cooling CHEVROLET ASTRO CARGO VAN 2004 2.G Owner's Manual

Long Trip/Highway Denition
Follow this scheduled maintenanceonlyif 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.
Long Trip/Highway Intervals
Every 7,500 Miles (12 500 km):Engine Oil and Filter
Change (or every 12 months, whichever occurs
rst). Chassis Lubrication (or 12 months, whichever
occurs rst). Drive Axle Fluid Check. Tire Rotation.
Every 15,000 Miles (25 000 km):Engine Air Cleaner
Filter Inspection. 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 (two–wheel drive only)
(or at each brake relining, whichever occurs rst).Every 50,000 Miles (83 000 km):Automatic
Transmission Service (normal conditions).
Transfer Case Fluid Change.
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
rst). Engine Accessory Drive Belt Inspection.
These intervals only summarize maintenance services.
Be sure to follow the complete scheduled maintenance
on the following pages.
Short Trip/City Scheduled
Maintenance
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.
6-6

❑Replace fuel lter.An Emission Control Service.
(See footnote †.)
❑Replace engine air cleaner lter. SeeEngine Air
Cleaner/Filter on page 5-21for more information.
An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-71for proper rotation pattern and additional
information.(See footnote +.)
93,000 Miles (155 000 km)
❑Change engine oil and lter (or every 3 months,
whichever occurs rst).An Emission Control Service.
❑Lubricate chassis components (or every 3 months,
whichever occurs rst).(See footnote #.)
96,000 Miles (160 000 km)
❑Change engine oil and lter (or every 3 months,
whichever occurs rst).An Emission Control Service.
❑Lubricate chassis components (or every 3 months,
whichever occurs rst).(See footnote #.)
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-71for proper rotation pattern and additional
information.(See footnote +.)
99,000 Miles (165 000 km)
❑Change engine oil and lter (or every 3 months,
whichever occurs rst).An Emission Control Service.
❑Lubricate chassis components (or every 3 months,
whichever occurs rst).(See footnote #.)
100,000 Miles (166 000 km)
❑Inspect spark plug wires.An Emission
Control Service.
❑Replace spark plugs.An Emission Control Service.
❑If you have not used your vehicle under severe
service conditions listed previously and, therefore,
have not changed your automatic transmission
uid, change both the uid and lter.
❑Change transfer case uid.
❑Inspect Positive Crankcase Ventilation (PCV) valve.
An Emission Control Service.
150,000 Miles (240 000 km)
❑Drain, ush and rell cooling system (or every
60 months since last service, whichever occurs rst).
SeeEngine Coolant on page 5-26for what to use.
Inspect hoses. Clean radiator, condenser, pressure
cap and neck. Pressure test cooling system and
pressure cap.An Emission Control Service.
❑Inspect engine accessory drive belt.
An Emission Control Service.
6-15

When doing frequent trailer towing.
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).
❑Replace fuel lter.An Emission Control Service.
(See footnote †).
❑Replace engine air cleaner lter. SeeEngine Air
Cleaner/Filter on page 5-21for more information.
An Emission Control Service.
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-71for proper rotation pattern and additional
information.(See footnote +).
97,500 Miles (162 500 km)
❑Change engine oil and lter (or every
12 months, whichever occurs rst).
An Emission Control Service.
❑Lubricate chassis components (or every 12 months,
whichever occurs rst).(See footnote #).
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-71for proper rotation pattern and additional
information.(See footnote +).
100,000 Miles (166 000 km)
❑Inspect spark plug wires.An Emission
Control Service.
❑Replace spark plugs.An Emission Control Service.
❑If you have not used your vehicle under severe
service conditions listed previously and, therefore,
have not changed your automatic transmission uid,
change both the uid and lter.
❑Change transfer case uid.
❑Inspect Positive Crankcase Ventilation (PCV) valve.
An Emission Control Service.
150,000 Miles (240 000 km)
❑Drain, ush and rell cooling system (or every
60 months since last service, whichever occurs rst).
SeeEngine Coolant on page 5-26for what to use.
Inspect hoses. Clean radiator, condenser, pressure
cap and neck. Pressure test the cooling system
and pressure cap.An Emission Control Service.
❑Inspect engine accessory drive belt.
An Emission Control Service.
6-21

