check engine CHEVROLET ASTRO PASSENGER 1994 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Cooling System Capacity
ENGINE
4.3L
4.3L
VIN CODE
Z
w
QUANTITY* Without Rear
Heater
13.5 Quarts
( 12.8 Liters)
13.5 Quarts
(12.8 Liters)
QUANTITY*
With Rear Heater
16.5 Quarts
( 15.5 Liters)
16.5 Quarts
( 15.5 Liters)
*All quantities are approximate. After refill,
the level MUST be checked.
Crankcase Capacity
ENGINE
4.3L
4.3L
VIN CODE
Z
w
QUANTITY*
Without Filter
4 Quarts
(3.8 Liters)
4 Quarts
(3.8 Liters)
QUANTITY*
With Filter
4.5 Quarts
(4.3 Liters)
4.5 Quarts
(4.3 Liters)
*All quantities are approximate. After refill, the level MUST be checked.
Do not overfill.
Fuel Tank Capacity
TYPE
Standard Tank
*All quantities are approximate.
QUANTITY*
27 Gallons (102 Liters)
6-69

Downloaded from www.Manualslib.com manuals search engine Scheduled Maintenance Services
I
Section
This section covers the maintenance required for your vehicle . Your vehicle
needs these services to retain its safety. dependability. and emission control
performance
.
A Word About Maintenance ................. . . 7-2
Your Vehicle and the Environment
......................... 7-2
Scheduled Maintenance Services
............................... 7-3
Selecting The Proper Maintenance Schedule
................. 7-3
Maintenance Schedule I
.............................. 7-4
Maintenance Schedule I1
................................ 7-6
Explanation
of Scheduled Maintenance Services .............. 7-7
Owner Checks and Services
................................ 7-10
At Least Once a Month .............. ............... 7-10
At Least Once a Year
............. ........... .... 7-10
Periodic Maintenance Inspections
............... ...... 7-12
Recommended Fluids
& Lubricants ........................... 7-13
MaintenanceRecord
....................................... 7-15
Service Station Checks
................................... 7-16
Protection
Plan
Have you purchased the GM Protection Plan? The Plan supplements
your new vehicle warranties
. See your Vehicle dealer for details .
7-1

Downloaded from www.Manualslib.com manuals search engine A Word About Maintenance
We at General Motors want to help you keep your vehicle in good working
condition. But we don’t know exactly how you’ll drive
it. You may drive
very 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
GM vehicles, maintenance
needs vary.
You may even need more frequent checks and replacements than
you will find
in the schedules in this section. So please read this section and
note how
you drive. If you have any questions on how to keep your vehicle
in good condition, see your GM dealer, the place many GM owners choose
to have their maintenance work done. Your dealer can be relied upon to
use
proper parts and practices.
Your Vehicle A d The Environment
Proper vehicle mainte nce not only helps keep your vehicle in good
working condition, bur
11 also helps the environment. All recommended
maintenance procedures are important. Improper vehicle maintenance or the
removal of important components can significantly affect the quality
of the
air we breathe. Improper fluid levels or even the wrong tire inflation can
increase
the level of emissions from your vehicle. To help protect our
environment, and to help keep your vehicle
in good condition, please
maintain your vehicle properly.
If you are skilled enough to do some work on your vehicle,
you will
probably want to get the service information GM publishes. You will find a
list
of publications and how to get them in Section 8, Customer Assistance
Information.
See “Service Publications” in the Index.
The Maintenance Record provides a place for you to record the maintenance
performed on your vehicle. Whenever
any maintenance is performed, be
sure to write it down in this section. This will help you determine when your
next maintenance should be done. In addition,
it is a good idea to keep your
maintenance receipts. They may be needed
to qualify your vehicle for
warranty repairs.
7-2

Downloaded from www.Manualslib.com manuals search engine MAlNTENANCE SCHEDULE I/
Item Miles (000) 7.5 15 22.5 30
No. Kilometers (000) 12.5 25 37.5 50
Service
Oil Filter Change*- 12 Months, or
1 12 Months, or I 1 1 I
2 Chassis Lubrication-Every
3 Cooling System Service*
-Every
24 Months or
4 I Air Cleaner Filter Replacement* I I I I 0
5 Front Wheel Bearing Repack
(2WD Only) 0
6 Transmission Service **
7 Fuel Filter Replacement*$ 0
8 Spark Plug Replacement* 0
9 Spark Plug Wire Inspection*
10 Engine Timing Check*$
11 Fuel Tank, Cap and Lines
12 Engine Accessory Drive Belt
13 Tire and Wheel Rotation
0 0
14 Drive Axle Service 0.00
15 Brake Systems Inspection** Inspection*$
Inspection”
* An Emission Control Service
** See “Explanation of Scheduled Maintenance Services” in the Index
$ The California Air Resources Board has determined that the fail\
ure to perform this
maintenance item will not nullify the emission warranty or limi\
t recall liability prior
to the
completion
of vehicle useful life. General Motors, however, urges that all recommended
maintenance services be performed at the indicated intervals and\
the maintenance be
recorded.
THE SERVICES SHOWN
ON THIS CHART UP TO 60,000 MILES (100 000 km) ARE TO BE
DONE AFTER
60,000 MILES AT THE SAME INTERVALS.
TI 003
7-6

