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

Cleaning Tires
To clean your tires, use a stiff brush with tire cleaner.
Notice:Using petroleum-based tire dressing
products on your vehicle may damage the paint
nish and/or tires. When applying a tire dressing,
always wipe off any overspray from all painted
surfaces on your vehicle.
Sheet Metal Damage
If the vehicle is damaged and requires sheet metal
repair or replacement, make sure the body repair shop
applies anti-corrosion material to parts repaired or
replaced to restore corrosion protection.
Original manufacturer replacement parts will provide
the corrosion protection while maintaining the warranty.
Finish Damage
Any stone chips, fractures or deep scratches in the
nish should be repaired right away. Bare metal
will corrode quickly and may develop into major
repair expense.
Minor chips and scratches can be repaired with touch-up
materials available from your dealer. Larger areas of
nish damage can be corrected in your dealer’s
body and paint shop.
Underbody Maintenance
Chemicals used for ice and snow removal and dust
control can collect on the underbody. If these are
not removed, corrosion and rust can develop on the
underbody parts such as fuel lines, frame, oor pan,
and exhaust system even though they have
corrosion protection.
At least every spring, ush these materials from the
underbody with plain water. Clean any areas where
mud and debris can collect. Dirt packed in close areas
of the frame should be loosened before being ushed.
Your dealer or an underbody car washing system can
do this for you.
Chemical Paint Spotting
Some weather and atmospheric conditions can create
a chemical fallout. Airborne pollutants can fall upon and
attack painted surfaces on the vehicle. This damage can
take two forms: blotchy, ring-shaped discolorations, and
small, irregular dark spots etched into the paint surface.
Although no defect in the paint job causes this, GM
will repair, at no charge to the owner, the surfaces
of new vehicles damaged by this fallout condition within
12 months or 12,000 miles (20 000 km) of purchase,
whichever occurs rst.
5-97

Normal Maintenance Replacement Parts
Replacement parts identied below by name, part number, or specication can be obtained from your dealer.
Part GM Part Number ACDelco®Part Number
Engine Air Cleaner/Filter 25098463 A1163C
Engine Oil Filter 25010792 PF47
Fuel Filter 15050894 GF481
PCV Valve 6487532 CV 769-C
Spark Plugs 25162556 41–932
Wiper Blades (Trico Type)
Front – 18 inches (45.7 cm)
Rear – 14 inches (35.5 cm)22110431
22121329—
—
5-109

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
How This Section is Organized.........................6-3
Part A: Scheduled Maintenance Services...........6-4
Using Your Maintenance Schedule....................6-4
Selecting the Right Schedule...........................6-5
Short Trip/City Scheduled Maintenance..............6-6
Long Trip/Highway Scheduled Maintenance......6-16
Part B: Owner Checks and Services................6-22
At Each Fuel Fill..........................................6-22
At Least Once a Month.................................6-22
At Least Twice a Year...................................6-22At Least Once a Year...................................6-23
Part C: Periodic Maintenance Inspections.........6-26
Steering, Suspension and Front Drive
Axle Boot and Seal Inspection....................6-26
Exhaust System Inspection............................6-26
Fuel System Inspection..................................6-26
Engine Cooling System Inspection...................6-26
Throttle System Inspection.............................6-27
Transfer Case and Front Axle
(All-Wheel Drive) Inspection........................6-27
Brake System Inspection................................6-27
Part D: Recommended Fluids
and Lubricants..........................................6-28
Part E: Maintenance Record...........................6-30
Section 6 Maintenance Schedule
6-1

Maintenance Schedule
Introduction
Important: Keep engine oil at the proper level and
change as recommended.
Have you purchased the GM Protection Plan? The Plan
supplements your new vehicle warranties. See your
Warranty and Owner Assistance booklet or your dealer
for details.
Maintenance Requirements
Maintenance intervals, checks, inspections and
recommended uids and lubricants as prescribed in
this manual are necessary to keep your vehicle in good
working condition. Any damage caused by failure to
follow scheduled maintenance may not be covered
by warranty.
Your Vehicle and the Environment
Proper vehicle maintenance not only helps to keep your
vehicle in good working condition, but also helps the
environment. Improper vehicle maintenance can
even affect the quality of the air we breathe. Improper
uid levels or the wrong tire ination can increase
the level of emissions from your vehicle. To help protect
our environment, and to keep your vehicle in good
condition, be sure to maintain your vehicle properly.
6-2

