2002 Chevrolet Astro Owners Manual

Weatherstrip Lubrication Silicone grease on weatherstrips will make them last longer, seal better, and not stick or squeak. Apply silicone grease with a clean cloth. During very cold, damp weather more frequent application may be required. See “Recommended Fluids and Lubricants” in the Index.

Automatic Transmission Check Check the transmission fluid level; add if needed. See “Automatic Transmission Fluid” in the Index. A fluid loss may indicate a problem. Check the system and repair if needed. At Least Once a Year

Key Lock Cylinders Service Lubricate the key lock cylinders with the lubricant specified in Part D.

Body Lubrication Service Lubricate all body door hinges, the body hood, fuel door and rear compartment hinges, latches and locks inluding interior glove box and console doors, hood latch assembly, secondary latch, pivots, spring anchor, release pawl and any moving seat hardware. Lubricate the hood safety lever pivot and prop rod pivot. Part D tells you what to use. More frequent lubrication may be required when exposed to a corrosive environment.

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Starter Switch Check

CAUTION:

When you are doing this check, the vehicle could move suddenly. If it does, you or others could be injured. Follow the steps below.

1. Before you start, be sure you have enough room

around the vehicle.

2. Firmly apply both the parking brake and the regular brake. See “Parking Brake” in the Index if necessary. Do not use the accelerator pedal, and be ready to turn off the engine immediately if it starts.

3. Try to start the engine in each gear. The starter

should work only in PARK (P) or NEUTRAL (N). If the starter works in any other position, your vehicle needs service.

Automatic Transmission Shift Lock Control System Check

CAUTION:

When you are doing this check, the vehicle could move suddenly. If it does, you or others could be injured. Follow the steps below.

1. Before you start, be sure you have enough

room around the vehicle. It should be parked on a level surface.

2. Firmly apply the parking brake. See “Parking Brake”

in the Index if necessary. Be ready to apply the regular brake immediately if the vehicle begins to move.

3. With the engine off, turn the key to the RUN

position, but don’t start the engine. Without applying the regular brake, try to move the shift lever out of PARK (P) with normal effort. If the shift lever moves out of PARK (P), your vehicle needs service.

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Ignition Transmission Lock Check While parked, and with the parking brake set, try to turn the ignition key to LOCK in each shift lever position. D The key should turn to LOCK only when the shift

lever is in PARK (P).

D The key should come out only in LOCK.

Parking Brake and Automatic Transmission PARK (P) Mechanism Check

CAUTION:

When you are doing this check, your vehicle could begin to move. You or others could be injured and property could be damaged. Make sure there is room in front of your vehicle in case it begins to roll. Be ready to apply the regular brake at once should the vehicle begin to move.

Park on a fairly steep hill, with the vehicle facing downhill. Keeping your foot on the regular brake, set the parking brake. D To check the parking brake’s holding ability: With the engine running and transmission in NEUTRAL (N), slowly remove foot pressure from the regular brake pedal. Do this until the vehicle is held by the parking brake only.

D To check the PARK (P) mechanism’s holding

ability: With the engine running, shift to PARK (P). Then release the parking brake followed by the regular brake.

Underbody Flushing Service At least every spring, use plain water to flush any corrosive materials from the underbody. Take care to clean thoroughly any areas where mud and other debris can collect.

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Part C: Periodic Maintenance Inspections Listed in this part are inspections and services which should be performed at least twice a year (for instance, each spring and fall). You should let your dealer’s service department or other qualified service center do these jobs. Make sure any necessary repairs are completed at once. Proper procedures to perform these services may be found in a service manual. See “Service and Owner Publications” in the Index.

Steering, Suspension and Front Drive Axle Boot and Seal Inspection Inspect the front and rear suspension and steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect the power steering lines and hoses for proper hook-up, binding, leaks, cracks, chafing, etc. Clean and then inspect the drive axle boot seals for damage, tears or leakage. Replace seals if necessary. Exhaust System Inspection Inspect the complete exhaust 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 connections or other conditions which could cause a heat build-up in the floor pan or could let exhaust fumes into the vehicle. See “Engine Exhaust” in the Index.

