trailer CHEVROLET ASTRO CARGO VAN 2003 2.G Service Manual

67,500 Miles (112 500 km)
qChange engine oil and ®lter (or every 12 months,
whichever occurs ®rst).An Emission Control
Service.
qLubricate chassis components (or every 12 months,
whichever occurs ®rst).(See footnote #).
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle seals
for leaking.
qRotate tires. See
Tire Inspection and Rotation on
page 5-64for proper rotation pattern and additional
information.(See footnote +).
75,000 Miles (125 000 km)
qChange engine oil and ®lter (or every 12 months,
whichever occurs ®rst).An Emission Control
Service.
qLubricate chassis components (or every 12 months,
whichever occurs ®rst).(See footnote #).
qInspect engine air cleaner ®lter. SeeEngine Air
Cleaner/Filter on page 5-24for more information.An Emission Control Service. (See footnote ².)
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle seals
for leaking.
qChange automatic transmission ¯uid and ®lter if the
vehicle is mainly driven under one or more of these
conditions:
þ In heavy city traffic where the outside
temperature regularly reaches 90ÉF (32ÉC)
or higher.
þ In hilly or mountainous terrain.
þ When doing frequent trailer towing.
þ Uses such as found in taxi, police or delivery
service.
If you do not use your vehicle under any of these
conditions, change the ¯uid and ®lter every 50,000 miles
(83 000 km).
qRotate tires. SeeTire Inspection and Rotation on
page 5-64for proper rotation pattern and additional
information.(See footnote +).
6-23

82,500 Miles (137 500 km)
qChange engine oil and ®lter (or every 12 months,
whichever occurs ®rst).An Emission Control
Service.
qLubricate chassis components (or every 12 months,
whichever occurs ®rst).(See footnote #).
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle seals
for leaking.
qRotate tires. See
Tire Inspection and Rotation on
page 5-64for proper rotation pattern and additional
information.(See footnote +).
90,000 Miles (150 000 km)
qChange engine oil and ®lter (or every 12 months,
whichever occurs ®rst).An Emission Control
Service.
qLubricate chassis components (or every 12 months,
whichever occurs ®rst).(See footnote #).
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle seals
for leaking.
qFor Two-Wheel-Drive vehicles only: Clean and
repack the front wheel bearings (or at each
brake relining, whichever occurs ®rst).qChange automatic transmission ¯uid and ®lter if the
vehicle is mainly driven under one or more of these
conditions:
þ In heavy city traffic where the outside
temperature regularly reaches 90ÉF (32ÉC)
or higher.
þ In hilly or mountainous terrain.
þ When doing frequent trailer towing.
þ Uses such as found in taxi, police or delivery
service.
If you do not use your vehicle under any of these
conditions, change the ¯uid and ®lter every 50,000 miles
(83 000 km).
qReplace fuel ®lter.An Emission Control Service.
(See footnote ²).
qReplace engine air cleaner ®lter. SeeEngine Air
Cleaner/Filter on page 5-24for more information.An Emission Control Service.
qRotate tires. SeeTire Inspection and Rotation on
page 5-64for proper rotation pattern and additional
information.(See footnote +).
6-24

Customer Assistance Information........................ 7-8
Courtesy Transportation.................................. 7-8
Customer Assistance for Text Telephone
(TTY) Users.............................................. 7-4
Customer Assistance Offices........................... 7-4
Customer Satisfaction Procedure..................... 7-2
GM Mobility Program for Persons with
Disabilities................................................ 7-5
Reporting Safety Defects to General Motors....7-11
Reporting Safety Defects to the Canadian
Government............................................7-11
Reporting Safety Defects to the United States
Government............................................7-10
Roadside Assistance Program......................... 7-6
Service Publications Ordering Information........7-11
D
Daytime Running Lamps (DRL).........................3-14
Defensive Driving............................................. 4-2
Defogging and Defrosting.................................3-19
Directing the Air¯ow........................................3-20
Disabling the Theft-Deterrent Feature.................3-49
Doing Your Own Service Work........................... 5-3
Dome Lamps.................................................3-16
Door............................................................... 2-8
Front Doors.................................................. 2-8
Locks.......................................................... 2-7
Power Door Locks......................................... 2-8Door (cont.)
Programmable Automatic Door Locks............... 2-9
Rear Doors.................................................2-13
Sliding Side Door........................................2-10
Driver Information System................................2-42
Driver............................................................1-18
Position, Safety Belt.....................................1-18
Driving On Grades..........................................4-39
Driving on Snow or Ice....................................4-24
Driving Through Deep Standing Water...............4-18
Driving Through Flowing Water.........................4-18
Driving with a Trailer.......................................4-37
Driving..........................................................4-14
At Night.....................................................4-14
City...........................................................4-19
Defensive..................................................... 4-2
Drunken....................................................... 4-3
Freeway.....................................................4-20
Hill and Mountain Roads..............................4-22
In Rain and on Wet Roads...........................4-16
Winter........................................................4-24
E
Electrical System............................................5-92
Add-On Equipment......................................5-92
Fuses and Circuit Breakers...........................5-93
Headlamp Wiring.........................................5-92
4