Downloaded from www.Manualslib.com manuals search engine Explanation Of Scheduled Maintenance Services
Below are explanations of the services listed in the maintenance charts.
The proper fluids and lubricants to use are listed
in this section. Make sure
whoever services your vehicle uses these. All parts should
be replaced and
all necessary repairs done before you or anyone else drives the vehicle.
1.
2.
3.
4.
5.
ENGINE OIL AND OIL FILTER CHANGE“ - ALWAYS USE
API SERVICE
SH OR SG ENERGY CONSERVING I1 OILS OF THE
PROPER VISCOSITY. The
“SH7 or “SG7 designation may be shown
alone or in combination with others, such as “SWCD”, or
“SH, SG,
CD,” or “SG/CD”, etc. To determine the preferred viscosity oil for your
vehicle’s engine see “Engine Oil”
in the Index.
CHASSIS LUBRICATION - Lubricate the front suspension,
steering linkage, transfer case shift linkage, parking brake cab\
le guides,
and brake pedal springs at the intervals specified on the proper
maintenance schedule, or at every engine oil change, whichever \
comes
first.
Ball joints and king pin bushings should not be lubricated unless their
temperature is
10°F (-1 2°C) or higher. When the weather is cold, let
them warm up before lubricating them or they could be damaged.\

Also, be sure to check all the vehicle fluid levels at this \
time.
COOLING SYSTEM SERVICE* - Drain, flush and refill the
system
with new or approved recycled coolant conforming to “GM
Specification 6038-M”. See “Engine Coolant”
in the Index for the
proper coolant and mixture to use
in your vehicle.
Also inspect the hoses and replace them
if they are cracked, swollen, or
deteriorated. Clean the outside of the radiator and air conditioning
condenser. Wash the radiator neck.
To ensure proper operation,
pressure test the radiator and cap.
AIR CLEANER FILTER REPLACEMENT* - Replace at
specified intervals. Ask your dealer for the proper replacement
intervals for your driving conditions.
FRONT WHEEL BEARING REPACK
(2-WHEEL DRIVE ONLY)
- Clean and repack the front wheel
bearings at each brake relining,
or at the specified interval, whichever
comes first.
* An Emission Control Service
7-7

Downloaded from www.Manualslib.com manuals search engine 6. TRANSMISSION SERVICE: - Change the transmission fluid and
filter 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
In hilly or mountainous terrain.
higher.
Frequent trailer pulling.
0 Uses
such as taxi, police, delivery or other commercial service.
If the vehicle
is not used mainly under any of these conditions, change
the fluid and filter every
30,000 miles (50 000 km). See “Automatic
Transmission Fluid” in the Index for more information.
7. FUEL FILTER REPLACEMENT*$ - Replace the fuel filter at the
specified interval or sooner if clogged.
8. SPARK PLUG REPLACEMENT* - Replace spark plugs with the
type listed in Section
6. See “Specification Charts” in the Index.
9. SPARK PLUG WIRE INSPECTION* - Clean wires and inspect
for bums, cracks or other damage. Check the wire boot fit at the
distributor and at the spark plugs. Replace wires as needed.
Adjust timing to underhood label specifications. Inspect the inside and
outside
of the distributor cap and rotor for cracks, carbon tracking and
corrosion. Clean or replace as needed.
10. ENGINE TIMING CHECK AND DISTRIBUTOR CHECK*$ -
11. FUEL TANK, CAP AND LINES INSPECTION*$ - Inspect the
fuel tank, cap and lines for damage or leaks. Remove fuel cap, inspect
gasket for an even filler neck imprint, and any damage. Replace parts
as needed.
12. ENGINE ACCESSORY DRIVE BELT INSPECTION* - Inspect
belt.
Look for cracks, fraying, wear, and proper tension. Adjust or
replace as needed.
* An Emission Control Service
$ 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 vehicle useful life. General Motors, however, urges that all re\
commended
maintenance services be performed at the indicated intervals and\
the maintenance be
recorded.
7-8

