1999 CHEVROLET CAVALIER radiator cap

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5-13
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.
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.
How to Add Coolant to the Coolant
Surge Tank
If you haven't found a problem yet, 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.)

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5-16
1. 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.

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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.

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6-25 How to Check
You do not need to check the fluid level unless you
suspect a clutch problem. To check the fluid level, take
the cap off. If the fluid reaches the step inside the
reservoir, the fluid level is correct.
Surge Tank Pressure Cap
NOTICE:
Your surge tank 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.
Thermostat
Engine coolant temperature is controlled by a thermostat
in the engine coolant system. The thermostat stops the
flow of coolant through the radiator until the coolant
reaches a preset temperature.
When you replace your thermostat, an ACDelco


thermostat is recommended.
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.

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6-28
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 light comes on and
stays on, it means you're
low on engine coolant.
See ªLow Coolant Lightº in
the Index.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.
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.

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

Inspect spark plug wires (except 2.4L Code T L4 engine).
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
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7-29
100,000 Miles (166 000 km)

Inspect spark plug wires (except 2.4L Code T L4 engine).
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

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7-35
Part C: Periodic Maintenance
Inspections
Listed in this part are inspections and services which
should be performed at least twice a year (for instance,
each spring and fall). You should let your dealer's
service department or other qualified service center do
these jobs. Make sure any necessary repairs are
completed at once.
Proper procedures to perform these services may be
found in a service manual. See ªService and Owner
Publicationsº in the Index.
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection
Inspect the front and rear suspension and steering
system for damaged, loose or missing parts, signs of
wear or lack of lubrication. Inspect the power steering
lines and hoses for proper hook
-up, binding, leaks,
cracks, chafing, etc. Clean and then inspect the drive
axle boot seals for damage, tears or leakage. Replace
seals if necessary.
Exhaust System Inspection
Inspect the complete exhaust system. Inspect the body
near the exhaust system. Look for broken, damaged,
missing or out
-of-position parts as well as open seams,
holes, loose connections or other conditions which could
cause a heat build
-up in the floor pan or could let
exhaust fumes into the vehicle. See ªEngine Exhaustº in
the Index.
Engine Cooling System Inspection
Inspect the hoses and have them replaced if they are
cracked, swollen or deteriorated. Inspect all pipes,
fittings and clamps; replace as needed. Clean the outside
of the radiator and air conditioning condenser. To help
ensure proper operation, a pressure test of the cooling
system and pressure cap is recommended at least once
a year.