How This Section is Organized
This maintenance schedule is divided into ve parts:
“Part A: Scheduled Maintenance Services”explains
what to have done and how often. Some of these
services can be complex, so unless you are technically
qualied and have the necessary equipment, you
should let your GM dealer’s service department do
these jobs.
Your GM dealer has GM-trained and supported
service people that will perform the work using genuine
GM parts.
{CAUTION:
Performing maintenance work on a vehicle
can be dangerous. In trying to do some jobs,
you can be seriously injured. Do your own
maintenance work only if you have the
required know-how and the proper tools and
equipment for the job. If you have any doubt,
have a qualied technician do the work.If you want to get the service information, seeService
Publications Ordering Information on page 7-12.
“Part B: Owner Checks and Services”tells you
what should be checked and when. It also explains
what you can easily do to help keep your vehicle in
good condition.
“Part C: Periodic Maintenance Inspections”explains
important inspections that your dealer’s service
department can perform for you.
“Part D: Recommended Fluids and Lubricants”
lists some recommended products necessary to help
keep your vehicle properly maintained. These products,
or their equivalents, should be used whether you do
the work yourself or have it done.
“Part E: Maintenance Record”is a place for you to
record and keep track of the maintenance performed
on your vehicle. Keep your maintenance receipts.
They may be needed to qualify your vehicle for
warranty repairs.
6-3

Part A: Scheduled Maintenance
Services
In this part are scheduled maintenance services which
are to be performed at the mileage intervals specied.
Using Your Maintenance Schedule
We at General Motors want to help you to keep
your vehicle in good working condition. But we do not
know exactly how you will drive it. You may drive
short distances only a few times a week. Or you may
drive long distances all the time in very hot, dusty
weather. You may use your vehicle in making deliveries.
Or you may drive it to work, to do errands or in many
other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You may need more
frequent checks and replacements. So please read
the following and note how you drive. If you have any
questions on how to keep your vehicle in good condition,
see your dealer.This part tells you the maintenance services you
should have done and when to schedule them.
When you go to your dealer for your service needs,
you will know that GM-trained and supported service
people will perform the work using GM parts.
The proper uids and lubricants to use are listed in
Part D. Make sure whoever services your vehicle uses
them. All parts should be replaced and all necessary
repairs done before you or anyone else drives
the vehicle.
These schedules are for vehicles that:
carry passengers and cargo within recommended
limits. You will nd these limits on the tire and
loading information label. SeeLoading Your Vehicle
on page 4-29.
are driven on reasonable road surfaces within
driving limits.
use the recommended fuel. SeeGasoline Octane
on page 5-4.
6-4

Selecting the Right Schedule
First you will need to decide which of the two schedules
is right for your vehicle. Here is how to decide which
schedule to follow:
Short Trip/City Denition
Follow the Short Trip/City Scheduled Maintenance if any
one of these conditions is true for your vehicle:
Most trips are less than 5 miles (8 km). This is
particularly important when outside temperatures
are below freezing.
Most trips include extensive idling (such as frequent
driving in stop-and-go traffic).
You frequently tow a trailer or use a carrier on top
of your vehicle.
If the vehicle is used for delivery service, police,
taxi or other commercial application.
One of the reasons you should follow this schedule if
you operate your vehicle under any of these conditions
is that these conditions cause engine oil to break
down sooner.
Short Trip/City Intervals
Every 3,000 Miles (5 000 km):Engine Oil and
Filter Change (or 3 months, whichever occurs rst).
Chassis Lubrication (or 3 months, whichever occurs
rst). Drive Axle Fluid Check.
Every 6,000 Miles (10 000 km):Tire Rotation.
Every 15,000 Miles (25 000 km):Engine Air Cleaner
Filter Inspection. Front Wheel Bearing Repack
(two–wheel drive only) (or at each brake relining,
whichever occurs rst). Automatic Transmission
Service (severe conditions only).
Every 30,000 Miles (50 000 km):Engine Air Cleaner
Filter Replacement. Fuel Filter Replacement.
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.
6-5

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

SeePart B: Owner Checks and Services on page 6-22
andPart C: Periodic Maintenance Inspections on
page 6-26.
Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
#Lubricate the front suspension, ball joints and kingpin
bushings, steering linkage, parking brake cable
guides and brake pedal springs.
+A good time to check your brakes is during tire
rotation. See Brake System Inspection on page 6-27.
3,000 Miles (5 000 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 #.)
6,000 Miles (10 000 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 +.)
9,000 Miles (15 000 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 #.)
12,000 Miles (20 000 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 +.)
6-7

Long Trip/Highway 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.
SeePart B: Owner Checks and Services on page 6-22
andPart C: Periodic Maintenance Inspections on
page 6-26.
Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
#Lubricate the front suspension, ball joints and kingpin
bushings, steering linkage and transfer case shift linkage,
parking brake cable guides and brake pedal springs.
+A good time to check your brakes is during tire
rotation. See Brake System Inspection on page 6-27.
7,500 Miles (12 500 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 +).
15,000 Miles (25 000 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 #).
❑Inspect engine air cleaner lter. SeeEngine Air
Cleaner/Filter on page 5-21for more information.
An Emission Control Service. (See footnote †.)
❑Change automatic transmission uid and lter if
the vehicle is mainly driven under one or more
of these conditions:
In heavy city traffic where the outside
temperature regularly reaches 90°F (32°C)
or higher.
In hilly or mountainous terrain.
6-16