Downloaded from www.Manualslib.com manuals search engine 13. TIRE AND WHEEL ROTATION AND INSPECTION - For
proper wear and maximum tire life, rotate tires at the first
6,000 miles
(10
000 kilometers) for Schedule I or 7,500 miles (12 500 kilometers)
for Schedule I1 and
then every 15,000 miles (25 000 kilometers)
thereafter. Follow the instructions and patterns shown in Sectio\
n
6.
Check tires for uneven wear or damage. If irregular or premature wear
is apparent, check wheel alignment. Also, check for damaged wheels.
See “Tires” in the Index for more information.
14.
DRIVE AXLE SERVICE - Check readfront axle fluid level and add
as needed. Check constant velocity joints and axle seals for leaking.
Locking Differential - Drain fluid at first oil change and refill.
Check fluid level and add as needed at subsequent oil changes. In
dusty areas or trailer towing applications, drain fluid at every
15,000 miles (24 135 kilometers) and refill.?
Standard Differential - Check fluid level and add as needed at
every oil change. In dusty areas or trailer towing applications\
,
drain fluid every
15,000 miles (24 135 kilometers) and refill.?
15. BRAKE SYSTEM INSPECTION - When the engine oil is changed,
inspect the lines and hoses for proper hookup, binding, leaks, cracks,
chafing, etc. Check the parking brake adjustment, and the fluid\
level in the master cylinder. A low fluid level can indicate
worn disc brake pads
which may need to be serviced.?
When the wheels are removed for rotation, inspect disc brake pads for
wear and rotors for surface condition. Also inspect drum brake linings
for wear and cracks. Inspect other brake parts, including drums, wh\
eel
cylinders, parking brake, etc. at the same time.
Inspect brakes more often if driving habits or conditions resul\
t in
frequent braking.
-f A fluid loss in these systems may indicate a problem. Have them inspected a\
nd
repaired at once.
7-9

Downloaded from www.Manualslib.com manuals search engine Owner Checks and Services
Listed below are owner checks and services which would be made at the
time period specified
to help ensure proper safety, emission performance,
and dependability
of your vehicle.
Be sure
any necessary repairs are completed at once. Whenever any fluids
or lubricants are added to your vehicle, make sure they are t\
he proper ones,
as shown in this section.
At Least Once a Month
Tire Inflation Pressure Check - Check the tires for proper inflation. If
they
are low, inflate them to the level specified on the Certification label.
See “Inflation-Tire Pressure” in
the Index.
At Least Once a Year
Key Lock Cylinder Lubrication - Lubricate key lock cylinders with one
of the lubricants recommended in this section.
Transmission Neutral or Clutch Start Switch Operation -
1. Before you start, be sure you have enough room around the veh\
icle.
2. Firmly apply both the manual parking brake, and the regular br\
ake. See
“Brakes” and “Parking Brake”
in the Index. Do not use the accelerator
pedal.
3. Be ready to turn off the engine immediately if it starts.
4. Try to start the engine in each gear. The starter should work only in “P”
(Park) or “N’ (Neutral).
7- 10

Downloaded from www.Manualslib.com manuals search engine Steering Column Lock Operation - While parked, try to turn the key to
LOCK in each gear shift position.
0 The key should turn to LOCK only when the gear shift is in “P”
(Park).
On all vehicles, the key should come out only in
LOCK.
Parking Brake and Transmission
“P’ (Park) Mechanism Operation -
-
Park on a fairly steep hill, with the vehicle facing downhill. Keeping your
foot on the regular brake, set the manual parking brake.
0 To check the parking brake: With the engine running and the
transmission in
“N’ (Neutral), slowly remove foot pressure from the
regular brake pedal.
Do this until the vehicle is held by the parking
brake only.
0 To check the “P” (Park) mechanism’s holding ability: Apply the regular
brake and shift
to T“ (Park). Release the manual parking brake, then
slowly release the regular brake.
Lap and Shoulder Belts Condition and Operation - Inspect belt system,
including: webbing, buckles, latch plates, retractors, guide loops and
anchors. Have a belt assembly replaced if the webbing has been cut or
otherwise damaged.
Body Lubrication Service - Lubricate all body door hinges. Lubricate the
body hood, fuel door and rear compartment hinges, latches and locks
including interior
glove box and console doors, and any moving seat
hardware. Lubricate the hood safety lever pivot and prop rod pivot. More
frequent lubrication may be required when exposed
to a corrosive
environment.
7-11

Downloaded from www.Manualslib.com manuals search engine Periodic Maintenance Inspections
Listed below are inspections and services which should be perfo\
rmed at
least twice a year (for instance, each spring and fall). You should let your
GM dealer’s service department or other qualified service center do these
jobs. Make sure any necessary repairs are completed at once.
Steering and Suspension Inspection? - Inspect front and rear suspension
and steering system for damaged, loose or missing parts, signs of wear or
lack of lubrication. Inspect power steering lines and hoses for proper
hook-up, binding, leaks, cracks, chafing, etc. Lubricate the steering linkage.
Accelerator Control System - Lubricate all pivot points with engine oil,
except the
TBI throttle shaft. Do not lubricate the cam pulley. Remove all
external deposits from pulley.
Do not oil any accelerator or cruise control
cables. Replace any cables that have high effort or excessive \
wear.
Exhaust System Inspection - Inspect the complete 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 conn\
ections or
other conditions which could cause a heat buildup
in the floor pan or could
let exhaust fumes seep into the passenger compartments. See “\
Engine
Exhaust”
in the Index.
Drive Axle Service - Check readfront axle fluid level and add as needed.
Check constant velocity joints and axle seals for leaking.
Transfer Case (all-wheel drive) Inspection? - Every 12 months or at oil
change intervals, check front axle and transfer case and add l\
ubricant when
necessary. Oil the control lever pivot point (except
L Van) and all exposed
control linkage. Check vent hose at transfer case for kinks and proper
installation.
-F A fluid loss in these systems may indicate a problem. Have them inspected a\
nd
repaired
at once.
7- 12