engine CHEVROLET ASTRO CARGO VAN 2005 2.G Service Manual

Tow/Haul Mode
Tow/haul is designed to assist while your vehicle is
pulling a large or heavy load or trailer. Tow/haul is most
useful while pulling such a load in rolling terrain, in
stop-and-go traffic, or when you need improved
low-speed control, such as when parking. The purpose
of the tow/haul mode is to:
Reduce the frequency and improve the predictability
of transmission shifts,
provide the same solid shift feel when pulling a
heavy load as when the vehicle is unloaded, and
improve control of vehicle speed while requiring less
throttle pedal activity.
Press the button on the end of the shift lever to turn
tow/haul mode on and off. While activated, the indicator
light on the instrument panel will be on. Tow/haul
mode will turn off automatically when the ignition is
turned off. SeeTow/Haul Mode Light on page 3-36.Tow/haul is most effective when the vehicle and trailer
combined weight is at least 75 percent of the vehicle’s
Gross Combined Weight Rating (GCWR). See “Weight
of the Trailer” later in this section.
Driving with tow/haul activated without a heavy load will
cause reduced fuel economy and unpleasant engine
and transmission driving characteristics, but will
not cause damage.
Weight of the Trailer
How heavy can a trailer safely be?
It depends on how you plan to use your rig. For
example, speed, altitude, road grades, outside
temperature and how much your vehicle is used to pull
a trailer are all important. And, it can also depend
on any special equipment that you have on your vehicle.
The following chart shows how much your trailer can
weigh, based upon your vehicle model and options.
4-36

If you’ll be pulling a trailer that, when loaded, will weigh
more than 2,000 lbs (900 kg), be sure to use a
properly mounted, weight-distributing hitch and sway
control of the proper size. This equipment is very
important for proper vehicle loading and good handling
when you’re driving. You should always use a sway
control if your trailer will weigh more than these limits.
You can ask a hitch dealer about sway controls.
Will you have to make any holes in the body of your
vehicle when you install a trailer hitch?
If you’re using the wiring provided with the
factory-installed trailering package, you should not need
to make any holes in the body of your vehicle.
However, if you have an aftermarket hitch installed, you
may need to make holes in the body.
If you do, then be sure to seal the holes later when you
remove the hitch. If you don’t seal them, deadly
carbon monoxide (CO) from your exhaust can get into
your vehicle as well as dirt and water. See “Carbon
Monoxide” underEngine Exhaust on page 2-26.
Safety Chains
You should always attach chains between your vehicle
and your trailer. Cross the safety chains under the tongue
of the trailer to help prevent the tongue from contacting
the road if it becomes separated from the hitch.
Instructions about safety chains may be provided by the
hitch manufacturer or by the trailer manufacturer. Followthe manufacturer’s recommendation for attaching safety
chains and do not attach them to the bumper. Always
leave just enough slack so you can turn with your rig.
Never allow safety chains to drag on the ground.
Trailer Brakes
If your trailer weighs more than 1,000 lbs (450 kg)
loaded, then it needs its own brakes — and they must
be adequate. Be sure to read and follow the instructions
for the trailer brakes so you’ll be able to install, adjust
and maintain them properly.
Your trailer brake system can tap into your vehicle’s
hydraulic brake system, except:
Don’t tap into your vehicle’s brake system if the
trailer’s brake system will use more than 0.02 cubic
inch (0.3 cc) of uid from your vehicle’s master
cylinder. If it does, both braking systems won’t work
well. You could even lose your brakes.
Will the trailer parts take 3,000 psi (20 650 kPa) of
pressure? If not, the trailer brake system must not
be used with your vehicle.
If everything checks out this far, then make the
brake uid tap at the port on the master cylinder that
sends uid to the rear brakes. But don’t use
copper tubing for this. If you do, it will bend and
nally break off. Use steel brake tubing.
4-40