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Fuel System Inspection Inspect the complete fuel system for damage or leaks. Engine Cooling System Inspection Inspect the hoses and have them replaced if they are cracked, swollen or deteriorated. Inspect all pipes, fittings and clamps; replace as needed. Clean the outside of the radiator and air conditioning condenser. To help ensure proper operation, a pressure test of the cooling system and pressure cap is recommended at least once a year. Throttle System Inspection Inspect the throttle system for interference or binding, and for damaged or missing parts. Replace parts as needed. Replace any components that have high effort or excessive wear. Do not lubricate accelerator and cruise control cables.

Transfer Case and Front Axle (All-Wheel Drive) Inspection Every 12 months or at engine oil change intervals, check front axle and transfer case and add lubricant when necessary. A fluid loss could indicate a problem; check and have it repaired, if needed. Check vent hose at transfer case for kinks and proper installation. Brake System Inspection Inspect the complete system. Inspect brake lines and hoses for proper hook-up, binding, leaks, cracks, chafing, etc. 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, wheel cylinders, calipers, parking brake, etc. Check parking brake adjustment. You may need to have your brakes inspected more often if your driving habits or conditions result in frequent braking.

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Part D: Recommended Fluids and Lubricants Fluids and lubricants identified below by name, part number or specification may be obtained from your dealer.

USAGE

Engine Oil

Engine Coolant

FLUID/LUBRICANT

Engine oil with the American Petroleum Institute Certified for Gasoline Engines starburst symbol of the proper viscosity. To determine the preferred viscosity for your vehicle’s engine, see “Engine Oil” in the Index.

50/50 mixture of clean, drinkable water and use only GM GoodwrenchR DEX-COOLR or HavolineR DEX-COOLR Coolant. See “Engine Coolant” in the Index.

USAGE

FLUID/LUBRICANT

Hydraulic Brake System

Windshield Washer Solvent

Parking Brake Cable Guides

Power Steering System

Automatic Transmission

Key Lock Cylinders

Delco Supreme 11R Brake Fluid (GM Part No. 12377967 or equivalent DOT-3 brake fluid). GM OptikleenR Washer Solvent (GM Part No. 1051515) or equivalent.

Chassis Lubricant (GM Part No. 12377985 or equivalent) or lubricant meeting requirements of NLGI # 2, Category LB or GC-LB.

GM Power Steering Fluid (GM Part No. 1052884 - 1 pint, 1050017 - 1 quart, or equivalent). DEXRONR-III Automatic Transmission Fluid.

Multi-Purpose Lubricant, SuperlubeR (GM Part No. 12346241 or equivalent).

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USAGE

Chassis Lubrication

Front Wheel Bearings

Front Axle

Rear Axle

FLUID/LUBRICANT

Chassis Lubricant (GM Part No. 12377985 or equivalent) or lubricant meeting requirements of NLGI # 2, Category LB or GC-LB.

Wheel bearing lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. 1051344 or equivalent). SAE 80W-90 Axle Lubricant (GM Part No. 1052271 or equivalent). SAE 75W-90 Synthetic Axle Lubricant (GM Part No. 12378261) or equivalent meeting GM Specification 9986115.

USAGE

Transfer Case

FLUID/LUBRICANT AUTO-TRAK II Fluid (GM Part No. 12378508).

Hood Latch Assembly, Secondary Latch, Pivots, Spring Anchor and Release Pawl

Hood and Door Hinges

Weatherstrip Conditioning

LubriplateR Lubricant Aerosol (GM Part No. 12346293 or equivalent) or lubricant meeting requirements of NLGI # 2, Category LB or GC-LB.

Multi-Purpose Lubricant, SuperlubeR (GM Part No. 12346241 or equivalent).

