment
If an engine overheat warning is displayed but no
steam can be seen or heard, the problem may not be
too serious. Sometimes the engine can get a little too
hot when the vehicle:
Climbs a long hill on a hot day.
Stops after high-speed driving.
Idles for long periods in traffic.
If the overheat warning is displayed with no sign of
steam:
1. Turn the air conditioning off.
2. Turn the heater on to the highest temperature and
to the highest fan speed. Open the windows as
necessary.
3. If in a traffic jam, let the engine idle in N (Neutral)
while stopped. If it is safe to do so, pull off the
road, shift to P (Park) or N (Neutral) and let
the engine idle.
If the temperature overheat gage is no longer
in the overheat zone or an overheat warning
no longer displays, the vehicle can be driven.
5-29

Continue to drive the vehicle slow for about 10 minutes.
Keep a safe vehicle distance from the car in front of
you. If the warning does not come back on, continue
to drive normally.
If the warning continues, pull over, stop, and park the
vehicle right away.
If there is no sign of steam, idle the engine for three
minutes while parked. If the warning is still displayed,
turn off the engine until it cools down.
Power Steering Fluid
When to Check Power Steering Fluid
The power steering uid 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
uid unless you suspect there is a leak in the system or
you hear an unusual noise. A uid loss in this system
could indicate a problem. Have the system inspected
and repaired.
How to Check Power Steering Fluid
Turn the key off and let the engine compartment
cool down.
The level should be between the MIN (B) and MAX (A)
marks on the reservoir. If the level drops below the
MIN (B) mark, add power steering uid. Do not overll
the reservoir and remember to replace the cap tightly
when you are nished and clean up any spilled uid.
What to Use
To determine what kind of uid to use, see
Recommended Fluids and Lubricants on page 6-12.
Always use the proper uid. Failure to use the proper
uid can cause leaks and damage hoses and seals.
5-30

Windshield Washer Fluid
What to Use
When you need windshield washer uid, 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 uid that has sufficient
protection against freezing.
Adding Washer Fluid
Open the cap with the
washer symbol on it.
Add washer uid 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 the washer uid tank only three-quarters
full when it is very cold. This allows for uid
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 the vehicle’s
windshield washer system and paint.
5-31

Brakes
Brake Fluid
The vehicle has one
reservoir for both the
brake and clutch hydraulic
systems. It is lled with
DOT 3 brake uid.
SeeEngine Compartment Overview on page 5-12for
the location of the reservoir.
There are only two reasons why the brake uid level in
the reservoir might go down:
The brake uid level goes down because of normal
brake lining wear. When new linings are installed,
the uid level goes back up.
A uid leak in the brake or clutch hydraulic system
can also cause a low uid level. Have the brake or
clutch hydraulic system xed, since a leak means
that sooner or later the brakes will not work well.Do not top off the brake uid. Adding brake uid does
not correct a leak. If uid is added when the linings
are worn, there will be too much uid when new brake
linings are installed. Add or remove uid, as necessary,
only when work is done on the brake or clutch
hydraulic system.
{CAUTION:
If too much brake uid is added, it can spill on
the engine and burn, if the engine is hot enough.
You or others could be burned, and the vehicle
could be damaged. Add brake uid only when
work is done on the brake and/or clutch hydraulic
system.
When the brake uid falls to a low level, the brake
warning light comes on. SeeBrake System Warning
Light on page 3-28.
5-32

What to Add
Use only new DOT 3 brake uid from a sealed container.
SeeRecommended Fluids and Lubricants on page 6-12.
Always clean the brake uid reservoir cap and the
area around the cap before removing it. This helps keep
dirt from entering the reservoir.
{CAUTION:
With the wrong kind of uid in the brake or clutch
hydraulic system, the brakes or clutch might not
work well. This could cause a crash. Always use
the proper brake uid.Notice:
Using the wrong uid can badly damage brake
or clutch hydraulic system parts. For example,
just a few drops of mineral-based oil, such
as engine oil, in the brake or clutch hydraulic
system can damage brake or clutch hydraulic
system parts so badly that they will have
to be replaced. Do not let someone put in the
wrong kind of uid.
If brake uid is spilled on the vehicle’s painted
surfaces, the paint nish can be damaged.
Be careful not to spill brake uid on the vehicle.
If you do, wash it off immediately. SeeWashing
Your Vehicle on page 5-82.
5-33

Brake Adjustment
Every moderate brake stop, the disc brakes adjust for
wear. If rarely making moderate or heavier brake stops,
the brakes might not adjust correctly. Very carefully
making a few moderate brake stops about every
1,000 miles (1 600 km) will adjust the brakes properly.
If the vehicle has rear drum brakes and the brake pedal
goes down farther than normal, the rear drum brakes
might need adjustment. Adjust them by backing up and
rmly applying the brakes a few times.
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. The vehicle
was designed and tested with top-quality brake parts.
When parts of the braking system are replaced — for
example, when the brake linings wear down and new
ones are installed — be sure to get new approved
replacement parts. If this is not done, the brakes mightnot work properly. For example, if someone puts in
brake linings that are wrong for the vehicle, the balance
between the front and rear brakes can change — for the
worse. The braking performance expected can change
in many other ways if the wrong replacement brake parts
are installed.
Battery
This vehicle has a maintenance free battery. When it is
time for a new battery, see your dealer/retailer for 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.
5-35

Notice:Ignoring these steps could result in costly
damage to the vehicle that would not be covered
by the warranty.
Trying to start the vehicle by pushing or pulling it
will not work, and it could damage the vehicle.
1. Check the other vehicle. It must have a 12-volt
battery with a negative ground system.
Notice:If the other vehicle’s system is not a 12-volt
system with a negative ground, both vehicles can
be damaged. Only use vehicles with 12-volt systems
with negative grounds to jump start your vehicle.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles are not touching
each other. If they are, it could cause a ground
connection you do not want. You would not be able
to start your vehicle, and the bad grounding could
damage the electrical systems.
To avoid the possibility of the vehicles rolling, set
the parking brake rmly on both vehicles involved
in the jump start procedure. Put an automatic
transmission in P (Park) or a manual transmission
in N (Neutral) before setting the parking brake.Notice:If you leave the radio or other accessories
on during the jump starting procedure, they could
be damaged. The repairs would not be covered by
the warranty. Always turn off the radio and other
accessories when jump starting the vehicle.
3. Turn off the ignition on both vehicles. Unplug
unnecessary accessories plugged into the cigarette
lighter or the accessory power outlet. Turn off the
radio and all lamps that are not needed. This will
avoid sparks and help save both batteries. And it
could save the radio!
4. Open the hoods and locate the batteries. Find the
positive (+) and negative (−) terminal locations on
each vehicle. SeeEngine Compartment Overview
on page 5-12for more information on location.
{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.
5-37

{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.
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. 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.
5-38