2003 CHEVROLET ASTRO fuel cap

The 2003 Chevrolet Astro Owner Manual
Seats and Restraint Systems ........................... I-!
Front Seats ............................................... 1-2
Rear Seats
............................................... 1-7
Safety Belts
............................................. 1-13
Child Restraints
....................................... 1-35
Air Bag System
....................................... 1-62
Restraint System Check
............................ 1-71
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
................................................. 2-1 6
Theft-Deterrent Systems
............................ 2-1 8
Mirrors
.................................................... 2-32
HomeLink@ Transmitter
............................. 2-34
Features and Controls ..................................... 2-1
Starting and Operating Your Vehicle
........... 2-19
Storage Areas
Instrument Panel .
Instrument Panel
Climate Controls
......................................... 2-38
........................................... 3-1
Overview .......................... 3-2
...................................... 3-18
Warning Lights. Gages and Indicators
......... 3-23
Audio System(s)
....................................... 3-38
Driving Your Vehicle ....................................... 4-1
Your Driving, the Road, and Your Vehicle
........ 4-2
Towing
................................................... 4-29
Service and Appearance Care .......................... 5-1
Service ..................................................... 5-3
Fuel
......................................................... 5-5
All-Wheel Drive
........................................ 5-52
Rear Axle ............................................... 5-53
Front Axle
............................................... 5-54
Bulb Replacement
.................................... 5-55
Windshield Wiper Blade Replacement ......... 5-62
Tires
...................................................... 5-63
Appearance Care
..................................... 5-83
Vehicle Identification
................................. 5-91
Electrical System
...................................... 5-92
Capacities and Specifications
..................... 5-99
Normal Maintenance Replacement Parts
...... 5-1 01
Maintenance Schedule ..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance Information .................... 7-1
Customer Assistance Information
.................. 7-2
Reporting Safety Defects ........................... 7-10
Checking Things Under
the Hood
............... 5-11
Index ................................................................ 1

If the Light Is Flashing
The following may prevent more serious damage to
your vehicle:
Reducing vehicle speed.
Avoiding hard accelerations.
Avoiding steep uphill grades.
If you are towing a trailer, reduce the amount of
cargo being hauled as soon as it is possible.
If the light stops flashing and remains on steady,
see
“If the Light Is On Steady” following.
If the light continues to flash, when it is safe to do so,
stop the vehicle. Find a safe place to park your vehicle.
Turn the key off, wait at least
10 seconds and restart
the engine.
If the light remains on steady, see “If the
Light
Is On Steady” following. If the light is still flashing,
follow the previous steps, and drive the vehicle to
your dealer or qualified service center for service.
If the Light Is On Steady
You may be able to correct the emission system
malfunction by considering the following:
Did you recently put fuel into your vehicle?
If so, reinstall the fuel cap, making sure to fully
install the cap. See
Filling Your Tank on page 5-8.
The diagnostic system can determine if the fuel cap has
been left off or improperly installed. A loose or missing
fuel cap will allow fuel to evaporate into the atmosphere.
A few driving trips with the cap properly installed
should turn the light off.
Did you just drive through a deep puddle of water?
If
so, your electrical system may be wet. The condition
will usually be corrected when the electrical system
dries out.
A few driving trips should turn the light off.
Have you recently changed brands of fuel?
If
so, be sure to fuel your vehicle with quality fuel.
See
Gasoline Octane on page 5-5. Poor fuel quality
will cause your engine not to run as efficiently as
designed. You may notice this as stalling after start-up,
stalling when you put the vehicle into gear, misfiring,
hesitation on acceleration or stumbling on acceleration.
(These conditions may go away once the engine is
warmed up.) This will be detected by the system and
cause the light to turn on.
3-32

Towing Loading Your Vehicle
Towing
Your Vehicle
Consult your dealer or a professional towing service if
you need to have your disabled vehicle towed.
See
Roadside Assistance Program on page 7-6.
If you want to tow your vehicle behind another vehicle
for recreational purposes (such as behind a motorhome),
see “Recreational Vehicle Towing” following.
Recreational Vehicle Towing
Recreational vehicle towing means towing your vehicle
behind another vehicle
- such as behind a motorhome.
The two most common types
of recreational vehicle
towing are known as “dinghy towing” (towing your vehicle
with all four wheels on the ground) and “dolly towing”
(towing your vehicle with two wheels on the ground and
two wheels up on a device known as a “dolly”).
Your vehicle was not designed to be towed with any
of
its wheels on the ground. If your vehicle must be
towed, see
Towing Your Vehicle on page 4-29.
Notice: Towing an all-wheel-drive vehicle with all
four wheels on the ground, or even with only two
of
its wheels on the ground, will damage drivetrain
components. Don’t tow an all-wheel-drive vehicle
if
any of its wheels will be on the ground.
1 I GWVR GAWR FRT GAWR RR 1
COLD TIRE PRESSURI
DO nn
NERS MANUAL FOR ADDITIONAL INFORMATION^ I
The Certificationflire label in your vehicle will look
similar to this example.
The Certificationflire label is found on the rear edge of
the driver’s door. The label shows the size
of your
original tires and the inflation pressures needed to obtain
the gross weight capacity of your vehicle.
This is called the Gross Vehicle Weight Rating (GVWR).
The GVWR includes the weight of the vehicle, all
occupants, fuel, cargo and tongue weight,
if pulling
a trailer.
4-29