How to Add Coolant to the Coolant
Recovery Tank............................................5-34
How to Add Coolant to the Radiator..................5-37
How to Add Fluid............................................5-27
How to Check Lubricant...................................5-53
How to Check Power Steering Fluid..................5-40
How to Check........................................5-25, 5-64
How to Inspect the Engine Air Cleaner/Filter.......5-24
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-18
Hydroplaning..................................................4-18
I
If No Steam Is Coming From Your Engine..........5-32
If Steam Is Coming From Your Engine...............5-31
If the Light Is Flashing.....................................3-32
If the Light Is On Steady.................................3-32
If You Are Stuck in Sand, Mud, Ice or Snow.......4-28
If You Do Decide To Pull A Trailer.....................4-32
If You're Caught in a Blizzard...........................4-26
Ignition Positions.............................................2-19
Ignition Transmission Lock Check......................6-29
Infants and Young Children, Restraints...............1-38
In¯ation Ð Tire Pressure.................................5-64
Inspection......................................................6-31
Brake System.............................................6-31
Engine Cooling System................................6-30Inspection (cont.)
Exhaust System..........................................6-30
Fuel System...............................................6-30
Part C - Periodic Maintenance.......................6-30
Steering, Suspension and Front Drive Axle
Boot and Seal.........................................6-30
Throttle System...........................................6-31
Transfer Case and Front Axle
(All-Wheel Drive)......................................6-31
Installing a Garage Door Opener.......................2-40
Instrument Panel Brightness Control..................3-15
Instrument Panel Fuse Block............................5-93
Instrument Panel.............................................3-24
Cluster.......................................................3-24
Overview..................................................... 3-2
Interior Lamps................................................3-15
J
Jump Starting.................................................5-47
K
Key Lock Cylinders Service..............................6-27
Keyless Entry System....................................... 2-4
Keys............................................................... 2-2
7

Maintenance Schedule (cont.)
Fuel System Inspection................................6-30
How This Section is Organized....................... 6-3
Introduction.................................................. 6-2
Long Trip/Highway Scheduled Maintenance.....6-18
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4
Part B - Owner Checks and Services.............6-26
Part C - Periodic MaintenanceInspections......6-30
Part D - Recommended Fluids and Lubricants....6-32
Part E - Maintenance Record........................6-34
Selecting the Right Schedule.......................... 6-5
Short Trip/City Scheduled Maintenance............. 6-7
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection..........................6-30
Throttle System Inspection............................6-31
Transfer Case and Front Axle
(All-Wheel Drive) Inspection.......................6-31
Using Your................................................... 6-4
Your Vehicle and the Environment................... 6-2
Maintenance When Trailer Towing.....................4-40
Making Turns.................................................4-38
Malfunction Indicator Light................................3-30
Manual Lumbar Controls.................................... 1-3
Manual Seats................................................... 1-2
Manual Windows............................................2-16
Matching Transmitter(s) to Your Vehicle............... 2-5Mexico, Central America and Caribbean
Islands/Countries (Except Puerto Rico and
U.S. Virgin Islands) ± Customer Assistance....... 7-5
Mirrors..........................................................2-32
Manual Rearview Mirror................................2-32
Outside Convex Mirror.................................2-33
Outside Manual Mirror..................................2-32
Outside Power Mirrors..................................2-32
Model Reference................................................ vi
MyGMLink.com................................................ 7-4
N
New Vehicle Break-In......................................2-19
Normal Maintenance Replacement Parts...........5-101
O
Odometer......................................................3-25
Off-Road Recovery..........................................4-11
Oil ................................................................5-15
Engine.......................................................5-15
Pressure Gage............................................3-34
Older Children, Restraints................................1-35
Online Owner Center........................................ 7-4
9

