2002 CHEVROLET CAVALIER engine

5-13
2.4L L4 (LD9) Engine
A. Coolant Surge Tank with Pressure Cap
B. Electric Engine Cooling Fan
CAUTION:
An electric engine cooling fan under the hood can
start up even when the engine is not running and
can injure you. Keep hands, clothing and tools
away from any underhood electric fan.

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.

5-19
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.

5-21
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.

5-32
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
-6 Filling Your Tank
6
-8 Filling a Portable Fuel Container
6
-9 Checking Things Under the Hood
6
-14 Engine Oil
6
-21 Engine Air Cleaner/Filter
6
-23 Automatic Transaxle Fluid
6
-24 Manual Transaxle Fluid
6
-24 Hydraulic Clutch
6
-25 Engine Coolant
6
-28 Surge Tank Pressure Cap
6
-29 Power Steering Fluid6
-29 Windshield Washer Fluid
6
-31 Brakes
6
-35 Battery
6
-36 Bulb Replacement
6
-43 Tires
6
-51 Appearance Care
6
-52 Cleaning the Inside of Your Vehicle
6
-54 Care of Safety Belts
6
-55 Cleaning the Outside of Your Vehicle
6
-60 Vehicle Identification Number (VIN)
6
-61 Electrical System
6
-66 Replacement Bulbs
6
-66 Capacities and Specifications
6
-67 Normal Maintenance Replacement Parts