engine CHEVROLET ASTRO 2003 Repair Manual

Driving under these conditions causes engine oil to
break down sooner. If any one of these is true for your
vehicle, then you need to change your oil and filter
every
3,000 miles (5 000 km) or 3 months - whichever
occurs first.
If none of them is true, use the long trip/highway
maintenance schedule. Change the oil and filter every
7,500 miles (12 500 km) or 12 months - whichever
occurs first. Driving a vehicle with a fully warmed engine
under highway conditions will cause engine oil to
break down slower.
What to Do with Used Oil
Used engine oil contains certain elements that may be
unhealthy for your skin and could even cause cancer.
Don’t let used oil stay on your skin for very long. Clean
your skin and nails with soap and water, or a good
hand cleaner. Wash or properly dispose of clothing or
rags containing used engine oil. See the manufacturer’s
warnings about the use and disposal of oil products.
Used oil can be a threat to the environment.
If you
change your own oil, be sure to drain all the oil from
the filter before disposal. Never dispose of oil by putting
it in the trash, pouring it on the ground, into sewers,
or into streams or bodies of water. Instead, recycle
it
by taking it to a place that collects used oil. If you have
a problem properly disposing of your used oil, ask
your dealer, a service station or
a local recycling center
for help.
5-1 9

Engine Cover
Removing the Engine Cover
and passenger’s side corners.
1. Move both front seats as far back as they will go.
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5. Grasp the top of the heater duct and pull down
gently to remove it. 6. Loosen the two bolts on the engine cover. The bolts
are not supposed to come out of the cover, only from
the front of the dash.
When removing the cover, be careful not to damage
the instrument panel or the trim.
7. Disconnect the AM radio ground strap.
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8. Grasp the bottom of the cover and slide it rearward.
Then,
lift it up and out of the vehicle.
If the seal does not release, use the pull strap on
the driver’s side above the rear mount.
Reinstalling the Engine Cover
1. Lift the engine cover into the front of the vehicle
and slide it all the way forward. Make sure the
rubber seal
is over the latches.
2. Tighten the two bolts located on the engine cover
to reinstall the cover to the front of the dash.
3. Put the heater duct over the engine cover studs.
Push up on the duct gently until it snaps into place.
4. Reconnect the electrical connectors.
5. Reconnect the AM radio ground strap.
6. Reinstall the engine cover extension by gently
squeezing the sides and sliding it into place.
Make sure all of the fastener clips engage and the
extension fits properly in place. Reinstall and
tighten the two screws.
7. Reinstall the two nuts to secure the extension
in place.
5-23

Engine Air Cleaner/Filter
Refer to the Maintenance Schedule to determine
when to replace the engine air cleanedfilter and the
crankcase ventilation filter. See
Part A: Scheduled
Maintenance Services on page
6-4.
See Engine Compartment Overview on page 5-14 for
more information on location.
3. Change the filter.
4. Snap both clips to secure the engine air
cleaner/filter cover.
Be sure the engine air cleaner/filter cover is correctly
positioned
to seal out dust and contaminants that
are harmful to your engine.
To change the engine air cleaner/filter, do the following:
1. Unsnap both clips on the cover.
2. Remove the cover. Operat
...d the engine witt.
_.re air cleaner/ ____ er
off can cause you or others to be burned.
The air cleaner not only cleans the air,
it stops
flame if the engine backfires.
If it isn’t there
and the engine backfires, you could be burned.
Don’t drive with
it off, and be careful working
on the engine with the air cleaner/filter
off.
Notice: If the air cleanedfilter is off, a backfire
can cause a damaging engine fire. And, dirt
can easily get into your engine, which will damage
it. Always have the air cleanedfilter in place
when you’re driving.
5-24