Part C: Periodic Maintenance
Inspections
Listed in this part are inspections and services which
should be performed at least twice a year (for instance,
each spring and fall).You should let your dealer’s
service department do these jobs. Make sure any
necessary repairs are completed at once.
Proper procedures to perform these services may be
found in a service manual. SeeService Publications
Ordering Information on page 7-12.
Steering, Suspension and Front
Drive Axle Boot and Seal Inspection
Inspect the front and rear suspension and steering
system for damaged, loose or missing parts, signs of
wear or lack of lubrication. Inspect the power steering
lines and hoses for proper hook-up, binding, leaks,
cracks, chang, etc. Clean and then inspect the
drive axle boot seals for damage, tears or leakage.
Replace seals if necessary.
Exhaust System Inspection
Inspect the complete exhaust system. Inspect the body
near the exhaust system. Look for broken, damaged,
missing or out-of-position parts as well as open seams,
holes, loose connections or other conditions which
could cause a heat build-up in the oor pan or could let
exhaust fumes into the vehicle. SeeEngine Exhaust
on page 2-29.
Fuel System Inspection
Inspect the complete fuel system for damage or leaks.
Engine Cooling System Inspection
Inspect the hoses and have them replaced if they
are cracked, swollen or deteriorated. Inspect all pipes,
ttings and clamps; replace as needed. Clean the
outside of the radiator and air conditioning condenser.
To help ensure proper operation, a pressure test of
the cooling system and pressure cap is recommended
at least once a year.
6-26

Chains, Tire...................................................5-76
Charging System Light....................................3-26
Check
Engine Light...............................................3-29
Gages Warning Light...................................3-34
Checking Brake Fluid......................................5-41
Checking Coolant............................................5-27
Checking Engine Oil........................................5-13
Checking Things Under the Hood....................... 5-9
Chemical Paint Spotting...................................5-97
Child Restraints
Child Restraint Systems...............................1-43
Infants and Young Children...........................1-38
Lower Anchorages and Top Tethers for
Children (LATCH System)..........................1-51
Older Children.............................................1-35
Securing a Child Restraint Designed for
the LATCH System...................................1-54
Securing a Child Restraint in a Center
Seat Position...........................................1-56
Securing a Child Restraint in a Rear
Outside Seat Position...............................1-54
Securing a Child Restraint in the Right
Front Seat Position...................................1-58
Top Strap...................................................1-47
Top Strap Anchor Location............................1-49
Where to Put the Restraint...........................1-46
Cigarette Lighter.............................................3-16Cleaning
Inside of Your Vehicle..................................5-92
Outside of Your Vehicle................................5-95
Underbody Maintenance...............................5-97
Weatherstrips..............................................5-94
Cleaning Aluminum Wheels..............................5-96
Cleaning Exterior Lamps/Lenses.......................5-95
Cleaning Fabric/Carpet....................................5-92
Cleaning Glass Surfaces..................................5-94
Cleaning Interior Plastic Components.................5-94
Cleaning Leather............................................5-93
Cleaning the Top of the Instrument Panel...........5-93
Cleaning the Windshield and
Wiper Blades..............................................5-96
Cleaning Tires................................................5-97
Cleaning Vinyl................................................5-93
Climate Control System...................................3-17
Outlet Adjustment........................................3-19
Rear Air Conditioning System........................3-20
Rear Heating System...................................3-20
Compact Spare Tire........................................5-90
Composite Headlamps.....................................5-54
Control of a Vehicle.......................................... 4-5
Convenience Net............................................2-43
Coolant
Engine Temperature Gage............................3-28
Heater, Engine............................................2-21
Cooling System..............................................5-31
3

E
Electrical System
Add-On Equipment.....................................5-100
Fuses and Circuit Breakers.........................5-101
Headlamp Wiring.......................................5-100
Power Windows and Other Power Options....5-100
Windshield Wiper Fuses.............................5-100
Emissions Inspection and Maintenance
Programs...................................................3-31
Engine
Air Cleaner/Filter.........................................5-21
Battery.......................................................5-44
Check and Service Engine Soon Light............3-29
Coolant......................................................5-26
Coolant Heater............................................2-21
Coolant Temperature Gage...........................3-28
Cooling System Inspection............................6-26
Cover........................................................5-17
Drive Belt Routing......................................5-110
Engine Compartment Overview......................5-12
Exhaust.....................................................2-29
Fan Noise..................................................5-37
Oil .............................................................5-13
Overheating................................................5-29
Starting......................................................2-20
Engine Coolant Level Check.............................6-22Engine Oil Additives........................................5-16
Engine Oil Level Check...................................6-22
Entry Lighting.................................................3-14
Erasing HomeLink®Buttons..............................2-35
Event Data Recorders (EDR)............................7-10
Except Cargo Vans.................................1-38, 1-46
Exit Lighting...................................................3-14
Express-Down Window....................................2-16
Extender, Safety Belt.......................................1-34
Exterior Lamps...............................................3-12
F
Filter
Engine Air Cleaner......................................5-21
Finding a Station....................................3-37, 3-39
Finish Care....................................................5-95
Finish Damage...............................................5-97
Fixed Mast Antenna........................................3-47
Flash-to-Pass................................................... 3-7
Flat Tire........................................................5-77
Flat Tire, Changing.........................................5-78
Fluid
Automatic Transmission................................5-23
Power Steering...........................................5-38
Windshield Washer......................................5-39
5

