2004 Chevrolet Astro Owners Manual

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Buying New Tires .........................................5-70 Uniform Tire Quality Grading ..........................5-71 Wheel Alignment and Tire Balance ..................5-72 Wheel Replacement ......................................5-72 Tire Chains ..................................................5-74 If a Tire Goes Flat ........................................5-74 Changing a Flat Tire .....................................5-75 Compact Spare Tire ......................................5-86 5-1 Section 5 Service and Appearance Care Appearance Care ............................................5-86 Cleaning the Inside of Your Vehicle .................5-87 Care of Safety Belts ......................................5-89 Weatherstrips ...............................................5-89 Cleaning the Outside of Your Vehicle ..............5-90 Sheet Metal Damage .....................................5-92 Finish Damage .............................................5-93 Underbody Maintenance ................................5-93 Chemical Paint Spotting .................................5-93 Vehicle Care/Appearance Materials ..................5-94 Vehicle Identiﬁcation ......................................5-95 Vehicle Identiﬁcation Number (VIN) .................5-95 Service Parts Identiﬁcation Label .....................5-95 Electrical System ............................................5-95 Add-On Electrical Equipment ..........................5-95 Headlamp Wiring ..........................................5-96 Windshield Wiper Fuses ................................5-96 Power Windows and Other Power Options .......5-96 Fuses and Circuit Breakers ............................5-96 Capacities and Speciﬁcations ........................5-102 Normal Maintenance Replacement Parts .........5-104 Engine Drive Belt Routing ............................5-105 5-2 Service Your dealer knows your vehicle best and wants you to be happy with it. We hope you will go to your dealer for all your service needs. You will get genuine GM parts and GM-trained and supported service people. We hope you will want to keep your GM vehicle all GM. Genuine GM parts have one of these marks: Doing Your Own Service Work If you want to do some of your own service work, you will want to use the proper service manual. It tells you much more about how to service your vehicle than this manual can. To order the proper service manual, see ServicePublicationsOrderingInformationon page7-11. Your vehicle may have an air bag system. If it does, see ServicingYourAirBag-EquippedVehicleonpage1-69 before attempting to do your own service work. You should keep a record with all parts receipts and list the mileage and the date of any service work you perform. See PartE:MaintenanceRecordonpage6-32. {CAUTION: You can be injured and your vehicle could be damaged if you try to do service work on a vehicle without knowing enough about it. • Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task. CAUTION: (Continued) 5-3 CAUTION: (Continued) • Be sure to use the proper nuts, bolts and other fasteners. “English” and “metric” fasteners can be easily confused. If you use the wrong fasteners, parts can later break or fall off. You could be hurt. Adding Equipment to the Outside of Your Vehicle Things you might add to the outside of your vehicle can affect the airﬂow around it. This may cause wind noise and affect windshield washer performance. Check with your dealer before adding equipment to the outside of your vehicle. Fuel Use of the recommended fuel is an important part of the proper maintenance of your vehicle. Gasoline Octane Use regular unleaded gasoline with a posted octane of 87 or higher. If the octane is less than 87, you may get a heavy knocking noise when you drive. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. Otherwise, you might damage your engine. A little pinging noise when you accelerate or drive uphill is considered normal. This does not indicate a problem exists or that a higher-octane fuel is necessary. If you are using 87 octane or higher-octane fuel and hear heavy knocking, your engine needs service. 5-4 Gasoline Speciﬁcations It is recommended that gasoline meet speciﬁcations which were developed by automobile manufacturers around the world and contained in the World-Wide Fuel Charter which is available from the Alliance of Automobile Manufacturers at www.autoalliance.org. Gasoline meeting these speciﬁcations could provide improved driveability and emission control system performance compared to other gasoline. In Canada, look for the “Auto Makers’ Choice” label on the pump. California Fuel If your vehicle is certiﬁed to meet California Emission Standards (see the underhood emission control label), it is designed to operate on fuels that meet California speciﬁcations. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal speciﬁcations, but emission control system performance may be affected. The malfunction indicator lamp may turn on (see MalfunctionIndicatorLamponpage3-30 ) and your vehicle may fail a smog-check test. If this occurs, return to your authorized GM dealer for diagnosis. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. Canada Only 5-5 Some gasolines that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasolines. Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. If this occurs, return to your authorized GM dealer for service. Fuels in Foreign Countries If you plan on driving in another country outside the United States or Canada, the proper fuel may be hard to ﬁnd. Never use leaded gasoline or any other fuel not recommended in the previous text on fuel. Costly repairs caused by use of improper fuel would not be covered by your warranty. To check the fuel availability, ask an auto club, or contact a major oil company that does business in the country where you will be driving. Additives To provide cleaner air, all gasolines in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. You should not have to add anything to your fuel. However, some gasolines contain only the minimum amount of additive required to meet U.S. Environmental Protection Agency regulations. General Motors recommends that you buy gasolines that are advertised to help keep fuel injectors and intake valves clean. If your vehicle experiences problems due to dirty injectors or valves, try a different brand of gasoline. Gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines may be available in your area to contribute to clean air. General Motors recommends that you use these gasolines, particularly if they comply with the speciﬁcations described earlier. Notice: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage would not be covered under your warranty. 5-6 Filling Your Tank {CAUTION: Fuel vapor is highly ﬂammable. It burns violently, and that can cause very bad injuries. Do not smoke if you are near fuel or refueling your vehicle. Keep sparks, ﬂames and smoking materials away from fuel. While refueling, let the fuel cap hang by the tether below the fuel ﬁll opening. The tethered fuel cap is behind a hinged door on the driver’s side of your vehicle. 5-7 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 MalfunctionIndicatorLampon page3-30. 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 MalfunctionIndicatorLampon page3-30. 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. {CAUTION: If 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 CleaningtheOutside ofYourVehicleonpage5-90. When ﬁlling the tank do not overﬁll by squeezing in much more fuel after the pump shuts off. 5-8 Filling a Portable Fuel Container {CAUTION: 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. • Do not smoke while pumping gasoline. Checking Things Under the Hood {CAUTION: Things that burn can get on hot engine parts and start a ﬁre. These include liquids like fuel, oil, coolant, brake ﬂuid, windshield washer and other ﬂuids, and plastic or rubber. You or others could be burned. Be careful not to drop or spill things that will burn onto a hot engine. 5-9 Hood Release To open the hood, do the following: 1. Pull the handle located inside the vehicle on the lower driver’s side of the kick panel. 2. Then go to the front of the vehicle and release the secondary hood release. 5-10 3. Lift the hood, release the hood prop from its retainer and put the hood prop into the slot in the hood. 4. Lift the hood to relieve pressure on the hood prop and remove the hood prop from the slot in the hood. Before closing the hood, be sure all the ﬁller caps are on properly. 5. Return the prop to its retainer and pull the hood down. Then close it ﬁrmly. 