2005 CHEVROLET ASTRO CARGO VAN service

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 Fan
If 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.The coolant level should be at the ADD mark if the
engine is cold, or the FULL HOT mark if the engine is
warm. 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.
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Notice:
Using the wrong uid can badly damage brake
system parts. For example, just a few drops of
mineral-based oil, such as engine oil, in your
brake system can damage brake system
parts so badly that they will have to be replaced.
Do not let someone put in the wrong kind of
uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged.
Be careful not to spill brake uid on your
vehicle. If you do, wash it off immediately.
SeeAppearance Care on page 5-82.
Brake Wear
Your vehicle has four-wheel disc brakes.
Disc brake pads have built-in wear indicators that make
a high-pitched warning sound when the brake pads
are worn and new pads are needed. The sound
may come and go or be heard all the time your vehicle
is moving, except when you are pushing on the
brake pedal rmly.
{CAUTION:
The brake wear warning sound means that
soon your brakes will not work well. That
could lead to an accident. When you hear the
brake wear warning sound, have your vehicle
serviced.
Notice:Continuing to drive with worn-out brake
pads could result in costly brake repair.
Some driving conditions or climates may cause a brake
squeal when the brakes are rst applied or lightly
applied. This does not mean something is wrong with
your brakes.
Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to GM torque specications.
Brake linings should always be replaced as complete
axle sets.
SeeBrake System Inspection on page 6-29.
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9. Connect the other end of the negative (−) cable at
least 18 inches (45 cm) away from the dead battery,
but not near engine parts that move. The electrical
connection is just as good there, and the chance
of sparks getting back to the battery is much less.
10. Now start the vehicle with the good battery and run
the engine for a while.
11. Try to start the vehicle with the dead battery. If it
will not start after a few tries, it probably needs
service.
Notice:If the jumper cables are connected or
removed in the wrong order, electrical shorting may
occur and damage the vehicle. The repairs would
not be covered by your warranty. Always connect
and remove the jumper cables in the correct
order, making sure that the cables do not touch
each other or other metal.A. Heavy, Unpainted Metal Engine Part or Remote
Negative (−) Terminal
B. Good Battery or Remote Positive (+) and Remote
Negative (−) Terminals
C. Dead Battery or Remote Positive (+) TerminalJumper Cable Removal
5-44

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 6-29.
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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 6-29.
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Tires
Your new vehicle comes with high-quality tires made by
a leading tire manufacturer. If you ever have questions
about your tire warranty and where to obtain service,
see your GM Warranty booklet for details. For additional
information refer to the tire manufacturer’s booklet
included with your vehicle’s Owner Manual.
{CAUTION:
Poorly maintained and improperly used tires
are dangerous.
Overloading your tires can cause
overheating as a result of too much
friction. You could have an air-out and a
serious accident. SeeLoading Your
Vehicle on page 4-28.
CAUTION: (Continued)
CAUTION: (Continued)

Underinated tires pose the same danger
as overloaded tires. The resulting accident
could cause serious injury. Check all tires
frequently to maintain the recommended
pressure. Tire pressure should be
checked when your tires are cold. See
Inflation - Tire Pressure on page 5-61.
Overinated tires are more likely to be cut,
punctured or broken by a sudden
impact —such as when you hit a pothole.
Keep tires at the recommended pressure.
Worn, old tires can cause accidents.
If your tread is badly worn, or if your tires
have been damaged, replace them.
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Tire Sidewall Labelling
Useful information about a tire is molded into its
sidewall. The examples below show a typical passenger
vehicle tire and a compact spare tire sidewall.(A) Tire Size:The tire size is a combination of letters
and numbers used to dene a particular tire’s width,
height, aspect ratio, construction type and service
description. See the “Tire Size” illustration later in this
section for more detail.
(B) TPC Spec (Tire Performance Criteria
Specication):Original equipment tires designed to
GM’s specic tire performance criteria have a TPC
specication code molded onto the sidewall. GM’s TPC
specications meet or exceed all federal safety
guidelines.
(C) DOT (Department of Transportation):The
Department of Transportation (DOT) code indicates that
the tire is in compliance with the U.S. Department of
Transportation Motor Vehicle Safety Standards.
Passenger (P-Metric) Tire Example
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(B) Tire Ply Material:The type of cord and number of
plies in the sidewall and under the tread.
(C) Tire Identication Number (TIN):The letters and
numbers following the DOT (Department of
Transportation) code is the Tire Identication Number
(TIN). The TIN shows the manufacturer and plant code,
tire size, and date the tire was manufactured. The
TIN is molded onto both sides of the tire, although only
one side may have the date of manufacture.
(D) Maximum Cold Ination Load Limit:Maximum
load that can be carried and the maximum pressure
needed to support that load.
(E) Tire Ination:The temporary use tire or compact
spare tire should be inated to 60 psi (420 kPa).
For more information on tire pressure and ination see
Ination - Tire Pressure on page 5-61.
(F) Tire Size:A combination of letters and numbers
dene a tire’s width, height, aspect ratio, construction
type and service description. The letter T as the
rst character in the tire size means the tire is for
temporary use only.
(G) TPC Spec (Tire Performance Criteria
Specication):Original equipment tires designed to
GM’s specic tire performance criteria have a TPC
specication code molded onto the sidewall. GM’s TPC
specications meet or exceed all federal safety
guidelines.Tire Size
The following illustration shows an example of a typical
passenger vehicle tire size.
(A) Passenger (P-Metric) Tire:The United States
version of a metric tire sizing system. The letter P as the
rst character in the tire size means a passenger
vehicle tire engineered to standards set by the U.S. Tire
and Rim Association.
(B) Tire Width:The three-digit number indicates the
tire section width in millimeters from sidewall to sidewall.
(C) Aspect Ratio:A two-digit number that indicates
the tire height-to-width measurements. For example, if
the tire size aspect ratio is 60, as shown in item C of the
illustration, it would mean that the tire’s sidewall is 60
percent as high as it is wide.
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