GM Service Manual Online
For 1990-2009 cars only

When you decide it is safe to lift the hood, here is what you will see:

2.2L L4 Engine shown, 2.4L L4 and 2.0L L4 Supercharged Engines similar


Object Number: 1754563  Size: B3
  1. Electric Engine Cooling Fan

  2. Coolant Surge Tank with Pressure Cap

Caution: An electric engine cooling fan under the hood can start up even when the engine is not running and can cause injury. Keep hands, clothing, and tools away from any underhood electric fan.

If the coolant inside the coolant surge tank is boiling, do not do anything else until it cools down. The vehicle should be parked on a level surface.

The coolant level should be at the cold fill line. If it is not, you may have a leak at the radiator hoses, heater hoses, radiator, water pump, or somewhere else in the cooling system.

Caution: Heater and radiator hoses, and other engine parts, can be very hot. Do not touch them. If you do, you can be burned.

Do not 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 is not, your vehicle needs service. Turn off the engine.

Notice: Engine damage from running the engine without coolant is not covered by the warranty.

Notice: Using coolant other than DEX-COOL® can cause premature engine, heater core, or radiator corrosion. In addition, the engine coolant could require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by the vehicle warranty. Always use DEX-COOL® (silicate-free) coolant in the vehicle.

How to Add Coolant to the Coolant Surge Tank

If you have not found a problem yet, check to see if coolant is visible in the surge tank. If coolant is visible but the coolant level is not at the cold fill line, 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 Engine Coolant for more information.

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.

Caution: Adding only plain water to the cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. The vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, the engine could get too hot but you would not get the overheat warning. The 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. Use the recommended coolant and the proper coolant mixture.

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. Do not spill coolant on a hot engine.


    Object Number: 1225644  Size: B3
  1. You can remove the coolant surge tank pressure cap when the cooling system, including the upper radiator hose, is no longer hot. Turn the pressure cap slowly counterclockwise about one-quarter of a turn. 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.

  3. Object Number: 1225645  Size: B3
  4. Fill the coolant surge tank with the proper DEX-COOL® coolant mixture, to the cold fill line.
  5. 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.
  6. By this time, the coolant level inside the coolant surge tank may be lower. If the level is lower, add more of the proper DEX-COOL® coolant mixture to the coolant surge tank until the level reaches the cold fill line.

  7. Then replace the pressure cap. Be sure the pressure cap is hand-tight and fully seated.

Check the level in the surge tank when the cooling system has cooled down. If the coolant is not at the proper level, repeat Steps 1 through 3 and reinstall the pressure cap. If the coolant is not at the proper level when the system cools down again, see your retailer.

How to Add Coolant to the Intercooler System Fill Neck (2.0L L4 Supercharged Engine Only)

If you have not found a problem yet, turn the engine off and allow it to cool down, then check to see if coolant is visible within the horizontal tube section of the fill neck. If coolant is not visible, add a 50/50 mixture of clean, drinkable water and DEX-COOL® coolant to the fill neck. Be sure the Intercooler System, including the Intercooler System pressure cap, is cool before doing so. See Engine Coolant for more information.

Caution: Turning the Intercooler System pressure cap when the engine and intercooler are hot can allow steam and scalding liquids to blow out and burn you badly. Never turn the Intercooler System pressure cap, even a little, when the engine and intercooler are hot.

Caution: Adding only plain water to the cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. The vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, the engine could get too hot but you would not get the overheat warning. The 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. Use the recommended coolant and the proper coolant mixture.

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. Do not spill coolant on a hot engine.


    Object Number: 1441396  Size: B3
  1. You can remove the Intercooler System pressure cap when the Intercooler System, including the upper intercooler hoses, are no longer hot. Turn the pressure cap slowly counterclockwise about one-quarter of a turn. If you hear a hiss, wait for that to stop. This will allow any pressure still left to be vented.
  2. Then keep turning the pressure cap slowly, and remove it.
  3. Add the proper DEX-COOL® coolant mixture to the fill neck, until there is coolant visible in the horizontal tube section of the fill neck.
  4. With the Intercooler System pressure cap off, start the engine and let it run for a couple of minutes. Watch out for the engine cooling fan. Turn the engine off.
  5. By this time, the coolant level inside the fill neck may be lower. If the level drops to where coolant is no longer visible in the horizontal tube section of the fill neck, with the engine off add more of the DEX-COOL® coolant mixture to the fill neck until the level is again visible in the horizontal tube section.

  6. Then replace the pressure cap. Be sure the pressure cap is hand-tight and fully seated.

If the coolant is not at the proper level when the system cools down again, see your retailer.