engine CHEVROLET MALIBU 2000 5.G Manual PDF

6-18
NOTICE:
We recommend you use only fluid labeled
DEXRON-III, because fluid with that label is
made especially for your automatic transaxle.
Damage caused by fluid other than
DEXRON
-III is not covered by your new
vehicle warranty.
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.

6-19 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 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:
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.

6-20 Checking Coolant
The surge tank is located on the passenger's side of the
engine compartment.
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 or slightly higher.
If the low coolant light
comes on and stays on, it
means you're low on
engine coolant.
Adding Coolant
If you need more coolant, add the proper DEX
-COOL

coolant mixture at the surge tank, but only when the
engine is cool.

6-21
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.
When replacing the pressure cap, make sure it
is hand
-tight.
Surge Tank Pressure Cap
NOTICE:
Your pressure cap is a 15 psi (105 kPa)
pressure
-type cap and must be tightly installed to
prevent coolant loss and possible engine damage
from overheating.
When you replace your surge tank pressure cap, a GM
cap is recommended.
Power Steering Fluid
When to Check Power Steering Fluid
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.

6-22 How to Check Power Steering Fluid
Turn the key off, let the engine compartment cool down,
wipe the cap and the top of the reservoir clean, then
unscrew the cap and wipe the dipstick with a clean rag.
Replace the cap and completely tighten it. Then remove
the cap again and look at the fluid level on the dipstick.
The level should be at the FULL COLD mark. If
necessary, add only enough fluid to bring the level up to
the mark.
What to Use
To determine what kind of fluid to use, see
ªRecommended Fluids and Lubricantsº in the Index.
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.
Adding Washer Fluid
Open the cap labeled
WASHER FLUID ONLY.
Add washer fluid until the
tank is full.

6-23
NOTICE:

When using concentrated washer fluid,
follow the manufacturer's instructions for
adding water.

Don't mix water with ready
-to-use washer
fluid. Water can cause the solution to freeze
and damage your washer fluid tank and
other parts of the washer system. Also,
water doesn't clean as well as washer fluid.

Fill your washer fluid tank only
three
-quarters full when it's very cold.
This allows for expansion if freezing occurs,
which could damage the tank if it is
completely full.

Don't use engine coolant (antifreeze) in
your windshield washer. It can damage
your washer system and paint.
Brakes
Brake Fluid
Your brake master cylinder reservoir is on the driver's
side of the engine compartment. It is filled with DOT
-3
brake fluid.

6-24
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 won't work well, or won't work
at all.
So, it isn't a good idea to ªtop offº your brake fluid.
Adding brake fluid won't correct a leak. If you add fluid
when your linings are worn, then you'll 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 fluid, it can spill on the
engine. The fluid will burn if the engine is hot
enough. You or others could be burned, and your
vehicle could be damaged. Add brake fluid only
when work is done on the brake hydraulic system.
United States Canada
When your brake fluid falls to a low level, your brake
warning light will come on. See ªBrake System Warning
Lightº in the Index.
What to Add
When you do need brake fluid, use only DOT
-3 brake
fluid. Use new brake fluid from a sealed container only.
Refer to ªRecommended Fluids and Lubricantsº in the
Maintenance Schedule.
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.

6-25
CAUTION:
With the wrong kind of fluid 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 fluid.
NOTICE:

Using the wrong fluid 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'll have to be
replaced. Don't let someone put in the
wrong kind of fluid.

If you spill brake fluid on your vehicle's
painted surfaces, the paint finish can be
damaged. Be careful not to spill brake fluid
on your vehicle. If you do, wash it off
immediately. See ªAppearance Careº in
the Index.
Brake Wear
Your vehicle has front disc brakes and rear drum brakes.
Disc brake pads have built
-in wear indicators that make a
high
-pitched warning sound when the brake pads are worn
and new pads are needed. The sound may come and go or
be heard all the time your vehicle is moving (except when
you are pushing on the brake pedal firmly).
CAUTION:
The brake wear warning sound means that soon
your brakes won't work well. That could lead to
an accident. When you hear the brake wear
warning sound, have your vehicle serviced.
NOTICE:
Continuing to drive with worn-out brake pads
could result in costly brake repair.

6-26
Some driving conditions or climates may cause a brake
squeal when the brakes are first applied or lightly
applied. This does not mean something is wrong with
your brakes.
Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly torque wheel nuts in the
proper sequence to GM specifications.
Your rear drum brakes don't have wear indicators, but if
you ever hear a rear brake rubbing noise, have the rear
brake linings inspected immediately. Also, the rear
brake drums should be removed and inspected each time
the tires are removed for rotation or changing. When
you have the front brake pads replaced, have the rear
brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.
See ªBrake System Inspectionº in Section 7 of this
manual under Part C ªPeriodic Maintenance
Inspections.º
Brake Pedal Travel
See your dealer if the brake pedal does not return to
normal height, or if there is a rapid increase in pedal
travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a moderate brake stop, your disc
brakes adjust for wear. If you rarely make a moderate or
heavier stop, then your brakes might not adjust correctly. If
you drive in that way, then
-- very carefully -- make a few
moderate brake stops about every 1,000 miles (1 600 km),
so your brakes will adjust properly.
If your brake pedal goes down farther than normal, your
rear drum brakes may need adjustment. Adjust them by
pumping the brake pedal repeatedly while the engine is
running with the shift lever in PARK (P).
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
have to have new ones put in
-- be sure you get new
approved GM replacement parts. If you don't, 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've come to expect can change in many other ways if
someone puts in the wrong replacement brake parts.

6-28 Headlamps
1. With the hood open and the engine off, pull the
fastener out of the plastic splash shield covering the
top of the headlamp assembly and remove it.
2. Carefully pull directly up on the two latches.
3. Remove the lamp assembly from the vehicle by
pulling forward. Use care not to scratch the vehicle
with the lamp or the lamp with the fender.
4. Unclip the wiring harness and twist the bulb less
than a one
-quarter turn counterclockwise and
remove. Gently wiggle the bulb from the socket.