Automatic Transmission Fluid
When to Check and Change
A good time to check your automatic transmission fluid
level is when the engine oil is changed.
Change both the fluid and filter every
15,000 miles
(25
000 km) if the vehicle is mainly driven under one or
more of these conditions:
In heavy city traffic where the outside temperature
In hilly or mountainous terrain.
When doing frequent trailer towing.
Uses such as found in taxi, police or delivery
If you do not use your vehicle under any of these
conditions, change the fluid and filter every
50,000 miles (83 000 km).
See
Part A: Scheduled Maintenance Services on
page
6-4.
regularly reaches 90°F (32°C) or higher.
service.
How to Check
Because this operation can be a little difficult, you may
choose to have this done at the dealership service
department.
If you do it yourself, be sure to follow all the instructions
here, or you could get a false reading on the dipstick.
Notices Too much or too little fluid can damage
your transmission.
Too much can mean that some
of the fluid could come out and fall on hot engine
part or exhaust system parts, starting a fire.
Too little fluid could cause the transmission to
overheat. Be sure to get an accurate reading if you
check your transmission fluid.
Wait at least 30 minutes before checking the
transmission fluid level
if you have been driving:
When outside temperatures are above 90°F (32°C).
0 At high speed for quite a while.
In heavy traffic
- especially in hot weather.
While pulling a trailer.
To get the right reading, the fluid should be at normal
operating temperature, which is 180°F to 200°F
(82°C to 93°C).
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Get the vehicle warmed up by driving about 15 miles
(24 km) when outside temperatures are above 50°F
(10°C).
If it's colder than 50°F (IOOC), drive the vehicle
in THIRD
(3) until the engine temperature gage
moves and then remains steady for
10 minutes.
A cold fluid check can be made after the vehicle has
been sitting for eight hours or more with the engine
off,
but this is used only as a reference. Let the engine
run at idle for five minutes
if outside temperatures are
50°F (1 OOC) or more.
If it's colder than 50°F (IOOC), you may have to idle the
engine longer. Should the fluid level be low during
this cold check, you
must check the fluid hot before
adding fluid. Checking the fluid hot
will give you a more
accurate reading of the fluid level.
Checking the Fluid Level
Prepare your vehicle as follows:
Park your vehicle on a level place. Keep the engine
running.
With the parking brake applied, place the shift lever
in PARK (P).
With your foot on the brake pedal, move the shift
lever through each gear range, pausing for about
three seconds in each range. Then, position the shift
lever in PARK
(P).
Let the engine run at idle for three minutes or more. Then, without
shutting
off the engine, follow these steps:
The transmission dipstick has a red handle and is
located near the center of the engine compartment
behind the air cleaner. See
Engine Compartment
Overview on page 5-14
for more information on location.
1. Flip the handle up and then pull out the dipstick
and wipe it with a clean rag or paper towel.
2. Push it back in all the way, wait three seconds and
then pull
it back out again.
5-26

Engine Coolant
The cooling system in your vehicle is filled with
DEX-COOL@ engine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240
000 km), whichever occurs first, if you add
only DEX-COOL@ extended life coolant.
The following explains your cooling system and how to
add coolant when it
is low. If you have a problem
with engine overheating, see
Engine Overheating on
page
5-3 I.
A 50/50 mixture of clean, drinkable water and
DEX-COOL@ coolant will:
Give freezing protection down to -34°F (-37°C).
Give boiling protection up to 265°F (129°C).
Protect against rust and corrosion.
Help keep the proper engine temperature.
Let the warning lights and gages work as they
should.
Notice: When adding coolant, it is important that
you use only
DEX-COOL@ (silicate-free) coolant.
If coolant other than DEX-COOL@
is added to the
system, premature engine, heater core or radiator
corrosion may result.
In addition, the engine coolant
will require change sooner
- at 30,000 miles
(50,000 km) or 24 months, whichever occurs first. Damage
caused by the use
of coolant other than
DEX-COOL@
is not covered by your new vehicle
warranty.
What to Use
Use a mixture of one-half clean, drinkable water and
one-half DEX-COOL@ coolant which won’t damage
aluminum parts.
If you use this coolant mixture,
you don’t need to add anything else.
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture.
With plain water or the
wrong mixture, your engine could get too hot but you wouldn’t get the overheat warning.
Your engine could catch fire and you or others could be burned. Use a
50/50 mixture of clean,
drinkable water and the proper coolant.
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Notice: If you use an improper coolant mixture,
your engine could overheat and be badly damaged.
The repair cost wouldn’t be covered by your
warranty. Too much water
in the mixture can freeze
and
crack the engine, radiator, heater core and
other parts.
If you have to add coolant more than four times a year,
have your dealer check your cooling system.
Notice: If you use the proper coolant, you don’t
have to add extra inhibitors or additives which claim
to improve
the system. These can be harmful.
Checking Coolant
r
The engine coolant tank is
located in the engine
compartment on the
passenger’s side at the
front. See Engine
Compartment Overview
on page
5-14 for more
information on location. The
vehicle must be on a level surface. When your
engine is cold, the coolant level should be at
ADD,
or a little higher. When your engine is warm, the level
should be up to
FULL HOT, or a little higher.
Adding Coolant
If you need more coolant, add the proper DEX-COOL@
coolant mixtureat the coolant recovery tank.
Lvrl DEX-COOL@
L
A
A
Turning the radiato ressure cap when the
engine and radiator are hot can allow steam and
scalding
liquids to blow out and burn you badly.
With the coolant recovery tank, you will almost
never have to add coolant at the radiator.
Never
turn the radiator pressure cap - even a
little -when the engine and radiator are hot.
5-29

Add coolant mixture at the recovery tank, but be careful
not to
mill it.
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
Radiator Pressure Cap
Occasionally check the coolant level in the radiator.
For information on how to add coolant to the radiator,
see
Cooling System on page 5-33.
A L
The radiator pressure cap is located in the engine
compartment on the
passenger's side of
the vehicle.
Notice: Your radiator cap is a 15.6 psi (1 10 kPa)
pressure-type cap and must be tightly installed
to prevent coolant
loss and possible engine damage
from overheating. Be sure the arrows on the cap
line up with the overflow tube on the radiator filler.
5-30