service CHEVROLET ASTRO 2002 Service Manual

6-62
Cleaning Tires
To clean your tires, use a stiff brush with a tire cleaner.
NOTICE:
When applying a tire dressing always take care to
wipe off any overspray or splash from all painted
surfaces on the body or wheels of the vehicle.
Petroleum
-based products may damage the paint
finish and tires.
Sheet Metal Damage
If your vehicle is damaged and requires sheet metal
repair or replacement, make sure the body repair shop
applies anti
-corrosion material to the parts repaired or
replaced to restore corrosion protection.
Original manufacturer replacement parts will provide
the corrosion protection while maintaining the warranty.
Finish Damage
Any stone chips, fractures or deep scratches in the finish
should be repaired right away. Bare metal will corrode
quickly and may develop into a major repair expense.
Minor chips and scratches can be repaired with touch
-up
materials available from your dealer or other service
outlets. Larger areas of finish damage can be corrected
in your dealer's body and paint shop.

6-65
Vehicle Identification Number (VIN)
This is the legal identifier for your vehicle. It appears
on a plate in the front corner of the instrument panel,
on the driver's side. You can see it if you look through
the windshield from outside your vehicle. The VIN also
appears on the Vehicle Certification and Service Parts
labels and the certificates of title and registration.
Engine Identification
The 8th character in your VIN is the engine code.
This code will help you identify your engine,
specifications and replacement parts.
Service Parts Identification Label
You'll find this label on the inside of the rear edge of
the passenger's door. It's very helpful if you ever need
to order parts. On this label is:

your VIN,

the model designation,

paint information and

a list of all production options and
special equipment.
Be sure that this label is not removed from the vehicle.

6-74
Air Conditioning Refrigerant Capacity
If you do your own service work, you'll need the proper
service manual. See ªDoing Your Own Service Workº in
the Index for additional information. It is recommended
that service work on your air conditioning system be
performed by a qualified technician.
Refrigerant Type 134a
Front A/C 2.25 lbs. (1.02 kg). . . . . . . . . . . . . . . . . .
Front and Rear A/C 3.0 lbs. (1.36 kg). . . . . . . . . . . .
Use Refrigerant Oil, R134a Systems
Normal Maintenance
Replacement Parts
Replacement part numbers listed in this section are
based on the latest information available at the time of
printing, and are subject to change. If a part listed in this
manual is not the same as the part used in your vehicle
when it was built, or if you have any questions, please
contact your GM truck dealer.
Engine Oil Filter PF47*. . . . . . . . . . . . . . . . . . . . . . .
Engine Air Cleaner/Filter A1163C*. . . . . . . . . . . . . . .
Positive Crankcase Ventilation
(PCV) Valve CV769C*. . . . . . . . . . . . . . . . . . . . . .
Spark Plugs 41
-932* . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug Gap 0.060 inches (1.52 mm). . . . . . . . . .
Fuel Filter GF481*. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiper Blades (Front) Trico 22110158, Pin Type. . . . .
18 inches (45.7 cm) Length
Wiper Blade (Rear) Trico 22154396, Pin Type. . . . .
14 inches (35.5 cm) Length
*ACDelco

part number

7-
7-1
Section 7 Maintenance Schedule
This section covers the maintenance required for your vehicle. Your vehicle needs these services to retain its safety,
dependability and emission control performance.
7
- 2 Introduction
7
- 4 Part A: Scheduled Maintenance Services
7
- 8 Short Trip/City Scheduled Maintenance
7
- 31 Long Trip/Highway Scheduled Maintenance7
- 44 Part B: Owner Checks and Services
7
- 48 Part C: Periodic Maintenance Inspections
7
- 50 Part D: Recommended Fluids and Lubricants
7
- 52 Part E: Maintenance Record

7-3 How This Section is Organized
This maintenance schedule is divided into five parts:
ªPart A: Scheduled Maintenance Servicesº explains
what to have done and how often. Some of these services
can be complex, so unless you are technically qualified
and have the necessary equipment, you should let your
dealer's service department or another qualified service
center do these jobs.
CAUTION:
Performing maintenance work on a vehicle can
be dangerous. In trying to do some jobs, you can
be seriously injured. Do your own maintenance
work only if you have the required know
-how
and the proper tools and equipment for the job.
If you have any doubt, have a qualified
technician do the work.
If you want to get the service information, see ªService
and Owner Publicationsº in the Index.ªPart B: Owner Checks and Servicesº tells you
what should be checked and when. It also explains
what you can easily do to help keep your vehicle in
good condition.
ªPart C: Periodic Maintenance Inspectionsº explains
important inspections that your dealer's service
department or another qualified service center
should perform.
ªPart D: Recommended Fluids and Lubricantsº lists
some recommended products necessary to help keep
your vehicle properly maintained. These products, or
their equivalents, should be used whether you do the
work yourself or have it done.
ªPart E: Maintenance Recordº is a place for you
to record and keep track of the maintenance performed
on your vehicle. Keep your maintenance receipts.
They may be needed to qualify your vehicle for
warranty repairs.

