2004 CHEVROLET ASTRO CARGO VAN radiator cap

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

Adding Coolant
If you need more coolant, add the proper DEX-COOL®
coolant mixtureat the coolant recovery tank,but be
careful not to spill it.
{CAUTION:
Turning the radiator pressure cap when the
engine and radiator are hot can allow steam
and scalding liquids to blow out and burn you
badly. With the coolant recovery tank, you
will almost never have to add coolant at the
radiator. Never turn the radiator pressure
cap — even a little — when the engine and
radiator are hot.
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol,
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.Occasionally check the coolant level in the radiator.
For information on how to add coolant to the radiator,
seeCooling System on page 5-31.
Radiator Pressure Cap
Notice:If the pressure cap is not tightly installed,
coolant loss and possible engine damage may occur.
Be sure the cap is properly and tightly secured.
The radiator pressure cap
is located in the engine
compartment on the
passenger’s side of the
vehicle. SeeEngine
Compartment Overview
on page 5-12for more
information on location.
5-28

Cooling System
When you decide it is safe to lift the hood, here is what
you will see:
A. Coolant Recovery Tank
B. Radiator Pressure Cap
C. Engine Cooling FanIf the coolant inside the coolant recovery tank is
boiling, do not do anything else until it cools down.
The vehicle should be parked on a level surface.
SeeEngine Compartment
Overview on page 5-12
for more information
on location.
5-31

The coolant level should be at the ADD mark. If it is
not, you may have a leak at the pressure cap or in the
radiator hoses, heater hoses, radiator, water pump
or somewhere else in the cooling system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them.
If you do, you can be burned.
Do not run the engine if there is a leak.
If you run the engine, it could lose all coolant.
That could cause an engine re, and you
could be burned. Get any leak xed before
you drive the vehicle.If there seems to be no leak, start the engine again.
The engine cooling fan speed should increase when
idle speed is doubled by pushing the accelerator pedal
down. If it does not, your vehicle needs service.
Turn off the engine.
Notice:Engine damage from running your engine
without coolant is not covered by your warranty.
Notice:Using coolant other than DEX-COOL®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
5-32

When the coolant in the coolant recovery tank is at the
ADD mark, start your vehicle.
If the overheat warning continues, there is one more
thing you can try. You can add the proper coolant
mixture directly to the radiator, but be sure the cooling
system is cool before you do it.
{CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They
are under pressure, and if you turn the radiator
pressure cap — even a little — they can come
out at high speed. Never turn the cap when the
cooling system, including the radiator pressure
cap, is hot. Wait for the cooling system and
radiator pressure cap to cool if you ever have
to turn the pressure cap.
5-34

How to Add Coolant to the Radiator
1. You can remove the
radiator pressure
cap when the cooling
system, including the
radiator pressure cap
and upper radiator
hose, is no longer hot.
Turn the pressure cap
slowly counterclockwise
until it rst stops.
Do not press down
while turning the
pressure cap.
If you hear a hiss, wait for that to stop.
A hiss means there is still some pressure left.2. Then keep turning
the pressure cap,
but now push down
as you turn it.
Remove the
pressure cap.
5-35

3. Fill the radiator with the proper DEX-COOL®
coolant mixture, up to the base of the ller
neck. SeeEngine Coolant on page 5-26for more
information about the proper coolant mixture.4. Then ll the coolant recovery tank to the ADD mark.
5. Put the cap back on the coolant recovery tank,
but leave the pressure cap off.
5-36

3
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
ller neck may be lower. If the level is lower, add
more of the proper DEX-COOL
®coolant mixture
through the ller neck until the level reaches
the base of the ller neck.
Then replace the pressure cap. At any time during
this procedure if coolant begins to ow out of
the ller 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.
5-37