radiator cap CHEVROLET AVEO 2002 Service Repair Manual

Checking Coolant
The engine coolant surge tank is located in the rear
of the engine compartment on the driver’s side.
SeeEngine Compartment Overview on page 5-14
for more information on location.
{CAUTION:
Turning the surge tank pressure cap when the
engine and radiator are hot can allow steam
and scalding liquids to blow out and burn you
badly. Never turn the surge tank pressure
cap — even a little — when the engine and
radiator are hot.
The vehicle must be on a level surface. When your
engine is cold, the coolant level should be between the
MAX (A) and MIN (B) marks on the coolant surge
tank. The level rises at engine operation temperature
and drops again when the engine cools down.
5-24

The coolant level should be between the MIN (B) and
MAX (A) marks on the coolant surge tank when the
engine is cool. 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.
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 fan is running.
If the engine is overheating, the fan should be running.
If it is not, your vehicle needs service.
Notice:Engine damage from running your engine
without coolant is not covered by your warranty.
5-29

{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. Park the vehicle on a level surface.
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.
5-32

3. Fill the coolant surge tank with the proper mixture
to the MAX (A) mark on the coolant surge tank.
Wait about five minutes, then check to see if
the level is below the MAX (A) mark. If the level is
below the MAX (A) mark, add additional coolant
to bring the level up to the MAX (A) mark. Repeat
this procedure until the level remains constant
at the MAX (A) 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 (A) mark, add more of the proper
mixture to the coolant surge tank until the level
reaches the MAX (A) mark.
5. Then replace the pressure cap. Be sure the
pressure cap is hand-tight and fully seated.
See your dealer, if necessary.
5-33

Headlamps
1. Open the hood.
2. Disconnect the wiring harness connector from the
rear of the bulb.
3. Remove the headlamp cap.
4. Release the spring that retains the bulb.
5. Remove the old bulb.
6. Install the new bulb.
7. Install the bulb retaining spring.
8. Reverse Steps 1 through 3 to install the headlamp
assembly. Then, check the lamps.
Front Turn Signal and Parking Lamps
1. Open the hood.
2. Remove the five screws and the radiator grille.
3. Remove the three bolts and the headlamp
assembly.
4. Disconnect the wiring harness connector from the
rear of the bulb.
5. Turn the front turn signal bulb socket
counterclockwise.
5-46

❑Replace spark plugs.An Emission Control Service.
❑Inspect drive belts.
❑Inspect timing belt.
❑Drain, flush and refill cooling system. SeeEngine
Coolant on page 5-23for what to use. Inspect
hoses. Clean radiator, condenser, pressure cap
and neck. Pressure test the cooling system and
pressure cap.An Emission Control Service.
❑Inspect EVAP canister, vapor lines and solenoid valve
filter.An Emission Control Service. (See footnote †.)
❑Inspect PCV system.An Emission Control Service.
(See footnote †.)
❑Change brake/clutch fluid (or every 24 months,
whichever occurs first).
33,000 Miles (55 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
36,000 Miles (60 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation
on page 5-60for proper rotation pattern and
additional information.(See footnote +.)
39,000 Miles (65 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
42,000 Miles (70 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation
on page 5-60for proper rotation pattern and
additional information.(See footnote +.)
6-9

❑Replace spark plugs.An Emission Control Service.
❑Replace spark plug wires.An Emission Control
Service.
❑Inspect drive belts.
❑Replace timing belt.
❑Drain, flush and refill cooling system. SeeEngine
Coolant on page 5-23for what to use. Inspect
hoses. Clean radiator, condenser, pressure cap
and neck. Pressure test the cooling system
and pressure cap.An Emission Control Service.
❑Inspect EVAP canister, vapor lines and solenoid valve
filter.An Emission Control Service. (See footnote †.)
❑Inspect PCV system.An Emission Control Service.
(See footnote †.)
❑Change brake/clutch fluid (or every 24 months,
whichever occurs first).63,000 Miles (105 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
66,000 Miles (110 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation
on page 5-60for proper rotation pattern and
additional information.(See footnote +.)
69,000 Miles (115 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
72,000 Miles (120 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation
on page 5-60for proper rotation pattern and
additional information.(See footnote +.)
6-11