Driving with a Trailer
{CAUTION:
If you have a rear-most window open and you
pull a trailer with your vehicle, carbon
monoxide (CO) could come into your vehicle.
You can not see or smell CO. It can cause
unconsciousness or death. SeeEngine
Exhaust on page 2-26. To maximize your safety
when towing a trailer:
Have your exhaust system inspected for
leaks, and make necessary repairs before
starting on your trip.
Keep the rear-most windows closed.
If exhaust does come into your vehicle
through a window in the rear or another
opening, drive with your front, main
heating or cooling system on and with the
fan on any speed. This will bring fresh,
outside air into your vehicle. Do not use
the climate control setting for maximum air
because it only recirculates the air inside
your vehicle. See Climate Control System
in the Index.Towing a trailer requires a certain amount of experience.
Before setting out for the open road, you’ll want to get
to know your rig. Acquaint yourself with the feel of
handling and braking with the added weight of the trailer.
And always keep in mind that the vehicle you are
driving is now a good deal longer and not nearly as
responsive as your vehicle is by itself.
Before you start, check the trailer hitch and platform
(and attachments), safety chains, electrical connector,
lamps, tires and mirror adjustment. If the trailer has
electric brakes, start your vehicle and trailer moving and
then apply the trailer brake controller by hand to be
sure the brakes are working. This lets you check your
electrical connection at the same time.
During your trip, check occasionally to be sure that the
load is secure, and that the lamps and any trailer
brakes are still working.Following Distance
Stay at least twice as far behind the vehicle ahead as
you would when driving your vehicle without a trailer.
This can help you avoid situations that require
heavy braking and sudden turns.
4-41

When towing at high altitude on steep uphill grades,
consider the following: Engine coolant will boil at a lower
temperature than at normal altitudes. If you turn your
engine off immediately after towing at high altitude
on steep uphill grades, your vehicle may show signs
similar to engine overheating. To avoid this, let the
engine run while parked (preferably on level ground)
with the transmission in PARK (P) for a few minutes
before turning the engine off. If you do get the overheat
warning, seeEngine Overheating on page 5-28.
Parking on Hills
{CAUTION:
You really should not park your vehicle, with a
trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.
But if you ever have to park your rig on a hill, here’s
how to do it:
1. Apply your regular brakes, but don’t shift into
PARK (P) yet.2. Have someone place chocks under the trailer
wheels.
3. When the wheel chocks are in place, release the
regular brakes until the chocks absorb the load.
4. Reapply the regular brakes. Then apply your
parking brake, and shift to PARK (P).
5. Release the regular brakes.
When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you:
start your engine,
shift into a gear, and
release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the
chocks.
4-43

Maintenance When Trailer Towing
Your vehicle will need service more often when you’re
pulling a trailer. See the Maintenance Schedule for more
on this. Things that are especially important in trailer
operation are automatic transmission uid (don’t overll),
engine oil, axle lubricant, belt, cooling system and brake
system. Each of these is covered in this manual, and the
Index will help you nd them quickly. If you’re trailering,
it’s a good idea to review these sections before you start
your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
Trailer Wiring Harness
If you have the optional trailering package, your vehicle
will have an eight-wire harness, including the center
high-mounted stoplamp battery feed wire. The harness is
stored on the passenger’s side of the vehicle near the
rear wheel well. This harness has a 30 amp battery feed
wire and no connector, and should be wired by a qualied
electrical technician. After choosing an aftermarket trailer
mating connector pair, have the technician attach one
connector to the eight-wire trailer harness and the other
connector to the wiring harness on the trailer.
Be sure the wiring harness on the trailer is taped or
strapped to the trailer’s frame rail and leave it loose
enough so the wiring doesn’t bend or break, but not so
loose that it drags on the ground. The eight-wire harnessmust be routed out of your vehicle between the rear door
and the oor, with enough of the harness left on both
sides so that the trailer or the body won’t pull it.
If you do not have the optional trailering package, your
vehicle will still have a trailering harness. The harness
is located near the passenger’s side rear wheel
well. It consists of six wires that may be used by
after-market trailer hitch installers.
The technician can use the following color code chart
when connecting the wiring harness to your trailer.
Brown: Rear lamps
Yellow: Left stoplamp and turn signal
Dark Green: Right stoplamp and turn signal
White (Heavy Gage): Ground
Light Green: Back-up lamps
White (Light Gage): Center High-Mounted Stoplamp
Blue: Auxiliary circuit (eight-wire harness only)
Orange: Fused auxiliary (eight-wire harness only)
Store the harness in its original place. Wrap the
harness together and tie it neatly so it won’t
be damaged.
4-44