Dielectric Silicone Grease (GM Part No. 12345579 or equivalent).

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Part E: Maintenance Record After the scheduled services are performed, record the date, odometer reading and who performed the service in the boxes provided after the maintenance interval. Any additional information from “Owner Checks and Services” or “Periodic Maintenance” can be added on the following record pages. Also, you should retain all maintenance receipts. Your owner information portfolio is a convenient place to store them.

DATE

ODOMETER

READING

SERVICED BY

MAINTENANCE PERFORMED

Maintenance Record

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DATE

ODOMETER

READING

SERVICED BY

MAINTENANCE PERFORMED

Maintenance Record

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DATE

ODOMETER

READING

SERVICED BY

MAINTENANCE PERFORMED

Maintenance Record

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Section 8 Customer Assistance Information

Here you will find out how to contact Chevrolet if you need assistance. This section also tells you how to obtain service publications and how to report any safety defects.

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Customer Satisfaction Procedure Customer Assistance for Text Telephone (TTY) Users Customer Assistance Offices GM Mobility Program for Persons with Disabilities Chevrolet Roadside Assistance Program Canadian Roadside Assistance

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Courtesy Transportation Warranty Information Reporting Safety Defects to the United States Government Reporting Safety Defects to the Canadian Government Reporting Safety Defects to General Motors

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Customer Satisfaction Procedure

Your satisfaction and goodwill are important to your dealer and to Chevrolet. Normally, any concerns with the sales transaction or the operation of your vehicle will be resolved by your dealer’s sales or service departments. Sometimes, however, despite the best intentions of all concerned, misunderstandings can occur. If your concern has not been resolved to your satisfaction, the following steps should be taken: STEP ONE -- Discuss your concern with a member of dealership management. Normally, concerns can be quickly resolved at that level. If the matter has already been reviewed with the sales, service or parts manager, contact the owner of the dealership or the general manager.

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STEP TWO -- If after contacting a member of dealership management, it appears your concern cannot be resolved by the dealership without further help, contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020. In Canada, contact GM of Canada Customer Communication Centre in Oshawa by calling 1-800-263-3777 (English) or 1-800-263-7854 (French). We encourage you to call the toll-free number in order to give your inquiry prompt attention. Please have the following information available to give the Customer Assistance Representative: D Vehicle Identification Number (This is available from the vehicle registration or title, or the plate at the top left of the instrument panel and visible through the windshield.)

D Dealership name and location D Vehicle delivery date and present mileage When contacting Chevrolet, please remember that your concern will likely be resolved at a dealer’s facility. That is why we suggest you follow Step One first if you have a concern.

STEP THREE -- Both General Motors and your dealer are committed to making sure you are completely satisfied with your new vehicle. However, if you continue to remain unsatisfied after following the procedure outlined in Steps One and Two, you should file with the GM/BBB Auto Line Program to enforce any additional rights you may have. Canadian owners refer to your Warranty and Owner Assistance Information booklet for information on the Canadian Motor Vehicle Arbitration Plan (CAMVAP). The BBB Auto Line Program is an out of court program administered by the Council of Better Business Bureaus to settle automotive disputes regarding vehicle repairs or the interpretation of the New Vehicle Limited Warranty. Although you may be required to resort to this informal dispute resolution program prior to filing a court action, use of the program is free of charge and your case will generally be heard within 40 days. If you do not agree with the decision given in your case, you may reject it and proceed with any other venue for relief available to you.