Section 5 Service and Appearance Care
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 Specifications .................................... 5.5
California Fuel ............................................. -56
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 .................... 5-1 1
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
....................................... 5.31
Cooling 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
Replacement Bulbs
....................................... 5-61
Windshield Wiper Blade Replacement .............. 5-62
Tires .............................................................. 5.63
Inflation
- Tire Pressure ................................ 5-64
Tire Inspection and Rotation
........................... 5-64
When It
Is Time for New Tires ....................... 5-66
Buying New Tires
......................................... 5-66
Uniform Tire Quality Grading
.......................... 5-67
Wheel Alignment and Tire Balance
.................. 5-69
Wheel Replacement
...................................... 5-69
Tire Chains
.................................................. 5-70
If a Tire Goes Flat ........................................ 5.70
Changing a Flat Tire ..................................... 5.71
Compact Spare Tire ...................................... 5-82
Taillamps
.................................................... 5-60
5- 1

Filling Your Tank
Fuel vapor is highly flammable. It burns
violently, and that can cause very bad injuries.
Don’t smoke
if you’re near fuel or refueling
your vehicle. Keep sparks, flames and smoking
materials away from fuel.
The tethered fuel cap is behind a hinged door on the
driver’s side of your vehicle.
5-8

While refueling, let the fuel cap hang by the tether
below the fuel
fill opening.
To remove the fuel cap, turn it slowly to the left
(counterclockwise). The fuel cap has a spring in it;
if you let go of the cap too soon, it will spring back to
the right.
d lf you get fuel on yourself and then something
ignites
it, you could be badly burned. Fuel can
spray out on you if you open the fuel cap too
quickly. This spray can happen
if your tank is
nearly full, and is more likely in hot weather.
Open the fuel cap slowly and wait for any
“hiss” noise to stop. Then unscrew the cap
all the way.
Be careful not to spill fuel. Clean fuel from painted
surfaces as soon as possible. See
Cleaning the Outside
of Your Vehicle on page 5-86. When filling the tank
do not overfill by squeezing in much more fuel after the
pump shuts off.
5-9

When you put the fuel cap back on, turn it to the
right (clockwise) until you hear a clicking sound.
Make sure you fully install
the cap. The diagnostic
system can determine
if the fuel cap has been left off or
improperly installed. This would allow fuel to evaporate
into the atmosphere. See
Malfunction lndicator Lamp
on page 3-30.
Notice: If you need a new fuel cap, be sure to get
the right type. Your dealer can get one for you.
If you get the wrong type, it may not fit properly.
This may cause your malfunction indicator lamp to
light and may damage your fuel tank and emissions
system. See “Malfunction lndicator Lamp”
in the
Index.
Filhg a Portable Fuel Container
~
Never fill a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor. You can be badly burned and your vehicle
damaged if this occurs.
To help avoid injury to
you and others:
Dispense gasoline only into approved
containers.
Do not fill a container while it is inside a
vehicle,
in a vehicle’s trunk, pickup bed or
on any surface other than the ground.
Bring the fill nozzle in contact with the
inside of the
fill opening before operating
the nozzle. Contact should be maintained until the filling is complete.
Don’t smoke while pumping gasoline.
5-1 0

6. Start the engine and let it run until you can feel the
upper radiator hose getting hot. Watch out for the
engine cooling fan.
7. By this time, the coolant level inside the radiator
filler neck may be lower.
If the level is lower, add
more of the proper
DEX-COOL@ coolant mixture
through the filler neck until the level reaches
the base of the filler neck.
Then replace the pressure cap. At any time during
this procedure
if coolant begins to flow out of
the filler neck, reinstall the pressure cap. Be sure
the arrow on the pressure cap lines up.
Engine Fan Noise
This vehicle has a clutched engine cooling fan. When
the clutch is engaged, the fan spins faster to provide
more air to cool the engine. In most everyday driving
conditions, the clutch is not fully engaged. This improves
fuel economy and reduces fan noise. Under heavy
vehicle loading, trailer towing and/or high outside
temperatures, the fan speed increases when the clutch
engages.
So you may hear an increase in fan noise.
This is normal and should not be mistaken as the
transmission slipping or making extra shifts. It is merely
the cooling system functioning properly. The fan will
slow down when additional cooling is not required and
the clutch disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch disengages.
5-39