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-6
Filling the Tank..............................................5-7
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood....................5-10
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Cover...............................................5-17
Engine Air Cleaner/Filter................................5-21
Automatic Transmission Fluid.........................5-23
Engine Coolant.............................................5-25
Radiator Pressure Cap..................................5-28
Engine Overheating.......................................5-28
Cooling System............................................5-30
Engine Fan Noise.........................................5-34Power Steering Fluid.....................................5-35
Windshield Washer Fluid................................5-36
Brakes........................................................5-37
Battery........................................................5-40
Jump Starting...............................................5-41
All-Wheel Drive..............................................5-45
Rear Axle.......................................................5-46
Front Axle......................................................5-47
Bulb Replacement..........................................5-48
Halogen Bulbs..............................................5-48
Headlamps and Sidemarker Lamps.................5-48
Front Turn Signal and Parking Lamps..............5-52
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-52
Replacement Bulbs.......................................5-54
Windshield Wiper Blade Replacement..............5-54
Tires..............................................................5-55
Tire Sidewall Labelling...................................5-56
Tire Terminology and Denitions.....................5-59
Ination - Tire Pressure.................................5-61
Tire Inspection and Rotation...........................5-63
When It Is Time for New Tires.......................5-64
Buying New Tires.........................................5-65
Section 5 Service and Appearance Care
5-1

Service
Your dealer knows your vehicle best and wants you to
be happy with it. We hope you will go to your dealer
for all your service needs. You will get genuine GM parts
and GM-trained and supported service people.
We hope you will want to keep your GM vehicle all GM.
Genuine GM parts have one of these marks:
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many uids, and
some component wear by-products contain and/or emit
these chemicals.
5-3

Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle
can affect the airow around it. This may cause
wind noise and affect windshield washer performance.
Check with your dealer before adding equipment to
the outside of your vehicle.
Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
Use regular unleaded gasoline with a posted octane
of 87 or higher. If the octane is less than 87, you may
get a heavy knocking noise when you drive. If this
occurs, use a gasoline rated at 87 octane or higher as
soon as possible. Otherwise, you might damage
your engine. A little pinging noise when you accelerate
or drive uphill is considered normal. This does not
indicate a problem exists or that a higher-octane fuel is
necessary. If you are using 87 octane or higher-octane
fuel and hear heavy knocking, your engine needs
service.
Gasoline Specications
It is recommended that gasoline meet specications
which were developed by automobile manufacturers
around the world and contained in the World-Wide Fuel
Charter which is available from the Alliance of Automobile
Manufacturers at www.autoalliance.org/fuel_charter.htm.
Gasoline meeting these specications could provide
improved driveability and emission control system
performance compared to other gasoline.
California Fuel
If your vehicle is certied to meet California Emission
Standards, it is designed to operate on fuels that
meet California specications. See the underhood
emission control label. If this fuel is not available
in states adopting California emissions standards, your
vehicle will operate satisfactorily on fuels meeting
federal specications, but emission control system
performance may be affected. The malfunction indicator
lamp may turn on and your vehicle may fail a
smog-check test. SeeMalfunction Indicator Lamp on
page 3-31. If this occurs, return to your authorized
GM dealer for diagnosis. If it is determined that
the condition is caused by the type of fuel used,
repairs may not be covered by your warranty.
5-5

Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work
properly. In most cases, you should not have to add
anything to your fuel. However, some gasolines contain
only the minimum amount of additive required to
meet U.S. Environmental Protection Agency regulations.
General Motors recommends that you buy gasolines
that are advertised to help keep fuel injectors and intake
valves clean. If your vehicle experiences problems
due to dirty injectors or valves, try a different brand of
gasoline. Also, your GM dealer has additives that
will help correct and prevent most deposit-related
problems.
Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines may be available in
your area to contribute to clean air. General Motors
recommends that you use these gasolines, particularly if
they comply with the specications described earlier.
Notice:Your vehicle was not designed for fuel that
contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in your fuel
system and also damage the plastic and rubber
parts. That damage would not be covered under
your warranty.Some gasolines that are not reformulated for low
emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese
tricarbonyl (MMT); ask the attendant where you buy
gasoline whether the fuel contains MMT. General Motors
does not recommend the use of such gasolines.
Fuels containing MMT can reduce the life of spark plugs
and the performance of the emission control system
may be affected. The malfunction indicator lamp
may turn on. If this occurs, return to your authorized
GM dealer for service.
Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel may be hard
to nd. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly
repairs caused by use of improper fuel would not
be covered by your warranty.
To check the fuel availability, ask an auto club, or
contact a major oil company that does business in the
country where you will be driving.
5-6

Filling the Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your
engine when you are refueling. Do not smoke
if you are near fuel or refueling your vehicle.
Keep sparks, ames, and smoking materials
away from fuel. Do not leave the fuel pump
unattended when refueling your vehicle — this
is against the law in some places. Keep
children away from the fuel pump; never let
children pump fuel.The tethered fuel cap is located behind a hinged fuel
door on the driver’s side of the vehicle.
To remove the fuel cap, turn it slowly to the left
(counterclockwise). The fuel cap has a spring in it; if the
cap is released too soon, it will spring back to the right.
5-7