engine CHEVROLET CAVALIER 2001 3.G Repair Manual

5-14
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 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.
See ªEngine Compartment Overviewº in the Index for
more information on location.

5-15
CAUTION:
Adding only plain water to your cooling system
can be dangerous. Plain water, or some other
liquid like 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 wouldn't
get the overheat warning. Your engine could
catch fire 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.
So use the recommended coolant.
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. Don't spill coolant on a hot engine.

5-17
3. Then fill the coolant surge tank with the proper
mixture, to the FULL COLD mark.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, add
more of the proper mixture to the coolant surge tank
until the level reaches the FULL COLD mark.

5-19
Changing a Flat Tire
If a tire goes flat, avoid further tire and wheel damage
by driving slowly to a level place. Turn on your hazard
warning flashers.
CAUTION:
Changing a tire can cause an injury. The vehicle
can slip off the jack and roll over you or other
people. You and they could be badly injured.
Find a level place to change your tire. To help
prevent the vehicle from moving:
1. Set the parking brake firmly.
2. Put an automatic transaxle shift lever in
PARK (P), or shift a manual transaxle to
FIRST (1) or REVERSE (R).
3. Turn off the engine.
To be even more certain the vehicle won't move,
you can put blocks at the front and rear of the
tire farthest away from the one being changed.
That would be the tire on the other side of the
vehicle, at the opposite end.
The following steps will tell you how to use the jack and
change a tire.

5-30
If You're Stuck: In Sand, Mud,
Ice or Snow
In order to free your vehicle when it is stuck, you will
need to spin the wheels, but you don't want to spin your
wheels too fast. The method known as ªrockingº can
help you get out when you're stuck, but you must
use caution.
CAUTION:
If you let your tires spin at high speed, they can
explode, and you or others could be injured. And,
the transaxle or other parts of the vehicle can
overheat. That could cause an engine
compartment fire or other damage. When you're
stuck, spin the wheels as little as possible. Don't
spin the wheels above 35 mph (55 km/h) as shown
on the speedometer.
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 transaxle back and
forth, you can destroy your transaxle.
For information about using tire chains on your vehicle,
see ªTire Chainsº in the Index.
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 transaxle, 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 transaxle is in gear. By slowly spinning your
wheels in the forward and reverse directions, you will
cause a rocking motion that may free your vehicle. If
that doesn't get you out after a few tries, you may need
to be towed out. If you do need to be towed out, see
ªTowing Your Vehicleº in the Index.

6-
6-1
Section 6 Service and Appearance Care
Here you will find information about the care of your vehicle. 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 appearance care.
6
-2 Service
6
-3 Fuel
6
-5 Fuels in Foreign Countries
6
-5 Filling Your Tank
6
-7 Filling a Portable Fuel Container
6
-8 Checking Things Under the Hood
6
-12 Engine Oil
6
-17 Engine Air Cleaner/Filter
6
-19 Automatic Transaxle Fluid
(Three
-Speed Only)
6
-22 Automatic Transaxle Fluid
(Four
-Speed Only)
6
-23 Manual Transaxle Fluid
6
-23 Hydraulic Clutch
6
-24 Engine Coolant
6
-27 Surge Tank Pressure Cap6
-28 Power Steering Fluid
6
-29 Windshield Washer Fluid
6
-30 Brakes
6
-34 Battery
6
-34 Bulb Replacement
6
-42 Tires
6
-51 Appearance Care
6
-51 Cleaning the Inside of Your Vehicle
6
-53 Care of Safety Belts
6
-54 Cleaning the Outside of Your Vehicle
6
-59 Vehicle Identification Number (VIN)
6
-60 Electrical System
6
-64 Replacement Bulbs
6
-65 Capacities and Specifications
6
-66 Normal Maintenance Replacement Parts

6-3
CAUTION:
You can be injured and your vehicle could be
damaged if you try to do service work on a
vehicle without knowing enough about it.

Be sure you have sufficient knowledge,
experience, the proper replacement parts
and tools before you attempt any vehicle
maintenance task.

Be sure to use the proper nuts, bolts and
other fasteners. ªEnglishº and ªmetricº
fasteners can be easily confused. If you use
the wrong fasteners, parts can later break
or fall off. You could be hurt.
Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle can
affect the airflow around it. This may cause wind noise
and affect windshield washer performance. Check with
your dealer before adding equipment to the outside of
your vehicle.
Fuel
Use regular unleaded gasoline rated at 87 octane or
higher. It is recommended that the gasoline meet
specifications which were developed by the American
Automobile Manufacturers Association (AAMA) and
endorsed by the Canadian Motor Vehicle Manufacturers
Association for better vehicle performance and engine
protection. Gasolines meeting the AAMA specification
could provide improved driveability and emission control
system performance compared to other gasolines.
In Canada, look for the
ªAuto Makers' Choiceº
label on the fuel pump.
Canada Only
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.

6-4
If you're using fuel rated at 87 octane or higher and
you 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.
If your vehicle is certified to meet California Emission
Standards (indicated on the underhood emission control
label), it is designed to operate on fuels that meet
California specifications. If such fuels are not available
in states adopting California emissions standards,
your vehicle will operate satisfactorily on fuels meeting
federal specifications, but emission control system
performance may be affected. The malfunction indicator
lamp on your instrument panel may turn on and/or your
vehicle may fail a smog
-check test. See ªMalfunction
Indicator Lampº in the Index. If this occurs, return
to your authorized Chevrolet dealer for diagnosis to
determine the cause of failure. In the event it is
determined that the cause of the condition is the type of
fuels used, repairs may not be covered by your warranty.
Some gasolines that are not reformulated for low
emissions may contain an octane
-enhancing additive
called methylcyclopentadienyl manganese tricarbonyl
(MMT); ask your service station operator whether or
not the fuel contains MMT. General Motors does notrecommend the use of such gasolines. If fuels containing
MMT are used, spark plug life may be reduced and your
emission control system performance may be affected.
The malfunction indicator lamp on your instrument
panel may turn on. If this occurs, return to your
authorized Chevrolet dealer for service.
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent deposits from forming in your engine and fuel
system, allowing your emission control system to
function properly. Therefore, you should not have
to add anything to the fuel. In addition, gasolines
containing oxygenates, such as ethers and ethanol, and
reformulated gasolines may be available in your area to
contribute to clean air. General Motors recommends that
you use these gasolines, particularly if they comply with
the specifications described earlier.
NOTICE:
Your vehicle was not designed for fuel that
contains methanol. 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.

6-8
Checking Things Under the Hood
CAUTION:
An electric fan under the hood can start up and
injure you even when the engine is not running.
Keep hands, clothing and tools away from any
underhood electric fan.
CAUTION:
Things that burn can get on hot engine parts and
start a fire. These include liquids like gasoline,
oil, coolant, brake fluid, windshield washer and
other fluids, and plastic or rubber. You or others
could be burned. Be careful not to drop or spill
things that will burn onto a hot engine.
Hood Release
To open the hood, first pull
the handle located inside the
vehicle on the driver's side
under the instrument panel.

6-10 Engine Compartment Overview
When you open the hood on the 2.2L L4 engine (Code 4), you'll see:
A. Coolant Surge Tank
B. Power Steering Fluid Reservoir
C. Engine Oil Fill Cap/Dipstick
D. Brake Fluid ReservoirE. Hydraulic Clutch Fluid
Reservoir (If Equipped)
F. Automatic Transaxle Fluid
Dipstick (If Equipped)G. Engine Air Cleaner/Filter
H. Battery
I. Windshield Washer
Fluid Reservoir