fuel filter CHEVROLET ASTRO CARGO VAN 2004 2.G Owners Manual

Service............................................................5-3
Doing Your Own Service Work.........................5-3
Adding Equipment to the Outside
of Your Vehicle...........................................5-4
Fuel................................................................5-4
Gasoline Octane............................................5-4
Gasoline Specications....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-6
Filling Your Tank............................................5-7
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood.....................5-9
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Cover...............................................5-17
Engine Air Cleaner/Filter................................5-21
Automatic Transmission Fluid.........................5-23
Engine Coolant.............................................5-26
Radiator Pressure Cap..................................5-28
Engine Overheating.......................................5-29
Cooling System............................................5-31
Engine Fan Noise.........................................5-37
Power Steering Fluid.....................................5-38
Windshield Washer Fluid................................5-39Brakes........................................................5-40
Battery........................................................5-44
Jump Starting...............................................5-44
All-Wheel Drive..............................................5-50
Rear Axle.......................................................5-51
Front Axle......................................................5-52
Bulb Replacement..........................................5-53
Halogen Bulbs..............................................5-53
Headlamps..................................................5-53
Front Turn Signal Lamps...............................5-57
Taillamps.....................................................5-57
Replacement Bulbs.......................................5-59
Windshield Wiper Blade Replacement..............5-59
Tires..............................................................5-60
Ination - Tire Pressure.................................5-70
Tire Inspection and Rotation...........................5-71
When It Is Time for New Tires.......................5-72
Buying New Tires.........................................5-73
Uniform Tire Quality Grading..........................5-74
Wheel Alignment and Tire Balance..................5-75
Wheel Replacement......................................5-75
Tire Chains..................................................5-76
If a Tire Goes Flat........................................5-77
Changing a Flat Tire.....................................5-78
Compact Spare Tire......................................5-90
Section 5 Service and Appearance Care
5-1

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

Capacities and Specications
The following approximate capacities are given in English and metric conversions. Please refer to
Part D: Recommended Fluids and Lubricants on page 6-28for more information.
Capacities and Specications
ApplicationCapacities
English Metric
Air Conditioning Refrigerant (R134a)
Front A/C
Front and Rear A/C2.3 lbs.
3.0 lbs.1.0 kg
1.4 kg
Cooling System
Without Rear Heater
With Rear Heater13.5 quarts
16.5 quarts12.8 L
15.6 L
Differential Fluid
Front Axle
Rear Axle2.6 pints
3.5 pints1.2 L
1.7 L
Engine Oil with Filter 4.5 quarts 4.3 L
Fuel Tank 27.0 gallons 101.8 L
5-107

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

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

27,000 Miles (45 000 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 #.)
30,000 Miles (50 000 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 #.)
❑For Two-Wheel-Drive vehicles only: Clean and
repack the front wheel bearings (or at each
brake relining, whichever occurs rst).
❑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.❑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.
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).
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-71for proper rotation pattern and additional
information.(See footnote +.)
33,000 Miles (55 000 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 #.)
6-9

60,000 Miles (100 000 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 #.)
❑For Two-Wheel-Drive vehicles only: Clean and
repack the front wheel bearings (or at each
brake relining, whichever occurs rst).
❑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.
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 +.)
63,000 Miles (105 000 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 #.)
66,000 Miles (110 000 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 +.)
6-12

❑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).
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-71for proper rotation pattern and additional
information.(See footnote +).
22,500 Miles (37 500 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 +).
30,000 Miles (50 000 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 #).❑For Two-Wheel-Drive vehicles only: Clean and
repack the front wheel bearings (or at each
brake relining, whichever occurs rst).
❑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.
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).
❑Rotate tires. SeeTire Inspection and Rotation on
page 5-71for proper rotation pattern and additional
information.(See footnote +).
❑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.
6-17