engine CHEVROLET ASTRO CARGO VAN 2002 2.G Owners Manual

iv
Vehicle Damage Warnings
Also, in this book you will find these notices:
NOTICE:
These mean there is something that could damage
your vehicle.
In the notice area, we tell you about something that can
damage your vehicle. Many times, this damage would
not be covered by your warranty, and it could be costly.
But the notice will tell you what to do to help avoid
the damage.
When you read other manuals, you might see
CAUTION and NOTICE warnings in different
colors or in different words.
You'll also see warning labels on your vehicle.
They use the same words, CAUTION or NOTICE.
Vehicle Symbols
Your vehicle may be equipped with components and
labels that use symbols instead of text. Symbols,
used on your vehicle, are shown along with the text
describing the operation or information relating to a
specific component, control, message, gage or indicator.
If you need help figuring out a specific name of a
component, gage or indicator reference the following
topics in the Index:

ªEngine Compartment Overviewº

ªInstrument Panelº

ªComfort Controlsº

ªAudio Systemsº
Also see ªWarning Lights and Gagesº in the Index.

1-33

Your vehicle is equipped with a crash sensing and
diagnostic module, which records information about
the air bag system. The module records information
about the readiness of the system, when the system
commands air bag inflation and driver's safety belt
usage at deployment. The module also records speed,
engine rpm, brake and throttle data.

Let only qualified technicians work on your air bag
system. Improper service can mean that your air
bag system won't work properly. See your dealer
for service.
NOTICE:
If you damage the covering for the driver's or the
right front passenger's air bag, the bag may not
work properly. You may have to replace the air
bag module in the steering wheel or both the air
bag module and the instrument panel for the
right front passenger's air bag. Do not open or
break the air bag coverings.
Servicing Your Air Bag-Equipped Vehicle
Air bags affect how your vehicle should be serviced.
There are parts of the air bag system in several places
around your vehicle. You don't want the system to
inflate while someone is working on your vehicle.
Your dealer and the service manual have information
about servicing your vehicle and the air bag system.
To purchase a service manual, see ªService and Owner
Publicationsº in the Index.
CAUTION:
For up to 10 minutes after the ignition key is
turned off and the battery is disconnected, an
air bag can still inflate during improper service.
You can be injured if you are close to an air bag
when it inflates. Avoid wires wrapped with yellow
tape or yellow connectors. They are probably part
of the air bag system. Be sure to follow proper
service procedures, and make sure the person
performing work for you is qualified to do so.
The air bag system does not need regular maintenance.

2-
2-1
Section 2 Features and Controls
Here you can learn about the many standard and optional features on your vehicle, and information on starting,
shifting and braking. Also explained are the instrument panel and the warning systems that tell you if everything is
working properly
-- and what to do if you have a problem.
2
-2 Windows
2
-4 Keys
2
-6 Front Doors
2
-6 Rear Doors
2
-8 Door Locks
2
-10 Keyless Entry System (Option)
2
-13 Sliding Door
2
-16 Rear Hatch/Rear Doors
2
-17 Theft
2
-18 Passlock

2-18 New Vehicle ªBreak-Inº
2
-19 Ignition Positions
2
-20 Starting Your Engine
2
-22 Engine Coolant Heater (If Equipped)
2
-23 Automatic Transmission Operation
2
-26 Parking Brake
2
-27 Shifting Into PARK (P)
2
-30 Shifting Out of PARK (P)
2
-30 Parking Over Things That Burn2
-31 Engine Exhaust
2
-31 Running Your Engine While You're Parked
2
-32 Locking Rear Axle (If Equipped)
2
-32 All-Wheel Drive (Option)
2
-32 Horn
2
-33 Tilt Wheel (If Equipped)
2
-33 Turn Signal/Multifunction Lever
2
-40 Exterior Lamps
2
-43 Interior Lamps
2
-45 Mirrors
2
-46 Storage Compartments
2
-55 Ashtrays and Cigarette Lighter
2
-56 Sun Visors
2
-56 Accessory Power Outle
2
-57 HomeLink
Transmitter (Option)
2
-60 The Instrument Panel - Your
Information System
2
-63 Warning Lights, Gages and Indicators

2-11
This device complies with RSS-210 of Industry Canada.
Operation is subject to the following two conditions:
(1) this device may not cause interference, and
(2) this device must accept any interference received,
including interference that may cause undesired
operation of the device.
Changes or modifications to this system by other than
an authorized service facility could void authorization to
use this equipment.
At times you may notice a decrease in range. This is
normal for any remote keyless entry system. If the
transmitter does not work or if you have to stand closer
to your vehicle for the transmitter to work, try this:

Check the distance. You may be too far from your
vehicle. You may need to stand closer during rainy
or snowy weather.

