brake CHEVROLET ASTRO CARGO VAN 1995 2.G Service Manual

Downloaded from www.Manualslib.com manuals search engine To Check Brake Fluid
You can check the brake fluid without taking off the cap. Just look at the
windows
on the brake fluid reservoir. The fluid levels should be above MIN.
If they aren’t, have your brake system checked to see if there is a leak.
After work is done on the brake hydraulic system, make sure the levels are
above
MIN and below the top of each window.
What to Add
When you do need brake fluid, use only DOT-3 brake fluid - such as
Delco Supreme 11 @ (GM Part No. 1052535). Use new brake fluid from a
sealed container only, and always clean the brake fluid reservoir cap before
removing it.
NOTICE:
Don’t let someone put in the wrong kind of fluid. For
example, just
a few drops of mineral-based oil, such as engine
oil, in your brake system can damage brake system parts
so
badly that they’ll have to be replaced.
Brake fluid can damage paint, so be careful not to spill brake
fluid on your vehicle.
If you do, wash it off immediately. See
“Appearance Care” in the Index.
6-30

Downloaded from www.Manualslib.com manuals search engine Brake Wear
Your vehicle has front disc brakes and rear drum brakes.
Disc brake pads have built-in wear indicators that make
a high-pitched
warning sound when the brake pads are worn and new pads are needed. The
sound may come and go or be heard all the time your vehicle is moving
(except when you are pushing
on the brake pedal firmly).
NOTICE:
Continuing to drive with worn-out brake pads could result in
costly brake repair.
Some driving conditions or climates may cause a brake squeal when the
brakes are first applied or lightly applied. This does not mean something is
wrong with your brakes.
Your rear drum brakes don’t have wear indicators, but
if you ever hear a
rear brake rubbing noise, have the rear brake linings inspected. Also,
the
rear brake drums should be removed and inspected each time the tires are
removed for rotation or changing. When you have the front brakes replaced,
have
the rear brakes inspected, too.
Brake linings should always be replaced
as complete axle sets.
Brake Pedal Travel
See your dealer if the brake pedal does not return to normal height, or if
there is a rapid increase in pedal travel. This could be a sign of brake
trouble.
Brake Adjustment
Every time you make a brake stop, your disc brakes adjust for wear.
If your brake pedal goes down Farther than normal, your rear drum brakes
may need adjustment. Adjust them by backing
up and firmly applying the
brakes a few times.
6-3 1

Downloaded from www.Manualslib.com manuals search engine Replacing Brake System Parts
The braking system on a modern vehicle is complex. Its many parts have to
be of top quality and work well together if the vehicle is to have really good
braking. Vehicles we design and test have topquality
GM brake parts in
them, as your vehicle does when it is new. When you replace parts of your
braking system
- for example, when your brake linings wear down and
you have to have
new ones put in - be sure you get new genuine GM
replacement parts. If you don’t, your brakes may no longer work properly.
For example, if someone puts in brake linings that are wrong for your
vehicle, the balance between your front and rear brakes can change
- for
the worse. The braking performance you’ve come to expect can change in
many other ways if someone puts in the wrong replacement brake parts.
Hydro-Boost Brake System
The power steering pump also powers the Hydro-Boost. Refer to “Power
Steering Fluid” in this section when checking the fluid level or adding fluid.
Battery
Every new vehicle has a Delco Freedom’ battery. You never have to add
water to one of these. When it’s time for a new battery, we recommend
a
Delco Freedom’ battery. Get one that has the replacement number shown
on the original battery’s label.
Vehicle Storage
If you’re not going to drive your vehicle for 25 days or more, take off the
black, negative (-) cable from the battery. This will help keep your battery
from running down.
Contact your dealer
to learn how to prepare your vehicle for longer storage
periods.
6-32

Downloaded from www.Manualslib.com manuals search engine If you need to replace any of your wheels, wheel bolts, or wheel nuts,
replace them
only with new GM original equipment parts. This way, you
will
be sure to have the right wheel, wheel bolts, and wheel nuts for your
GM model.
A CAUTION:
Using the wrong replacement wheels, wheel bolts, or wheel nuts
on your vehicle can be dangerous. It could affect the braking
and handling
of your vehicle, make your tires lose air and make
you lose control. You could have a collision in which you or
others could be injured. Always use the correct wheel, wheel
bolts, and wheel nuts for replacement.
I NOTICE:
The wrong wheel can also cause problems with bearing life,
brake cooling, speedometer/odometer calibration, headlamp
aim, bumper height, vehicle ground clearance, and tire or tire
chain clearance to the body and chassis.
Used Replacement Wheels
A CAUTION:
Putting a used wheel on your vehicle is dangerous. You can’t
know how
it’s been used or how many miles it’s been driven. It
could fail suddenly and cause an accident. If you have to replace
a wheel use a new GM original equipment wheel.
6-47

Downloaded from www.Manualslib.com manuals search engine Instrument Cluster Lamps
NOTE: A PC part number indicates that the bulb and base are one
assembly and must be replaced
as such.
General Indicator
Lamp?
Instrument Cluster
1llum.T
Headlamp Beam
Indicator Lamp?'
Headlamp Beam
Indicator Lamp$
Malfunction Indicator
Lamp (Service Engine Soon)?
Malfunction Indicator
Lamp (Service Engine Soon)$
Directional Indicator? Directional Indicator$ Brake Warning
Indicator Lamp?
Brake Warning
Indicator Lamp$
Transmission Indicator
Dial$
Safety Belt Warning?
Safety Belt Warning$
Daytime Running
Lamps Indicator?
Daytime Running Lamps Indicator$
Anti-lock Warning
Indicator?
Anti-lock Warning Indicator$
Air Bag?
Air Bag$
?With Standard Cluster
$With Digital Cluster 1
1
1
1
2
2
2
2
2
PC74
PC94
PC74
PC161
PC74
PC 194
PC74
PC 194
PC74
PC 194
PC 194 PC74
PC194 PC74
PC161
PC74
PC 194 PC74
PC 194
6-64