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Customer Assistance Offices Chevrolet encourages customers to call the toll-free number for assistance. If a U.S. customer wishes to write to Chevrolet, the letter should be addressed to Chevrolet’s Customer Assistance Center. United States

Chevrolet Motor Division Chevrolet Customer Assistance Center P.O. Box 33170
Detroit, MI 48232-5170
1-800-222-1020
1-800-833-2438 (For Text Telephone devices (TTYs)) Roadside Assistance: 1-800-CHEV-USAR (243-8872) From: Puerto Rico:

1-800-496-9992 (English) 1-800-496-9993 (Spanish) 1-800-496-9994

U.S. Virgin Islands:

Fax Number: 313-381-0022

You may contact the BBB using the toll-free telephone number or write them at the following address:

BBB Auto Line Council of Better Business Bureaus, Inc. 4200 Wilson Boulevard Suite 800
Arlington, VA 22203-1804
Telephone: 1-800-955-5100

This program is available in all 50 states and the District of Columbia. Eligibility is limited by vehicle age, mileage and other factors. General Motors reserves the right to change eligibility limitations and/or discontinue its participation in this program. Customer Assistance for Text Telephone (TTY) Users To assist customers who are deaf, hard of hearing, or speech-impaired and who use Text Telephones (TTYs), Chevrolet has TTY equipment available at its Customer Assistance Center. Any TTY user can communicate with Chevrolet by dialing: 1-800-833-CHEV (2438). (TTY users in Canada can dial 1-800-263-3830.)

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Canada

General Motors of Canada Limited Customer Communication Centre, 163-005
1908 Colonel Sam Drive Oshawa, Ontario L1H 8P7
1-800-263-3777 (English) 1-800-263-7854 (French) 1-800-263-3830 (For Text Telephone devices (TTYs)) Roadside Assistance: 1-800-268-6800

All Overseas Locations Please contact the local General Motors Business Unit. Mexico, Central America and Caribbean Islands/Countries (Except Puerto Rico and U.S. Virgin Islands)

General Motors de Mexico, S. de R.L. de C.V. Customer Assistance Center Paseo de la Reforma # 2740
Col. Lomas de Bezares C.P. 11910, Mexico, D.F. 01-800-508-0000
Long Distance: 011-52 - 53 29 0 800

GM Mobility Program for Persons with Disabilities

This program, available to qualified applicants, can reimburse you up to $1,000
toward aftermarket driver or passenger adaptive equipment you may require for your vehicle (hand controls, wheelchair/scooter lifts, etc.).

This program can also provide you with free resource information, such as area driver assessment centers and mobility equipment installers. The program is available for a limited period of time from the date of vehicle purchase/lease. See your dealer for more details or call the GM Mobility Assistance Center at 1-800-323-9935. Text telephone (TTY) users, call 1-800-833-9935. GM of Canada also has a Mobility Program. Call 1-800-GM-DRIVE (463-7483) for details. When calling from outside Canada, please dial 1-905-644-3063. All TTY users call 1-800-263-3830.

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Roadside Assistance is available 24 hours a day, 365 days a year, by calling 1-800-CHEV-USA (243-8872). This toll-free number will provide you over-the-phone roadside assistance with minor mechanical problems. If your problem cannot be resolved over the phone, our advisors have access to a nationwide network of dealer recommended service providers. Roadside membership is free; however some services may incur costs. Roadside offers two levels of service to the customer, Basic Care and Courtesy Care: Roadside Basic Care provides: D Toll-free number, 1-800-CHEV-USA (243-8872), text telephone (TTY) users, call 1-888-889-2438

D Free towing for warranty repairs D Basic over-the-phone technical advice D Available dealer services at reasonable costs (i.e., wrecker services, locksmith/key service, glass repair, etc.)

Chevrolet Roadside Assistance Program

To enhance Chevrolet’s strong commitment to customer satisfaction, Chevrolet is excited to announce the establishment of the Chevrolet Roadside Assistance Center. As the owner of a 2002 Chevrolet, membership in Roadside Assistance is free.

