SOURCE: 1999 Pontiac Grand Am Overheating
I had the same problem on my 1999 Pontiac GA 3.4 litre. Replaced a bunch of stuff. It just kept pushing the coolant out the overflow once the temp got to 200 + like to drove me nuts. Ended up being that reservoir. If you measure the O.D. of the cap(brand new cap) and the I.D. of the reservoir filler neck there is no way it will seal(even tried to fit a different type cap,no luck). The system has to be able to build pressure or the coolant will boil out at 212. Causing the coolant to be pushed out the reservoir. Why? you say or How? did the filler neck increase in size. I dont know but GM has write ups about this problem. They say sand it with a piece of sandpaper to smooth it. Maybe someone sanded it way to much?? Around $40 bucks and I was on my way. Hope this helps someone.
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