Downloaded from www.Manualslib.com manuals search engine Fuses and Circuit Breakers
??BAT!?
4673
CIG LTRlDM
€9 HRN/TL LPS
E3 ECM B
I
0 I
GAGES
INST LPS
AUX ls.l HTR A/C
d ClRlERK u 30 PWR ACC
STOPlHAZ
I
TURN -B/U HTR A/C RADIO
nr'
I- 10 1 rT ClRiBRK 2J 10 % 4 25 u ECM 1 30 PWR WDO WIPER
AIR BAG BRAKE
3 FRONT
Fuse Legend
0 5 Amp - Tan
0 7.5 Amp - Brown
0 10 Amp - Red
0 15 Amp - Blue
0 20 Amp - Yellow
25 Amp - Clear
0 30 Amp - Green
6-65

Downloaded from www.Manualslib.com manuals search engine NAME
INST LPS
PWR ACCY
CIG LTFUDM
GAGES
CIRCUITS
PROTECTED
Instrument Panel
Lamps, Radio
Dial Lamps,
Heater Lamps
Power
Door
Locks, Power Seat
Digital Clock,
Cigarette
Lighter, Dome Lights, Radio
Memory, Glove
Box Lamp
Instrument Cluster Gages,
Brake Switch, Audio Alarm.
Headlight
Switch
Illumination,
Ash Tray
Illumination
AUX HTR-A/C Auxiliary
Heater-Rear
AIC (if
equipped)
STOP-HA2
HORN/TL
LMPS
TURN-BAJ
Stop Lamps,
Hazard Flash,
Digital Instrument
Cluster
Headlamp Switch, Rear
and Parking
Lamps, Horn
Relay
Direction
Signal
Flash, Back Up
Lamps
FUSE
10 Amp
CIRCUIT
BREAKER
30 Amp
20 Amp
20 Amp
25 Amp
20 Amp
20 Amp
20 Amp
6-66

Downloaded from www.Manualslib.com manuals search engine NAME
HTR A/C
RADIO
ECM B
ECM I
PWR WDO
AIR BAG
WIPER
BRAKE
DRL** PWR
MIRRORS*
TRAILER*
CIRCUITS
PROTECTED
Front Heater &
Air
Conditioning
Radio
Engine Control
Module
Engine Control Module
Power
Windows
Air Bag
Windshield Wiper
Anti-Lock
Brake System,
Speedometer,
Cruise Control
Canadian Daytime
Running Lamps
rower Mirror
Trailer Wiring
Harness
FUSE
20 Amp
15 Amp
15 Amp
10 Amp
CIRCUIT
BREAKER
30 Amp
10 Amp
25 Amp
15 Amp
10 Amp
3 Amp
30 Amp
*In-line fuse
**Canada
only
***In-line fuse (certain models)
6-67

Downloaded from www.Manualslib.com manuals search engine I Schedule I Definition I
Follow Maintenance Schedule I if any one of these is true for your vehicle:
Most trips are less than 5 to 10 miles (8 to 16 km). This is particularly
important when outside temperatures are below freezing.
Most trips include extensive idling (such as frequent driving in stop and
Most trips are through dusty areas.
go traffic).
You frequently tow a trailer or use a carrier on top of your vehicle.
Schedule
I should also be followed if the vehicle is used for delivery
service, police, taxi,
or other commercial application.
I Schedule I Intervals I
Every 3,000 Miles (5 000 km) or 3 Months
Engine Oil and Filter Change
Chassis Lubrication
Drive Axle Service
At 6,000 Miles (10 OOO km) - Then Every 12,000 Miles (25 OOO km)
Tire Rotation
Every 15,000 Miles (25 000 km)
Air Cleaner Filter Inspection, if driving in dusty conditions
Front Wheel Bearing Repack
(or at each brake relining, whichever occurs
first)
(2WD Only)
Every 30,000 Miles (50 000 km)
Air Cleaner Filter Replacement
Spark Plug Replacement
Fuel Filter Replacement
Cooling System Service (or every
24 months, whichever occurs first)
Every 50,000 Miles (83 000 km)
Automatic Transmission Service (severe conditions only)
7-4

Downloaded from www.Manualslib.com manuals search engine Every 60,000 Miles (100 000 km)
Engine Accessory Drive Belt Inspection
Spark Plug Wire Inspection
Engine Timing Check
Fuel Tank. CaD and Lines Inspection
Schedule 11 Definition I
Follow Schedule I1 only if none of the conditions from Schedule I is true.
Sohedule I1 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 Service
At 7,500 Miles (12 500 km) - Then Every 15,000 Miles (25 000 km)
Tire Rotation
Every 30,000 Miles (50 000 km)
Cooling System Service (or every 24 months, whichever occurs first)
Spark Plug Replacement
Fuel Filter Replacement
Air Cleaner Filter Replacement
Front Wheel Bearing Repack (or at each brake relining, whichever occurs
first
(2WD Only)
Every 50,000 Miles (83 000 km)
Automatic Transmission Service (severe conditions)
Every 60,000 Miles (100 000 km)
Spark Plug Wire Inspection
Engine Accessory Drive Belt Inspection
Fuel Tank, Cap and Lines Inspection
7-5