Hood
Checking Things Under.................................. 5-9
Release.....................................................5-10
Horn............................................................... 3-5
How to Add Coolant to the Coolant
Recovery Tank............................................5-33
How to Add Coolant to the Radiator..................5-35
How to Add Fluid............................................5-25
How to Check Lubricant...................................5-51
How to Check Power Steering Fluid..................5-38
How to Inspect the Engine Air Cleaner/Filter.......5-22
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-18
Hydroplaning..................................................4-16
I
If No Steam Is Coming From Your Engine..........5-30
If Steam Is Coming From Your Engine...............5-29
If the Light Is Flashing.....................................3-30
If the Light Is On Steady.................................3-30
If You Are Caught in a Blizzard.........................4-26
If You Are Stuck in Sand, Mud, Ice or Snow.......4-28
If You Do Decide To Pull A Trailer.....................4-35
Ignition Positions.............................................2-18Ignition Transmission Lock Check......................6-25
Infants and Young Children, Restraints...............1-38
Ination - Tire Pressure...................................5-70
Inspection
Brake System.............................................6-27
Engine Cooling System................................6-26
Exhaust System..........................................6-26
Fuel System...............................................6-26
Part C - Periodic Maintenance.......................6-26
Steering, Suspension and Front Drive
Axle Boot and Seal..................................6-26
Throttle System...........................................6-27
Transfer Case and Front Axle
(All-Wheel Drive)......................................6-27
Installing a Garage Door Opener.......................2-39
Instrument Panel
Cluster.......................................................3-23
Overview..................................................... 3-2
Instrument Panel Brightness Control..................3-14
Instrument Panel Fuse Block..........................5-101
Interior Lamps................................................3-14
J
Jump Starting.................................................5-44
7

M
Maintenance, Normal Replacement Parts..........5-109
Maintenance Schedule
At Each Fuel Fill.........................................6-22
At Least Once a Month................................6-22
At Least Once a Year..................................6-23
At Least Twice a Year..................................6-22
Brake System Inspection..............................6-27
Engine Cooling System Inspection.................6-26
Exhaust System Inspection...........................6-26
Fuel System Inspection................................6-26
How This Section is Organized....................... 6-3
Introduction.................................................. 6-2
Long Trip/Highway Scheduled
Maintenance............................................6-16
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4
Part B - Owner Checks and Services.............6-22
Part C - Periodic Maintenance Inspections......6-26
Part D - Recommended Fluids and
Lubricants...............................................6-28
Part E - Maintenance Record........................6-30
Selecting the Right Schedule.......................... 6-5
Short Trip/City Scheduled Maintenance............. 6-6Maintenance Schedule (cont.)
Steering, Suspension and Front Drive
Axle Boot and Seal Inspection...................6-26
Throttle System Inspection............................6-27
Transfer Case and Front Axle
(All-Wheel Drive) Inspection.......................6-27
Using Your................................................... 6-4
Your Vehicle and the Environment................... 6-2
Maintenance When Trailer Towing.....................4-44
Making Turns.................................................4-42
Malfunction Indicator Light................................3-29
Manual Lumbar Controls.................................... 1-4
Manual Seats................................................... 1-3
Manual Windows............................................2-15
Matching Transmitter(s) to Your Vehicle............... 2-6
Mexico, Central America and Caribbean
Islands/Countries (Except Puerto Rico and
U.S. Virgin Islands) – Customer Assistance....... 7-5
Mirrors
Manual Rearview Mirror................................2-31
Outside Convex Mirror.................................2-32
Outside Manual Mirror..................................2-31
Outside Power Mirrors..................................2-31
Model Reference................................................ vi
MyGMLink.com................................................ 7-4
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