Check the location. Other vehicles or objects may be
blocking the signal. Take a few steps to the left or
right, hold the transmitter higher, and try again.

Check to determine if battery replacement is
necessary. See the instructions that follow.

If you're still having trouble, see your dealer or a
qualified technician for service.Operation
UNLOCK: When you press
UNLOCK, the driver's door
will unlock automatically,
the parking lamps will
flash and the interior lights
will go on.
If you press UNLOCK again within three seconds, all
doors will unlock, the parking lamps will flash and the
interior lights will go on.
LOCK: Press LOCK to lock all the doors. Press LOCK
again within three seconds and the horn will chirp.
REAR 2X: When you press the REAR button twice
within three seconds to unlock the rear hatch or cargo
doors, the parking lamps will flash and the interior lights
will go on. If the engine is running, the automatic
transmission must be in PARK (P) or NEUTRAL (N)
for the REAR 2X button to operate.

2-16
Rear Hatch/Rear Doors
CAUTION:
It can be dangerous to drive with the rear hatch
or rear doors open because carbon monoxide
(CO) gas can come into your vehicle. You can't
see or smell CO. It can cause unconsciousness
and even death.
If you must drive with the rear hatch or rear
doors open or if electrical wiring or other cable
connections must pass through the seal between
the body and the rear hatch or rear doors:

Make sure all other windows are shut.

Turn the fan on your heating or cooling
system to its highest speed with the setting
on anything but MAX A/C. That will force
outside air into your vehicle. See ªComfort
Controlsº in the Index.

If you have air outlets on or under the
instrument panel, open them all the way.
See ªEngine Exhaustº in the Index.
Hatch Release
You can use your key to unlock the hatch and all of the
other doors from the outside. Insert the key into the
hatch release button and turn it counterclockwise.
All of the doors will unlock.
You may also use the keyless entry system
described earlier.
The hatch can be opened or closed without a key if the
door lock system is unlocked.

2-18
Passlock

Your vehicle is equipped with the Passlock
theft
-deterrent system.
Passlock is a passive theft
-deterrent system. Passlock
enables fuel if the ignition lock cylinder is turned with a
valid key. If a correct key is not used or the ignition lock
cylinder is tampered with, fuel is disabled.
During normal operation, the SECURITY light will
go off approximately five seconds after the key is turned
to RUN.
If the engine stalls and the SECURITY light flashes,
wait about 10 minutes until the light stops flashing
before trying to restart the engine. Remember to release
the key from START as soon as the engine starts.
If the engine is running and the SECURITY light
comes on, you will be able to restart the engine if you
turn the engine off. However, your Passlock system is
not working properly and must be serviced by your
dealer. Your vehicle is not protected by Passlock at
this time. You may also want to check the fuses
(see ªFuses and Circuit Breakersº in the Index).
See your dealer for service.
In an emergency, call GM Roadside Assistance.
See ªRoadside Assistanceº in the Index.
New Vehicle ªBreak-Inº
NOTICE:
Your vehicle doesn't need an elaborate
ªbreak
-in.º But it will perform better in
the long run if you follow these guidelines:

Keep your speed at 55 mph (88 km/h) or
less for the first 500 miles (805 km).

Don't drive at any one speed
-- fast or
slow
-- for the first 500 miles (805 km).
Don't make full
-throttle starts.

Avoid making hard stops for the first
200 miles (322 km) or so. During this time
your new brake linings aren't yet broken
in. Hard stops with new linings can mean
premature wear and earlier replacement.
Follow this breaking
-in guideline every
time you get new brake linings.

Don't tow a trailer during break
-in.
See ªTowing a Trailerº in the Index for
more information.

2-19
Ignition Positions
With the key in the ignition, you can turn it to five
different positions.
A (ACCESSORY): This position lets you use things
like the radio, power windows and windshield wipers
when the engine is off. To get into ACCESSORY,
push in the key and turn it toward you. Your steering
wheel will remain locked, just as it was before you
inserted the key.
NOTICE:
Don't operate accessories in the ACCESSORY
position for long periods of time. Prolonged
operation of accessories in the ACCESSORY
position could drain your battery and prevent
you from starting your vehicle.
B (LOCK): This position locks your ignition, steering
wheel and transmission. It's a theft
-deterrent feature.
You will only be able to remove your key when the
ignition is turned to LOCK.
NOTICE:
If your key seems stuck in LOCK and you can't
turn it, be sure you are using the correct key;
if so, is it all the way in? If it is, then turn the
steering wheel left and right while you turn the
key hard. Turn the key only with your hand.
Using a tool to force it could break the key or the
ignition switch. If none of this works, then your
vehicle needs service.