7-4
Part A: Scheduled
Maintenance Services
Using Your Maintenance Schedule
We at General Motors want to help you keep your
vehicle in good working condition. But we don't know
exactly how you'll drive it. You may drive very short
distances only a few times a week. Or you may drive
long distances all the time in very hot, dusty weather.
You may use your vehicle in making deliveries.
Or you may drive it to work, to do errands or in
many other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You may need more
frequent checks and replacements. So please read the
following and note how you drive. If you have any
questions on how to keep your vehicle in good
condition, see your dealer.
This part tells you the maintenance services you should
have done and when you should schedule them. If you
go to your dealer for your service needs, you'll know
that GM
-trained and supported service people will
perform the work using genuine GM parts.The proper fluids and lubricants to use are listed in
Part D. Make sure whoever services your vehicle
uses these. All parts should be replaced and all
necessary repairs done before you or anyone else
drives the vehicle.
These schedules are for vehicles that:

carry passengers and cargo within recommended
limits. You will find these limits on your vehicle's
Certification/Tire label. See ªLoading Your Vehicleº
in the Index.

are driven on reasonable road surfaces within legal
driving limits.

use the recommended fuel. See ªFuelº in the Index.
Selecting the Right Schedule
First you'll need to decide which of the two schedules
is right for your vehicle. Here's how to decide which
schedule to follow:

Scheduled Maintenance
7-5
Short Trip/City Definition
Follow the Short Trip/City Scheduled Maintenance if
any one of these conditions is true for your vehicle:

Most trips are less than 5 miles (8 km). This is
particularly important when outside temperatures are
below freezing.

Most trips include extensive idling (such as frequent
driving in stop
-and-go traffic).

You frequently tow a trailer or use a carrier on top of
your vehicle.

If the vehicle is used for delivery service, police, taxi
or other commercial application.
One of the reasons you should follow this schedule
if you operate your vehicle under any of these
conditions is that these conditions cause engine
oil to break down sooner.
Short Trip/City Intervals
Every 3,000 Miles (5 000 km): Engine Oil and
Filter Change (or 3 months, whichever occurs first).
Chassis Lubrication (or 3 months, whichever occurs
first). Drive Axle Fluid Check.
Every 6,000 Miles (10 000 km): Tire Rotation.
Every 15,000 Miles (25 000 km): Engine Air Cleaner
Filter Inspection, if driving in dusty conditions.
Front Wheel Bearing Repack (2WD only) (or at each
brake relining, whichever occurs first). Automatic
Transmission Service (severe conditions only).
Every 30,000 Miles (50 000 km): Engine Air Cleaner
Filter Replacement. Fuel Filter Replacement.
Every 50,000 Miles (83 000 km): Automatic
Transmission Service (normal conditions).
Transfer Case Fluid Change.
Every 60,000 Miles (100 000 km): Engine Accessory
Drive Belt Inspection.

Scheduled Maintenance
7-6
Short Trip/City Intervals
Every 100,000 Miles (166 000 km): Spark Plug Wire
Inspection. Spark Plug Replacement. Positive
Crankcase Ventilation (PCV) Valve Inspection.
Every 150,000 Miles (240 000 km): Cooling System
Service (or every 60 months, whichever occurs first).
These intervals only summarize maintenance services.
Be sure to follow the complete scheduled maintenance
on the following pages.
Long Trip/Highway Definition
Follow this scheduled maintenance only if none of
the conditions from the Short Trip/City Scheduled
Maintenance are true. Do not use this schedule if the
vehicle is used for trailer towing, driven in a dusty area
or used off paved roads. Use the Short Trip/City
schedule for these conditions.
Driving a vehicle with a fully warmed engine under
highway conditions will cause engine oil to break
down slower.

Scheduled Maintenance
7-7
Long Trip/Highway Intervals
Every 7,500 Miles (12 500 km): Engine Oil and Filter
Change (or every 12 months, whichever occurs first).
Chassis Lubrication (or every 12 months, whichever
occurs first). Drive Axle Fluid Check. Tire Rotation.
Every 15,000 Miles (25 000 km): Automatic
Transmission Service (severe conditions only).
Every 30,000 Miles (50 000 km): Fuel Filter
Replacement. Engine Air Cleaner Filter Replacement.
Front Wheel Bearing Repack (2WD only)
(or at each brake relining, whichever occurs first).
Every 50,000 Miles (83 000 km): Automatic
Transmission Service (normal conditions).
Transfer Case Fluid Change.
Long Trip/Highway Intervals
Every 60,000 Miles (100 000 km): Engine Accessory
Drive Belt Inspection.
Every 100,000 Miles (166 000 km): Spark Plug Wire
Inspection. Spark Plug Replacement. Positive
Crankcase Ventilation (PCV) Valve Inspection.
Every 150,000 Miles (240 000 km): Cooling System
Service (or every 60 months, whichever occurs first).
These intervals only summarize maintenance services.
Be sure to follow the complete scheduled maintenance
on the following pages.

Short Trip/City Scheduled Maintenance
7-8
The services shown in this schedule up to 100,000 miles
(166 000 km) should be repeated after 100,000 miles
(166 000 km) at the same intervals for the life of
this vehicle. The services shown at 150,000 miles
(240 000 km) should be repeated at the same interval
after 150,000 miles (240 000 km) for the life of
this vehicle.
See ªOwner Checks and Servicesº and ªPeriodic
Maintenance Inspectionsº following.Footnotes

The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that
the failure to perform this maintenance item will not
nullify the emission warranty or limit recall liability
prior to the completion of the vehicle's useful life.
We, however, urge that all recommended maintenance
services be performed at the indicated intervals and the
maintenance be recorded.
# Lubricate the front suspension, ball joints and
kingpin bushings, steering linkage and transfer case
shift linkage, parking brake cable guides, and brake
pedal springs.
+ A good time to check your brakes is during tire
rotation. See ªBrake System Inspectionº under
ªPeriodic Maintenance Inspectionsº in Part C
of this schedule.