radiator CHEVROLET CAVALIER 2002 3.G Owners Manual

5-14
If the coolant inside the coolant surge tank is boiling,
don't do anything else until it cools down. The vehicle
should be parked on a level surface.
The coolant level should be
at the FULL COLD mark.
If it isn't, you may have a
leak at the pressure cap or
in the radiator hoses, heater
hoses, radiator, water pump
or somewhere in the
cooling system.
CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Don't touch them.
If you do, you can be burned.
Don't run the engine if there is a leak. If you run
the engine, it could lose all coolant. That could
cause an engine fire, and you could be burned.
Get any leak fixed 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 isn't, your vehicle needs service.

5-15
NOTICE:
Engine damage from running your engine
without coolant isn't covered by your warranty.
NOTICE:
When adding coolant, it is important that you
use only DEX
-COOL
(silicate-free) coolant.
If coolant other than DEX-COOL is added to
the system, premature engine, heater core or
radiator corrosion may result. In addition, the
engine coolant will require change sooner
-- at
30,000 miles (50 000 km) or 24 months,
whichever occurs first. Damage caused by the
use of coolant other than DEX
-COOL
is not
covered by your new vehicle warranty.
How to Add Coolant to the Coolant
Surge Tank
NOTICE:
This vehicle has a specific coolant fill procedure.
Failure to follow this procedure could cause your
engine to overheat and be severely damaged.
If you haven't found a problem yet, check to see if
coolant is visible in the surge tank. If coolant is visible
but the coolant level isn't at the FULL COLD mark,
add a 50/50 mixture of clean, 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. See ªEngine
Coolantº in the Index for more information.

5-17
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 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.

5-18
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.

5-19
3. Then 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 fan.
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.

6-25
Engine Coolant
The cooling system in your vehicle is filled with
DEX
-COOL engine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs first, if you add only
DEX
-COOL extended life coolant.
The following explains your cooling system and how to
add coolant when it is low. If you have a problem with
engine overheating, see ªEngine Overheatingº in
the Index.
A 50/50 mixture of clean, drinkable water and
DEX
-COOL coolant will:

Give freezing protection down to
-34F (-37C).

Give boiling protection up to 265F (129C).

Protect against rust and corrosion.

Help keep the proper engine temperature.

Let the warning lights and gages work as
they should.
NOTICE:
When adding coolant, it is important that you use
only DEX
-COOL (silicate-free) coolant.
If coolant other than DEX-COOL is added to
the system, premature engine, heater core or
radiator corrosion may result. In addition, the
engine coolant will require change sooner
-- at
30,000 miles (50 000 km) or 24 months,
whichever occurs first. Damage caused by the
use of coolant other than DEX
-COOL is not
covered by your new vehicle warranty.

6-26 What to Use
Use a mixture of one-half clean, drinkable water and
one
-half DEX-COOL
coolant which won't damage
aluminum parts. If you use this coolant mixture, you
don't need to add anything else.
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 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:
If you use an improper coolant mixture, your
engine could overheat and be badly damaged.
The repair cost wouldn't be covered by your
warranty. Too much water in the mixture can
freeze and crack the engine, radiator, heater core
and other parts.
If you have to add coolant more than four times a year,
have your dealer check your cooling system.
NOTICE:
If you use the proper coolant, you don't have to
add extra inhibitors or additives which claim to
improve the system. These can be harmful.

6-27 Checking Coolant
The surge tank is located
on the passenger's side of
the engine compartment.
See ªEngine Compartment
Overviewº in the Index
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 at the FULL
COLD mark.
If the low coolant light
comes on and stays on,
it means you're low on
engine coolant.
See ªLow Coolant Lightº in
the Index.

Short Trip/City Scheduled Maintenance
7-20
100,000 Miles (166 000 km)

Inspect spark plug wires (2.2L Code 4 L4 engine only).
An Emission Control Service.

Replace spark plugs.
An Emission Control Service.

Change automatic transaxle fluid and filter if the vehicle is mainly driven
under one or more of these conditions:
± In heavy city traffic where the outside temperature regularly
reaches 90
F (32
C) or higher.
± In hilly or mountainous terrain.
± When doing frequent trailer towing.
± Uses such as found in taxi, police or delivery service.
If you do not use your vehicle under any of these conditions, the fluid and
filter do not require changing.
Manual transaxle fluid doesn't require change.
150,000 Miles (240 000 km)
Drain, flush and refill cooling system (or every 60 months since last service,
whichever occurs first). See ªEngine Coolantº in the Index for what to use.
Inspect hoses. Clean radiator, condenser, pressure cap and neck. Pressure test
cooling system and pressure cap.
An Emission Control Service.
ACTUAL
SERVICED BY:MILEAGE
DATE
ACTUAL
SERVICED BY:MILEAGE
DATE

Long Trip/Highway Scheduled Maintenance
7-29
100,000 Miles (166 000 km)

Inspect spark plug wires (2.2L Code 4 L4 engine only).
An Emission Control Service.

Replace spark plugs.
An Emission Control Service.

Change automatic transaxle fluid and filter if the vehicle is mainly driven
under one or more of these conditions:
± In heavy city traffic where the outside temperature regularly
reaches 90
F (32
C) or higher.
± In hilly or mountainous terrain.
± When doing frequent trailer towing.
± Uses such as found in taxi, police or delivery service.
If you do not use your vehicle under any of these conditions, the fluid and
filter do not require changing.
Manual transaxle fluid doesn't require change.
150,000 Miles (240 000 km)
Drain, flush and refill cooling system (or every 60 months since last service,
whichever occurs first). See ªEngine Coolantº in the Index for what to use.
Inspect hoses. Clean radiator, condenser, pressure cap and neck. Pressure test
the cooling system and pressure cap.
An Emission Control Service.
ACTUAL
SERVICED BY:MILEAGE
DATE
ACTUAL
SERVICED BY:MILEAGE
DATE