5-11 Engine Compartment Overview When you open the hood, this is what you will see: 5-12 A. Windshield Washer Fluid. See WindshieldWasher Fluidonpage5-38. B. Engine Coolant. See EngineCoolantonpage5-25. C. Engine Oil Dipstick. See EngineOilonpage5-13. D. Transmission Dipstick. See AutomaticTransmission Fluidonpage5-22. E. Engine Air Cleaner/Filter. See EngineAir Cleaner/Filteronpage5-21. F. Engine Oil Fill. See EngineOilonpage5-13. G. Brake Master Cylinder Reservoir. See Brakeson page5-39. H. Power Steering Fluid Reservoir. See PowerSteering Fluidonpage5-37. I. Battery. See Batteryonpage5-42. Engine Oil Checking Engine Oil It is a good idea to check your engine oil every time you get fuel. In order to get an accurate reading, the oil must be warm and the vehicle must be on level ground. The engine oil dipstick handle is a yellow loop. See EngineCompartmentOverviewonpage5-12 for the location of the engine oil dipstick. Turn off the engine and give the oil several minutes to drain back into the oil pan. If you don’t, the oil dipstick might not show the actual level. Pull out the dipstick and clean it with a paper towel or cloth, then push it back in all the way. Remove it again, keeping the tip down, and check the level. 5-13 See EngineCompartment Overviewonpage5-12 for the location of the engine oil ﬁll cap. When to Add Engine Oil If the oil is at or below the ADD line, then you will need to add at least one quart of oil. But you must use the right kind. This section explains what kind of oil to use. For engine oil crankcase capacity, see Capacities andSpeciﬁcationsonpage5-102. Notice: Do not add too much oil. If your engine has so much oil that the oil level gets above the cross-hatched area that shows the proper operating range, your engine could be damaged. Be sure to add enough oil to put the level somewhere in the proper operating range. Push the dipstick all the way back in when you are through. What Kind of Engine Oil to Use Look for two things: • GM6094M Your vehicle’s engine requires oil meeting GM Standard GM6094M. You should look for and use only an oil that meets GM Standard GM6094M. 5-14 • SAE 5W-30 As shown in the viscosity chart, SAE 5W-30 is best for your vehicle. However, if it is going to be 0°F (–18°C) or above and SAE 5W-30 is not available, you may use SAE 10W-30. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certiﬁed by the American Petroleum Institute (API). You should look for this information on the oil container, and use only those oils that are identiﬁed as meeting GM Standard GM6094M and have the starburst symbol on the front of the oil container. 5-15 Notice: Use only engine oil identiﬁed as meeting GM Standard GM6094M and showing the American Petroleum Institute Certiﬁed For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench® oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below - 20°F (- 29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. Engine Oil Additives Do not add anything to your oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all you will need for good performance and engine protection. When to Change Engine Oil If any one of these are true for you, use the short trip/city maintenance schedule: • 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. • The vehicle is used for delivery service, police, taxi or other commercial application. Driving under these conditions causes engine oil to break down sooner. If any one of these is true for your vehicle, then you need to change your oil and ﬁlter every 3,000 miles (5 000 km) or 3 months – whichever occurs ﬁrst. 5-16 Engine Cover Removing the Engine Cover 1. Move both front seats as far back as they will go. If none of them is true, use the long trip/highway maintenance schedule. Change the oil and ﬁlter every 7,500 miles (12 500 km) or 12 months – whichever occurs ﬁrst. Driving a vehicle with a fully warmed engine under highway conditions will cause engine oil to break down slower. What to Do with Used Oil Used engine oil contains certain elements that may be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer’s warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the ﬁlter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Instead, recycle it by taking it to a place that collects used oil. If you have a problem properly disposing of your used oil, ask your dealer, a service station or a local recycling center for help. 5-17 2. Remove the instrument panel extension by removing the two nuts that secure it in place. The nuts are located at the bottom of the extension on the driver’s and passenger’s side corners. 3. Remove the screws located near the top on each side of the extension. Grasp the extension from both sides and gently remove it. 5-18 4. Disconnect the electrical connectors and set the extension aside. 5. Grasp the top of the heater duct and pull down gently to remove it. 5-19 6. Loosen the two bolts on the engine cover. The bolts are not supposed to come out of the cover, only from the front of the dash. When removing the cover, be careful not to damage the instrument panel or the trim. 7. Disconnect the AM radio ground strap. 