engine CHEVROLET ASTRO CARGO VAN 2004 2.G Repair Manual

A. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-39.
B. Engine Coolant Recovery Tank. SeeCooling System
on page 5-31.
C. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-13.
D. Automatic Transmission Fluid Dipstick. See
“Checking the Fluid Level” underAutomatic
Transmission Fluid on page 5-23.
E. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-21.
F. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-13.
G. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-40.
H. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-38.
I. Battery. SeeBattery on page 5-44.Engine Oil
Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
Turn off the engine and give the oil several minutes to
drain back into the oil pan. If you don’t, the oil
dipstick might not show the actual level.
Pull out the dipstick and clean it with a paper towel or
cloth, then push it back in all the way. Remove it again,
keeping the tip down, and check the level.
5-13

When to Add Engine Oil
If the oil is at or below the ADD line, then you will need
to add at least one quart of oil. But you must use the
right kind. This section explains what kind of oil to use.
For engine oil crankcase capacity, seeCapacities
and Specications on page 5-107.
Notice:Do not add too much oil. If your engine
has so much oil that the oil level gets above
the cross-hatched area that shows the proper
operating range, your engine could be damaged.SeeEngine Compartment
Overview on page 5-12
for the location of the
engine oil ll cap.
Be sure to add enough oil to put the level somewhere
in the proper operating range. Push the dipstick all
the way back in when you are through.
What Kind of Engine Oil to Use
Look for two things:
GM6094M
Your vehicle’s engine requires oil meeting GM
Standard GM6094M. You should look for and use
only an oil that meets GM Standard GM6094M.
5-14

You should look for this information on the oil container,
and useonlythose oils that are identied as meeting
GM Standard GM6094M and have the starburst symbol
on the front of the oil container.
Notice:Use only engine oil identied as meeting
GM Standard GM6094M and showing the American
Petroleum Institute Certied For Gasoline Engines
starburst symbol. Failure to use the recommended
oil can result in engine damage not covered by
your warranty.
GM Goodwrench
®oil meets all the requirements for
your vehicle.
If you are in an area of extreme cold, where the
temperature falls below−20°F (−29°C), it is
recommended that you use either an SAE 5W-30
synthetic oil or an SAE 0W-30 oil. Both will provide
easier cold starting and better protection for your
engine at extremely low temperatures.
Engine Oil Additives
Do not add anything to your oil. The recommended
oils with the starburst symbol that meet GM Standard
GM6094M are all you will need for good performance
and engine protection.
When to Change Engine Oil
If any one of these are true for you, use the short
trip/city maintenance schedule:
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.
The vehicle is used for delivery service, police,
taxi or other commercial application.
Driving under these conditions causes engine oil to
break down sooner. If any one of these is true for your
vehicle, then you need to change your oil and lter
every 3,000 miles (5 000 km) or 3 months – whichever
occurs rst.
If none of them is true, use the long trip/highway
maintenance schedule. Change the oil and lter every
7,500 miles (12 500 km) or 12 months – whichever
occurs rst. Driving a vehicle with a fully warmed engine
under highway conditions will cause engine oil to
break down slower.
5-16

What to Do with Used Oil
Used engine oil contains certain elements that may be
unhealthy for your skin and could even cause cancer.
Do not let used oil stay on your skin for very long.
Clean your skin and nails with soap and water,
or a good hand cleaner. Wash or properly dispose
of clothing or rags containing used engine oil. See the
manufacturer’s warnings about the use and disposal
of oil products.
Used oil can be a threat to the environment. If you
change your own oil, be sure to drain all the oil from
the lter before disposal. Never dispose of oil by putting
it in the trash, pouring it on the ground, into sewers,
or into streams or bodies of water. Instead, recycle it
by taking it to a place that collects used oil. If you
have a problem properly disposing of your used oil,
ask your dealer, a service station or a local recycling
center for help.
Engine Cover
Removing the Engine Cover
1. Move both front seats as far back as they will go.
5-17

6. Loosen the two bolts on the engine cover. The
bolts are not supposed to come out of the cover,
only from the front of the dash.
When removing the cover, be careful not to
damage the instrument panel or the trim.
7. Disconnect the AM radio ground strap.8. Grasp the bottom of the cover and slide it rearward.
Then, lift it up and out of the vehicle.
If the seal does not release, use the pull strap on
the driver’s side above the rear mount.
5-20