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Roadside Courtesy Care provides: D Roadside Basic Care services (as outlined previously)

Plus:

D FREE Non-Warranty Towing (to the closest dealer

from a legal roadway)

D FREE Locksmith/Key Service (when keys are lost

on the road or locked inside)

D FREE Flat Tire Service (spare installed on the road) D FREE Jump Start (at home or on the road) D FREE Fuel Delivery ($5 of fuel delivered on the road) Chevrolet offers Courtesy Transportation for customers needing warranty service. Courtesy Transportation will be offered in conjunction with the coverage provided by the Bumper-to-Bumper New Vehicle Limited Warranty to eligible purchasers of 2002 Chevrolet passenger cars and light duty trucks. (Please see your selling dealer for details.)

Courtesy Care is available to retail and retail lease customers operating 2002 and newer Chevrolet vehicles for a period of 3 years/36,000 miles (60 000 km), whichever occurs first. All Courtesy Care services must be pre-arranged by Chevrolet Roadside or dealer service management. Basic Care and Courtesy Care are not part of or included in the coverage provided by the New Vehicle Limited Warranty. Chevrolet reserves the right to modify or discontinue Basic Care and Courtesy Care at any time. The Roadside Assistance Center uses companies that will provide you with quality and priority service. When roadside services are required, our advisors will explain any payment obligations that may be incurred for utilizing outside services.

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For prompt assistance when calling, please have the following available to give to the advisor: D Vehicle Identification Number (VIN) D License plate number D Vehicle color D Vehicle location D Telephone number where you can be reached D Vehicle mileage D Description of problem Canadian Roadside Assistance Vehicles purchased in Canada have an extensive Roadside Assistance program accessible from anywhere in Canada or the United States. Please refer to the Warranty and Owner Assistance Information book or call 1-800-268-6800 for emergency services.

Courtesy Transportation Chevrolet has always exemplified quality and value in its offering of motor vehicles. To enhance your ownership experience, we and our participating dealers are proud to offer Courtesy Transportation, a customer support program for new vehicles. The Courtesy Transportation program is offered to retail purchase/lease customers in conjunction with the Bumper-to-Bumper coverage provided by the New Vehicle Limited Warranty. Several transportation options are available when warranty repairs are required. This will reduce your inconvenience during warranty repairs. Plan Ahead When Possible When your vehicle requires warranty service, you should contact your dealer and request an appointment. By scheduling a service appointment and advising your service consultant of your transportation needs, your dealer can help minimize your inconvenience. If your vehicle cannot be scheduled into the service department immediately, keep driving it until it can be scheduled for service, unless, of course, the problem is safety-related. If it is, please call your dealership, let them know this, and ask for instructions.

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If the dealer requests that you simply drop the vehicle off for service, you are urged to do so as early in the work day as possible to allow for same day repair. Transportation Options Warranty service can generally be completed while you wait. However, if you are unable to wait Chevrolet helps minimize your inconvenience by providing several transportation options. Depending on the circumstances, your dealer can offer you one of the following:

Shuttle Service Participating dealers can provide you with shuttle service to get you to your destination with minimal interruption of your daily schedule. This includes a one way shuttle ride to a destination up to 10 miles from the dealership.

Public Transportation or Fuel Reimbursement If your vehicle requires overnight warranty repairs, reimbursement up to $30 per day (five days maximum) may be available for the use of public transportation such as taxi or bus. In addition, should you arrange transportation through a friend or relative, reimbursement for reasonable fuel expenses up to $10 per day (five day maximum) may be available. Claim amounts should reflect actual costs and be supported by original receipts.

Courtesy Rental Vehicle When your vehicle is unavailable due to overnight warranty repairs, your dealer may arrange to provide you with a courtesy rental vehicle or reimburse you for a rental vehicle you obtained, at actual cost, up to a maximum of $30.00 per day supported by receipts. This requires that you sign and complete a rental agreement and meet state, local and rental vehicle provider requirements. Requirements vary and may include minimum age requirements, insurance coverage, credit card, etc. You are responsible for fuel usage charges and may also be responsible for taxes, levies, usage fees, excessive mileage or rental usage beyond the completion of the repair. Generally it is not possible to provide a like-vehicle as a courtesy rental. Additional Program Information Courtesy Transportation is available during the Bumper-to-Bumper warranty coverage period, but it is not part of the New Vehicle Limited Warranty. A separate booklet entitled “Warranty and Owner Assistance Information” furnished with each new vehicle provides detailed warranty coverage information.