❑Replace spark plugs.An Emission Control Service.
❑Replace fuel filter.An Emission Control Service.
(See footnote †.)
❑Inspect drive belts.
❑Inspect timing belt.
❑Drain, flush and refill cooling system. SeeEngine
Coolant on page 5-23for what to use. Inspect
hoses. Clean radiator, condenser, pressure cap
and neck. Pressure test the cooling system
and pressure cap.An Emission Control Service.
❑Inspect EVAP canister, vapor lines and solenoid valve
filter.An Emission Control Service. (See footnote †.)
❑Inspect PCV system.An Emission Control Service.
(See footnote †.)
❑Change brake/clutch fluid (or every 24 months,
whichever occurs first).93,000 Miles (155 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
96,000 Miles (160 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation
on page 5-60for proper rotation pattern and
additional information.(See footnote +.)
99,000 Miles (165 000 km)
❑Change engine oil and filter (or every 3 months,
whichever occurs first).An Emission Control Service.
6-13

22,500 Miles (37 500 km)
❑Change engine oil and filter (or every 12 months,
whichever occurs first).An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-60for proper rotation pattern and additional
information.(See footnote +.)
30,000 Miles (50 000 km)
❑Change engine oil and filter (or every 12 months,
whichever occurs first).An Emission Control Service.
❑Replace passenger compartment air filter. If you drive
regularly under dusty conditions, the filter may require
replacement more often.
❑Replace engine air cleaner filter. SeeEngine Air
Cleaner/Filter on page 5-20for more information.
An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-60for proper rotation pattern and additional
information.(See footnote +.)
❑Replace spark plugs.An Emission Control Service.
❑Inspect drive belts.❑Inspect timing belt.
❑Drain, flush and refill cooling system. SeeEngine
Coolant on page 5-23for what to use. Inspect hoses.
Clean radiator, condenser, pressure cap and neck.
Pressure test the cooling system and pressure cap.
An Emission Control Service.
❑Inspect EVAP canister, vapor lines and solenoid valve
filter.An Emission Control Service. (See footnote †.)
❑Inspect PCV system.An Emission Control Service.
(See footnote †.)
❑Change brake/clutch fluid (or every 24 months,
whichever occurs first).
37,500 Miles (62 500 km)
❑Change engine oil and filter (or every 12 months,
whichever occurs first).An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-60for proper rotation pattern and additional
information.(See footnote +.)
6-15

❑Drain, flush and refill cooling system. SeeEngine
Coolant on page 5-23for what to use. Inspect hoses.
Clean radiator, condenser, pressure cap
and neck. Pressure test the cooling system and
pressure cap.An Emission Control Service.
❑Inspect EVAP canister, vapor lines and solenoid valve
filter.An Emission Control Service. (See footnote †.)
❑Inspect PCV system.An Emission Control Service.
(See footnote †.)
❑Change brake/clutch fluid (or every 24 months,
whichever occurs first).
67,500 Miles (112 500 km)
❑Change engine oil and filter (or every 12 months,
whichever occurs first).An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-60for proper rotation pattern and additional
information.(See footnote +.)
75,000 Miles (125 000 km)
❑Change engine oil and filter (or every 12 months,
whichever occurs first).An Emission Control Service.
❑Replace passenger compartment air filter. If you drive
regularly under dusty conditions, the filter may require
replacement more often.
❑Inspect engine air cleaner filter. SeeEngine Air
Cleaner/Filter on page 5-20for more information.
An Emission Control Service. (See footnote †.)
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-60for proper rotation pattern and additional
information.(See footnote +.)
❑Inspect drive belts.
82,500 Miles (137 500 km)
❑Change engine oil and filter (or every 12 months,
whichever occurs first).An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-60for proper rotation pattern and additional
information.(See footnote +.)
6-17