Reinstalling the Engine Cover
1. Lift the engine cover into the front of the vehicle
and slide it all the way forward. Make sure the
rubber seal is over the latches.
2. Tighten the two bolts located on the engine cover
to reinstall the cover to the front of the dash.
3. Put the heater duct over the engine cover
studs. Push up on the duct gently until it snaps
into place.
4. Reconnect the electrical connectors.
5. Reconnect the AM radio ground strap.
6. Reinstall the engine cover extension by gently
squeezing the sides and sliding it into place.
Make sure all of the fastener clips engage and
the extension ts properly in place. Reinstall and
tighten the two screws.
7. Reinstall the two nuts to secure the extension
in place.
Engine Air Cleaner/Filter
SeeEngine Compartment Overview on page 5-12for
the location of the engine air cleaner/lter.
When to Inspect the Engine
Air Cleaner/Filter
Inspect the engine air cleaner/lter every
15,000 miles (25 000 km) and replace every
30,000 miles (50 000 km). If you are driving in
dusty/dirty conditions, inspect the lter at each
engine oil change.
5-21

How to Inspect the Engine
Air Cleaner/Filter
To inspect the air cleaner/lter remove the lter from
the vehicle and lightly shake the lter to release
loose dust and dirt. If the lter remains caked with dirt,
a new lter is required.
To inspect or replace the engine air cleaner/lter,
do the following:
1. Unsnap both clips on the lter cover.
2. Remove the cover.
3. Inspect or replace the engine air cleaner/lter.
4. Replace the cover.
5. Snap both clips to secure the cover.
{CAUTION:
Operating the engine with the air cleaner/lter
off can cause you or others to be burned.
The air cleaner not only cleans the air, it helps
to stop ame if the engine backres. If it is
not there and the engine backres, you could
be burned. Do not drive with it off, and be
careful working on the engine with the air
cleaner/lter off.
Notice:If the air cleaner/lter is off, a backre
can cause a damaging engine re. And, dirt
can easily get into your engine, which will damage
it. Always have the air cleaner/lter in place
when you are driving.
5-22

Automatic Transmission Fluid
When to Check and Change
A good time to check your automatic transmission uid
level is when the engine oil is changed.
Change both the uid and lter every 15,000 miles
(25,000 km) 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.
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).
SeePart A: Scheduled Maintenance Services
on page 6-4.
How to Check
Because this operation can be a little difficult, you may
choose to have this done at the dealership service
department.
If you do it yourself, be sure to follow all the instructions
here, or you could get a false reading on the dipstick.
Notice:Too much or too little uid can damage
your transmission. Too much can mean that some
of the uid could come out and fall on hot engine
part or exhaust system parts, starting a re.
Too little uid could cause the transmission to
overheat. Be sure to get an accurate reading if
you check your transmission uid.
Wait at least 30 minutes before checking the
transmission uid level if you have been driving:
When outside temperatures are above 90°F (32°C).
At high speed for quite a while.
In heavy traffic — especially in hot weather.
While pulling a trailer.
To get the right reading, the uid should be
at normal operating temperature, which is
180°F to 200°F (82°C to 93°C).
5-23

Get the vehicle warmed up by driving about
15 miles (24 km) when outside temperatures are
above 50°F (10°C). If it is colder than 50°F (10°C),
drive the vehicle in DRIVE (D) until the engine
temperature gage moves and then remains steady
for 10 minutes.
A cold uid check can be made after the vehicle has
been sitting for eight hours or more with the engine off,
but this is used only as a reference. Let the engine
run at idle for ve minutes if outside temperatures are
50°F (10°C) or more. If it is colder than 50°F (10°C),
you may have to idle the engine longer. Should the uid
level be low during this cold check, youmustcheck
the uid hot before adding uid. Checking the uid hot
will give you a more accurate reading of the uid level.
Checking the Fluid Level
Prepare your vehicle as follows:
Park your vehicle on a level place. Keep the
engine running.
With the parking brake applied, place the shift
lever in PARK (P).
With your foot on the brake pedal, move the shift
lever through each gear range, pausing for about
three seconds in each range. Then, position the
shift lever in PARK (P).
Let the engine run at idle for three minutes or more.
Then, without shutting off the engine, follow these steps:
The transmission dipstick
is located near the center
of the engine compartment
and will be labeled with
the graphic shown.
SeeEngine Compartment Overview on page 5-12for
more information on location.
1. Flip the handle up and then pull out the dipstick
and wipe it with a clean rag or paper towel.
2. Push it back in all the way, wait three seconds
and then pull it back out again.
5-24

Engine Coolant
The cooling system in your vehicle is lled with
DEX-COOL®engine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs rst, if you add
only DEX-COOL
®extended life coolant.
The following explains your cooling system and how
to add coolant when it is low. If you have a problem
with engine overheating, seeEngine Overheating
on page 5-29.
A 50/50 mixture of clean, drinkable water and
DEX-COOL
®coolant will:
Give freezing protection down to−34°F (−37°C).
Give boiling protection up to 265°F (129°C).
Protect against rust and corrosion.
Help keep the proper engine temperature.
Let the warning lights and gages work as
they should.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
What to Use
Use a mixture of one-halfclean, drinkable waterand
one-half DEX-COOL®coolant which will not damage
aluminum parts. If you use this coolant mixture, you do
not need to add anything else.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and the proper coolant.
5-26