2003 CHEVROLET ASTRO CARGO VAN automatic transmission

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 over®ll),
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.
4-40

Service............................................................5-3
Doing Your Own Service Work.........................5-3
Adding Equipment to the Outside
of Your Vehicle...........................................5-4
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Speci®cations....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling Your Tank............................................5-8
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-11
Hood Release..............................................5-11
Engine Compartment Overview.......................5-14
Engine Oil...................................................5-15
Engine Cover...............................................5-20
Engine Air Cleaner/Filter................................5-24
Automatic Transmission Fluid.........................5-25
Engine Coolant.............................................5-28
Radiator Pressure Cap..................................5-30
Engine Overheating.......................................5-31Cooling System............................................5-33
Engine Fan Noise.........................................5-39
Power Steering Fluid.....................................5-40
Windshield Washer Fluid................................5-41
Brakes........................................................5-42
Battery........................................................5-46
Jump Starting...............................................5-47
All-Wheel Drive..............................................5-52
Rear Axle.......................................................5-53
Front Axle......................................................5-54
Bulb Replacement..........................................5-55
Halogen Bulbs..............................................5-55
Headlamps..................................................5-55
Front Turn Signal Lamps...............................5-59
Taillamps.....................................................5-60
Replacement Bulbs.......................................5-61
Windshield Wiper Blade Replacement..............5-62
Tires..............................................................5-63
In¯ation Ð Tire Pressure...............................5-64
Tire Inspection and Rotation...........................5-64
When It Is Time for New Tires.......................5-66
Section 5 Service and Appearance Care
5-1

Notice:If the air cleaner/®lter is off, a back®re 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're driving.
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 90ÉF (32ÉC) 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).
See
Part 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 90ÉF (32ÉC).
·At high speed for quite a while.
·In heavy traffic Ð especially in hot weather.
·While pulling a trailer.
To get the right reading, the ¯uid should be at normal
operating temperature, which is 180ÉF to 200ÉF
(82ÉC to 93ÉC).
5-25

3. Check both sides of the dipstick, and read the lower
level. The ¯uid level must be in the COLD area,
below the cross-hatched area, for a cold check or in
the HOT area or cross-hatched area for a hot check.
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 6-32.
Add ¯uid only after checking the transmission ¯uid while
it is hot. (A cold check is used only as a reference.)
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. It doesn't take much ¯uid, generally less
than one pint (0.5 L).
Don't over®ll.
Notice:We recommend you use only ¯uid labeled
DEXRONž-III, because ¯uid with that label is
made especially for your automatic transmission.
Damage caused by ¯uid other than DEXRON
ž-III is
not covered by your new vehicle warranty.
·After adding ¯uid, recheck the ¯uid level as
described under ªHow to Check.º
·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.
5-27

1. Check the other vehicle. It must have a 12±-volt
battery with a negative ground system.
Notice:If the other system isn't a 12-volt system
with a negative ground, both vehicles can be
damaged.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles aren't touching
each other. If they are, it could cause a ground
connection you don't want. You wouldn't be able to
start your vehicle, and the bad grounding could
damage the electrical systems.
To avoid the possibility of the vehicles rolling, set
the parking brake ®rmly on both vehicles involved in
the jump start procedure. Put an automatic
transmission in PARK (P) and a manual
transmission in NEUTRAL.
3. Turn off the ignition on both vehicles. Unplug
unnecessary accessories plugged into the cigarette
lighter or accessory power outlets. Turn off all
lamps that aren't needed as well as radios.
This will avoid sparks and help save both batteries.
In addition, it could save your radio!
Notice:If you leave your radio on, it could be badly
damaged. The repairs wouldn't be covered by
your warranty.4. Open the hoods and locate the batteries. Find the
positive (+) and negative (-) terminals on each
battery.
{CAUTION:
Using a match near a battery can cause battery
gas to explode. People have been hurt doing
this, and some have been blinded. Use a
¯ashlight if you need more light.
Be sure the battery has enough water. You
don't need to add water to the ACDelco
ž
battery installed in your new vehicle. But if a
battery has ®ller caps, be sure the right
amount of ¯uid is there. If it is low, add water
to take care of that ®rst. If you don't, explosive
gas could be present.
Battery ¯uid contains acid that can burn you.
Don't get it on you. If you accidentally get it in
your eyes or on your skin, ¯ush the place with
water and get medical help immediately.
5-48

Selecting the Right Schedule
First you'll need to decide which of the two schedules is
right for your vehicle. Here's how to decide which
schedule to follow:
Short Trip/City De®nition
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 De®nition
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.
6-6

12,000 Miles (20 000 km)
qChange engine oil and ®lter (or every 3 months,
whichever occurs ®rst).An Emission Control Service.
qLubricate chassis components (or every 3 months,
whichever occurs ®rst).(See footnote #.)
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle seals
for leaking.
qRotate tires. See
Tire Inspection and Rotation on
page 5-64for proper rotation pattern and additional
information.(See footnote +.)
15,000 Miles (25 000 km)
qChange engine oil and ®lter (or every 3 months,
whichever occurs ®rst).An Emission Control Service.
qLubricate chassis components (or every 3 months,
whichever occurs ®rst).(See footnote #.)
qInspect engine air cleaner ®lter. If necessary, replace
the ®lter. If vehicle is driven in dusty/dirty conditions,
inspect ®lter at every engine oil change. See
Engine
Air Cleaner/Filter on page 5-24for more information.An Emission Control Service. (See footnote ².)
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle seals
for leaking.qFor Two-Wheel-Drive vehicles only: Clean and repack
the front wheel bearings (or at each brake relining,
whichever occurs ®rst).
qChange automatic transmission ¯uid and ®lter if the
vehicle is mainly driven under one or more of these
conditions:
þ In heavy city traffic where the outside
temperature regularly reaches 90ÉF (32ÉC)
or higher.
þ In hilly or mountainous terrain.
þ When doing frequent trailer towing.
þ 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).
18,000 Miles (30 000 km)
qChange engine oil and ®lter (or every 3 months,
whichever occurs ®rst).An Emission Control Service.
qLubricate chassis components (or every 3 months,
whichever occurs ®rst).(See footnote #.)
qCheck rear/front axle ¯uid level and add ¯uid as
needed. Check constant velocity joints and axle seals
for leaking.
qRotate tires. See
Tire Inspection and Rotation on
page 5-64for proper rotation pattern and additional
information.(See footnote +.)
6-8