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Courtesy Transportation is available only at participating dealers and all program options, such as shuttle service, may not be available at every dealer. Please contact your dealer for specific information about availability. All Courtesy Transportation arrangements will be administered by appropriate dealer personnel. Canadian Vehicles: For warranty repairs during the Complete Vehicle Coverage period of the General Motors of Canada New Vehicle Limited Warranty, alternative transportation may be available under the Courtesy Transportation Program. Please consult your dealer for details. General Motors reserves the right to unilaterally modify, change or discontinue Courtesy Transportation at any time and to resolve all questions of claim eligibility pursuant to the terms and conditions described herein at its sole discretion. Warranty Information Your vehicle comes with a separate warranty booklet that contains detailed warranty information.

REPORTING SAFETY DEFECTS TO THE UNITED STATES GOVERNMENT If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA), in addition to notifying General Motors. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer or General Motors. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in the Washington, D.C. area) or write to:

NHTSA, U.S. Department of Transportation Washington, D.C. 20590

You can also obtain other information about motor vehicle safety from the hotline.

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REPORTING SAFETY DEFECTS TO THE CANADIAN GOVERNMENT If you live in Canada, and you believe that your vehicle has a safety defect, you should immediately notify Transport Canada, in addition to notifying General Motors of Canada Limited. You may write to:

Transport Canada 330 Sparks Street Tower C Ottawa, Ontario K1A 0N5

REPORTING SAFETY DEFECTS TO GENERAL MOTORS In addition to notifying NHTSA (or Transport Canada) in a situation like this, we certainly hope you’ll notify us. Please call us at 1-800-222-1020, or write:

Chevrolet Motor Division Chevrolet Customer Assistance Center P.O. Box 33170
Detroit, MI 48232-5170

In Canada, please call us at 1-800-263-3777 (English) or 1-800-263-7854 (French). Or, write: General Motors of Canada Limited Customer Communication Centre, 163-005
1908 Colonel Sam Drive Oshawa, Ontario L1H 8P7

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SERVICE PUBLICATIONS ORDERING INFORMATION

Service Manuals Service Manuals have the diagnosis and repair information on engines, transmission, axle, suspension, brakes, electrical, steering, body, etc. RETAIL SELL PRICE: $120.00
Transmission, Transaxle, Transfer Case Unit Repair Manual This manual provides information on unit repair service procedures, adjustments and specifications for GM transmissions, transaxles and transfer cases. RETAIL SELL PRICE: $50.00
Service Bulletins Service Bulletins give technical service information needed to knowledgeably service General Motors cars and trucks. Each bulletin contains instructions to assist in the diagnosis and service of your vehicle.

Owner’s Information Owner publications are written specifically for owners and intended to provide basic operational information about the vehicle. The owner’s manual will include the Maintenance Schedule for all models. In-Portfolio: Includes a Portfolio, Owner’s Manual and Warranty Booklet. RETAIL SELL PRICE: $35.00

Without Portfolio: Owner’s Manual only. RETAIL SELL PRICE: $25.00
Current and Past Model Order Forms Service Publications are available for current and past model GM vehicles. To request an order form, please specify year and model name of the vehicle.

ORDER TOLL FREE: 1-800-551-4123 – Monday-Friday 8:00 AM – 6:00 PM Eastern Time

Visit Helm, Inc. on the World Wide Web at: www.helminc.com

For Credit Card Orders Only (VISA-MasterCard-Discover)

Helm, Incorporated S P.O. Box 07130 S Detroit, MI 48207

Prices are subject to change without notice and without incurring obligation. Allow ample time for delivery.

Note to Canadian Customers: All listed prices are quoted in U.S. funds. Canadian residents are to make checks payable in U.S. funds.

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