2002 Chevy Cavalier Surge Tank Pressure Cap will not unscrew off.

What size motor?

If you can't see separate oil dipstick (usually has an yellow plastic handle), then your oil level dipstick is connected to oil filler cap. When you unscrew the oil cap you'll be able to see the dipstick and level meter.

remove the coolant reservior tanks cap and check with a coolant tester

Check Fuel Pressure with a gauge when it does run

Fuel Pump may be failing

Check that the Cooling Fans come on
& it isn't going into fail-safe, if that applies

Check coolant,not just look at recovery tank
Remove radiator cap & look

Have to have your car checked over once
or twice a year at a repair shop

Not just wait for break down maintainance

your tank is not venting properly. check along fuel line from tank to motor for a pressure relief valve to canister

Removal & Installation To Remove:
WARNING
To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is on or is still hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.
CAUTION
If the vehicle's coolant is low, drained out, or has repeatedly needed coolant or water added to the system, then the system should be completely flushed.

1. Before servicing the vehicle refer to the precautions at the beginning of this section.
2. Drain the cooling system.
3. Remove or disconnect the following:
   • Inlet hose from the radiator
   • Radiator outlet hose from the radiator
   • Lower fan shroud
   • Surge tank hose
   • Vent inlet hose from the radiator
   • Surge tank hose
   • Engine oil cooler lines from the radiator
   • Transmission oil cooler lines from the radiator Remove the radiator
     
     
   • Radiator bolts
   • Radiator from the vehicle

To Install:

1. Install or connect the following:
   • Radiator to the vehicle
   • Radiator bolts and tighten the bolts, Torque to: 18 ft-lbs (25 Nm)
   • Engine oil cooler lines to the radiator
   • Transmission oil cooler lines to the radiator
   • Radiator vent inlet hose to the radiator
   • Lower fan shroud
   • Outlet hose to the radiator
   • Inlet hose to the radiator
2. Fill the cooling system.
3. Test drive the vehicle to confirm the repairs.

ECOTec 2.4 Liter engine (and all ECOTec engine blocks in 4 cylinder sizes) have a cartridge type oil filter housing on the front of the block, driver's side of the vehicle.

The cap must be removed with a wrench, and the filter pulled out, then the new one put in. Now is usually a good time to replace the O-ring on the cap.

Replace the gas cap,(tight don't mean it seals)
check evap hoses coming from the gas tank and the hoses on the evap canister

Ours has a red cap, located on the transmission case under the brake master cylinder. You unscrew the cap use a funnel with a long hose and fill to the top.

yes. the hose closest to the cap over flows onto the ground. so the bottle will not bust if pressure is to high. if it is a v6 engine you have to bleed the air out of the system when refilling. follow the upper radiator hose to the engine there will be a bleeder screw open bleeder fill coolant bottle. engine off close screw start engine for a minute shut off engine and repeat several times until you can feel the heater inside the car starting to get warm. good luck.