Tires.............................................................5-63
Buying New Tires........................................5-66
Chains.......................................................5-70
Changing a Flat Tire....................................5-71
Compact Spare Tire.....................................5-82
If a Tire Goes Flat.......................................5-70
In¯ation Ð Tire Pressure..............................5-64
Inspection and Rotation................................5-64
Uniform Tire Quality Grading.........................5-67
Wheel Alignment and Tire Balance.................5-69
Wheel Replacement.....................................5-69
When It Is Time for New Tires......................5-66
To Use the Engine Coolant Heater....................2-22
Top Strap Anchor Location...............................1-50
Top Strap......................................................1-48
Torque Lock...................................................2-29
Total Weight on Your Vehicle's Tires..................4-35
Tow/Haul Mode Button.....................................2-25
Tow/Haul Mode Light.......................................3-36
Towing..........................................................4-29
Recreational Vehicle.....................................4-29
Towing a Trailer..........................................4-31
Your Vehicle...............................................4-29
Trailer Brakes.................................................4-36
Trailer Wiring Harness.....................................4-41
Trailering Package..........................................4-31
Transfer Case................................................5-52Transmission Operation, Automatic....................2-23
Transmission, Transaxle, Transfer Case Unit
Repair Manual............................................7-11
Transmission..................................................5-25
Fluid, Automatic...........................................5-25
Transportation Options...................................... 7-9
Trip Odometer................................................3-25
Turn and Lane Change Signals.......................... 3-6
Turn Signal/Multifunction Lever........................... 3-6
Turn Signals When Towing a Trailer..................4-38
U
Underbody Flushing Service.............................6-29
Underhood Fuse Block....................................5-96
Understanding Radio Reception........................3-50
Uniform Tire Quality Grading............................5-67
United States ± Customer Assistance.................. 7-4
Unlocking the Theft-Deterrent Feature After a
Power Loss................................................3-49
Used Replacement Wheels..............................5-70
Using Cleaner on Fabric..................................5-84
Using HomeLink
ž...........................................2-37
14

V
Vehicle Identi®cation........................................5-91
Number (VIN).............................................5-91
Service Parts Identi®cation Label...................5-91
Vehicle Storage..............................................5-47
Vehicle............................................................ 4-6
Control........................................................ 4-6
Damage Warnings........................................... iv
Loading......................................................4-29
Symbols......................................................... iv
Visor Vanity Mirror..........................................2-17
Visors...........................................................2-17
Voltmeter Gage..............................................3-28
W
Warning Lights, Gages and Indicators................3-23
Warnings......................................................... 3-4
Hazard Warning Flashers............................... 3-4
Other Warning Devices.................................. 3-5
Safety and Symbols......................................... iii
Vehicle Damage.............................................. iv
Washing Your Vehicle......................................5-86
Weatherstrip Lubrication...................................6-27Weight of the Trailer Tongue.............................4-35
Weight of the Trailer........................................4-33
What Kind of Engine Oil to Use........................5-17
What to Do with Used Oil................................5-19
What to Use..........................5-28, 5-40, 5-41, 5-53
Wheels..........................................................5-69
Alignment and Tire Balance..........................5-69
Replacement...............................................5-69
When to Add Engine Oil..................................5-16
When to Change Engine Oil.............................5-18
When to Check and Change............................5-25
When to Check Lubricant.................................5-53
When to Check Power Steering Fluid................5-40
When to Check..............................................5-64
When to Inspect the Engine Air Cleaner/Filter.....5-24
When You Are Ready to Leave After Parking on
a Hill.........................................................4-40
Where to Put the Restraint...............................1-47
Why Safety Belts Work....................................1-14
Windows.......................................................2-16
Manual......................................................2-16
Power........................................................2-17
Windshield Washer Fluid Level Check................6-26
Windshield Washer........................................... 3-8
Fluid..........................................................5-41
15