maintenance schedule CHEVROLET ASTRO CARGO VAN 2004 2.G Owners Manual

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-3
Rear Seats
............................................... 1-7
Safety Belts
.............................................1-13
Child Restraints
.......................................1-35
Air Bag System
.......................................1-62
Restraint System Check
............................1-68
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-15
Theft-Deterrent Systems
............................2-17
Starting and Operating Your Vehicle
...........2-18
Mirrors
....................................................2-31
HomeLink
®Transmitter
.............................2-32
Storage Areas
.........................................2-36
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-2
Climate Controls
......................................3-17
Warning Lights, Gages, and Indicators
........3-22
Audio System(s)
.......................................3-35
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-29Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-4
Checking Things Under the Hood
................. 5-9
All-Wheel Drive
........................................5-50
Rear Axle
...............................................5-51
Front Axle
...............................................5-52
Bulb Replacement
....................................5-53
Windshield Wiper Blade Replacement
.........5-59
Tires
......................................................5-60
Appearance Care
.....................................5-91
Vehicle Identication
.................................5-99
Electrical System
....................................5-100
Capacities and Specications
...................5-107
Normal Maintenance Replacement Parts
....5-109
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-11
Index................................................................ 1
2004 Chevrolet Astro Owner ManualM

Oil Pressure Gage
The oil pressure gage
shows the engine oil
pressure in psi (pounds
per square inch) when
the engine is running.
Canadian vehicles indicate pressure in kPa
(kilopascals). Oil pressure may vary with engine speed,
outside temperature and oil viscosity, but readings
above the low pressure zone indicate the normal
operating range.
A reading in the low pressure zone may be caused by
a dangerously low oil level or other problems causing
low oil pressure.{CAUTION:
Do not keep driving if the oil pressure is low.
If you do, your engine can become so hot that
it catches re. You or others could be burned.
Check your oil as soon as possible and have
your vehicle serviced.
Notice:Lack of proper engine oil maintenance
may damage the engine. The repairs would not
be covered by your warranty. Always follow
the maintenance schedule in this manual for
changing engine oil.
3-32

Parking on Hills
{CAUTION:
You really should not park your vehicle, with
a trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.
But if you ever have to park your rig on a hill, here’s
how to do it:
1. Apply your regular brakes, but don’t shift into
PARK (P) yet.
2. Have someone place chocks under the
trailer wheels.
3. When the wheel chocks are in place, release
the regular brakes until the chocks absorb
the load.
4. Reapply the regular brakes. Then apply
your parking brake, and shift to PARK (P).
5. Release the regular brakes.
When You Are Ready to Leave
After Parking on a Hill
1. Apply your regular brakes and hold the pedal
down while you:
start your engine,
shift into a gear, and
release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store
the chocks.
Maintenance When Trailer Towing
Your vehicle will need service more often when you’re
pulling a trailer. See the Maintenance Schedule for
more on this. Things that are especially important in
trailer operation are automatic transmission uid
(don’t overll), engine oil, axle lubricant, belt, cooling
system and brake system. Each of these is covered
in this manual, and the Index will help you nd
them quickly. If you’re trailering, it’s a good idea to
review these sections before you start your trip.
Check periodically to see that all hitch nuts and
bolts are tight.
4-44

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

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

3. Check both sides of the dipstick, and read the lower
level. The uid level must be in the COLD area for
a cold check or in the HOT or cross-hatched
area for a hot check. Be sure to keep the dipstick
pointed down to get an accurate reading.
4. If the uid level is in the acceptable range, push
the dipstick back in all the way; then ip the
handle down to lock the dipstick in place.
How to Add Fluid
Refer to the Maintenance Schedule to determine
what kind of transmission uid to use. SeePart D:
Recommended Fluids and Lubricants on page 6-28.If the uid level is low, add only enough of the
proper uid to bring the level up to the HOT area
for a hot check.
1. Pull out the dipstick.
2. Using a funnel, add uid down the transmission
dipstick tube only after checking the transmission
uid while it is hot. (A cold check is used only
as a reference.)
It does not take much uid, generally less than
one pint (0.5 L).Do not overll.
Notice:We recommend you use only uid labeled
DEXRON
®-III, because uid with that label is
made especially for your automatic transmission.
Damage caused by uid other than DEXRON
®-III is
not covered by your new vehicle warranty.
3. After adding uid, recheck the uid level as
described under “How to Check,” earlier in
this section.
4. When the correct uid level is obtained, push the
dipstick back in all the way; then ip the handle
down to lock the dipstick in place.
5-25

{CAUTION:
If you have too much brake uid, it can spill on
the engine. The uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
uid only when work is done on the brake
hydraulic system. See “Checking Brake Fluid”
in this section.
Refer to the Maintenance Schedule to determine
when to check your brake uid. SeePart C: Periodic
Maintenance Inspections on page 6-26.
Checking Brake Fluid
You can check the brake uid without taking off the cap.
Just look at the brake uid reservoir. The uid level
should be above MIN. If it is not, have your brake
system checked to see if there is a leak.
After work is done on the brake hydraulic system,
make sure the level is above the MIN but not over
the MAX mark.
5-41

All-Wheel Drive
Lubricant checks in this section also apply to these
vehicles. However, there are two additional systems
that need lubrication.
Transfer Case
When to Check Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant. SeePart C: Periodic
Maintenance Inspections on page 6-26.
How to Check Lubricant
To get an accurate reading, the vehicle should be on
a level surface.
If the level is below the bottom of the ller plug hole,
you’ll need to add some lubricant. Add enough lubricant
to raise the level to the bottom of the ller plug hole.
Use care not to overtighten the plug.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeePart D: Recommended
Fluids and Lubricants on page 6-28.
5-50

Rear Axle
When to Check Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant. SeePart A: Scheduled
Maintenance Services on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on
a level surface.If the level is below the bottom of the ller plug hole,
you’ll need to add some lubricant. Add enough lubricant
to raise the level to the bottom of the ller plug hole.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeePart D: Recommended
Fluids and Lubricants on page 6-28.
5-51

Front Axle
When to Check and Change Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant and when to change it. See
Part A: Scheduled Maintenance Services on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on
a level surface.
If the level is below the
bottom of the ller plug
hole, you may need to
add some lubricant.When the differential is cold, add enough lubricant
to raise the level to 1/2 inch (12 mm) below the ller
plug hole.
When the differential is at operating temperature
(warm), add enough lubricant to raise the level to
the bottom of the ller plug hole.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeePart D: Recommended
Fluids and Lubricants on page 6-28.
5-52