2-20
C (OFF): This position lets you turn off the engine but
still turn the steering wheel. Use OFF if you must have
your vehicle in motion while the engine is off (for
example, if your vehicle is being towed).
D (RUN): This is the position for driving.
E (START): This position starts your engine.
Retained Accessory Power (RAP)
Your vehicle is equipped with a Retained Accessory
Power (RAP) feature which will allow certain features
on your vehicle to continue to work up to 20 minutes
after the ignition key is turned to OFF.
Your radio, power windows and overhead console will
work when the ignition key is in RUN or ACCESSORY.
Once the key is turned from RUN to OFF, these features
will continue to work for up to 20 minutes or until a
door is opened.
Starting Your Engine
Move your shift lever to PARK (P) or NEUTRAL (N).
Your engine won't start in any other position
-- that's a
safety feature. To restart when you're already moving,
use NEUTRAL (N) only.
NOTICE:
Don't try to shift to PARK (P) if your vehicle
is moving. If you do, you could damage the
transmission. Shift to PARK (P) only when your
vehicle is stopped.
1. With your foot off the accelerator pedal, turn the
ignition key to START. When the engine starts, let
go of the key. The idle speed will go down as your
engine gets warm.

2-21
NOTICE:
Holding your key in START for longer than
15 seconds at a time will cause your battery to
be drained much sooner. And the excessive heat
can damage your starter motor. Wait about
15 seconds between each try to help avoid
draining your battery or damaging your starter.
2. If it doesn't start within 10 seconds, push the
accelerator pedal all the way to the floor, while you
hold the ignition key in START. When the engine
starts, let go of the key and let up on the accelerator
pedal. Wait about 15 seconds between each try.
When starting your engine in very cold weather
(below 0
F or
-18
C), do this:
1. With your foot off the accelerator pedal, turn the
ignition key to START and hold it there up to
15 seconds. When the engine starts, let go of the key.2. If your engine still won't start (or starts but then
stops), it could be flooded with too much gasoline.
Try pushing your accelerator pedal all the way to the
floor and holding it there as you hold the key in
START for about three seconds. When the engine
starts, let go of the key and accelerator. If the vehicle
starts briefly but then stops again, do the same
thing, but this time keep the pedal down for five
or six seconds. This clears the extra gasoline from
the engine.
NOTICE:
Your engine is designed to work with the
electronics in your vehicle. If you add electrical
parts or accessories, you could change the way
the engine operates. Before adding electrical
equipment, check with your dealer. If you don't,
your engine might not perform properly.
Fuel Regulator
You have a fuel regulator that shuts the fuel off when the
engine reaches 5,600 rpm.

2-22
Engine Coolant Heater (If Equipped)
In very cold weather,
0
F (
-18
C) or colder,
the engine coolant
heater can help.
You'll get easier
starting and better
fuel economy during
engine warm
-up.
Usually, the coolant heater should be plugged in a
minimum of four hours prior to starting your vehicle.
'At temperatures above 32
F (0
C), use of the coolant
heater is not required.
To Use the Engine Coolant Heater
1. Turn off the engine.
2. Open the hood and unwrap the electrical cord.
The engine coolant heater cord is located on the
driver's side of the engine compartment, near the
power steering fluid reservoir.3. Plug it into a normal, grounded 110
-volt AC outlet.
CAUTION:
Plugging the cord into an ungrounded outlet
could cause an electrical shock. Also, the wrong
kind of extension cord could overheat and cause
a fire. You could be seriously injured. Plug the
cord into a properly grounded three
-prong
11 0
-volt AC outlet. If the cord won't reach, use a
heavy
-duty three-prong extension cord rated for
at least 15 amps.
4. Before starting the engine, be sure to unplug and store
the cord as it was before to keep it away from moving
engine parts. If you don't, it could be damaged.
How long should you keep the coolant heater plugged
in? The answer depends on the outside temperature, the
kind of oil you have, and some other things. Instead of
trying to list everything here, we ask that you contact
your dealer in the area where you'll be parking your
vehicle. The dealer can give you the best advice for that
particular area.