8. Grasp the bottom of the cover and slide it rearward. Then, lift it up and out of the vehicle. If the seal does not release, use the pull strap on the driver’s side above the rear mount. 5-20 Reinstalling the Engine Cover 1. Lift the engine cover into the front of the vehicle and slide it all the way forward. Make sure the rubber seal is over the latches. 2. Tighten the two bolts located on the engine cover to reinstall the cover to the front of the dash. 3. Put the heater duct over the engine cover studs. Push up on the duct gently until it snaps into place. 4. Reconnect the electrical connectors. 5. Reconnect the AM radio ground strap. 6. Reinstall the engine cover extension by gently squeezing the sides and sliding it into place. Make sure all of the fastener clips engage and the extension ﬁts properly in place. Reinstall and tighten the two screws. 7. Reinstall the two nuts to secure the extension in place. Engine Air Cleaner/Filter See EngineCompartmentOverviewonpage5-12 for the location of the engine air cleaner/ﬁlter. When to Inspect the Engine Air Cleaner/Filter Inspect the engine air cleaner/ﬁlter every 15,000 miles (25 000 km) and replace every 30,000 miles (50 000 km). If you are driving in dusty/dirty conditions, inspect the ﬁlter at each engine oil change. 5-21 How to Inspect the Engine Air Cleaner/Filter To inspect the engine air cleaner/ﬁlter remove the ﬁlter from the vehicle and lightly shake ﬁlter to release loose dust and dirt. If the ﬁlter remains caked with dirt, a new ﬁlter is required. To inspect or replace the ﬁlter, do the following: 1. Unsnap both clips on the cover. 2. Remove the cover. 3. Change the ﬁlter. 4. Snap both clips to secure the engine air cleaner/ﬁlter cover. {CAUTION: Operating the engine with the air cleaner/ﬁlter off can cause you or others to be burned. The air cleaner not only cleans the air, it helps to stop ﬂame if the engine backﬁres. If it is not there and the engine backﬁres, you could be burned. Do not drive with it off, and be careful working on the engine with the air cleaner/ﬁlter off. 5-22 Notice: If the air cleaner/ﬁlter is off, a backﬁre can cause a damaging engine ﬁre. And, dirt can easily get into your engine, which will damage it. Always have the air cleaner/ﬁlter in place when you are driving. Automatic Transmission Fluid When to Check and Change A good time to check your automatic transmission ﬂuid level is when the engine oil is changed. Change both the ﬂuid and ﬁlter 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 90°F (32°C) 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 ﬂuid and ﬁlter every 50,000 miles (83 000 km). See PartA:ScheduledMaintenanceServiceson page6-4. 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 ﬂuid can damage your transmission. Too much can mean that some of the ﬂuid could come out and fall on hot engine part or exhaust system parts, starting a ﬁre. Too little ﬂuid could cause the transmission to overheat. Be sure to get an accurate reading if you check your transmission ﬂuid. Wait at least 30 minutes before checking the transmission ﬂuid level if you have been driving: • When outside temperatures are above 90°F (32°C). • At high speed for quite a while. • In heavy traffic – especially in hot weather. • While pulling a trailer. To get the right reading, the ﬂuid should be at normal operating temperature, which is 180°F to 200°F (82°C to 93°C). Get the vehicle warmed up by driving about 15 miles (24 km) when outside temperatures are above 50°F (10°C). If it’s colder than 50°F (10°C), drive the vehicle in DRIVE (D) until the engine temperature gage moves and then remains steady for 10 minutes. A cold ﬂuid check can be made after the vehicle has been sitting for eight hours or more with the engine off, but this is used only as a reference. Let the engine run at idle for ﬁve minutes if outside temperatures are 50°F (10°C) or more. If it’s colder than 50°F (10°C), you may have to idle the engine longer. Should the ﬂuid level be low during this cold check, you must check the ﬂuid hot before adding ﬂuid. Checking the ﬂuid hot will give you a more accurate reading of the ﬂuid level. 5-23 Checking the Fluid Level Prepare your vehicle as follows: • Park your vehicle on a level place. Keep the engine running. • With the parking brake applied, place the shift lever in PARK (P). • With your foot on the brake pedal, move the shift lever through each gear range, pausing for about three seconds in each range. Then, position the shift lever in PARK (P). • Let the engine run at idle for three minutes or more. Then, without shutting off the engine, follow these steps: The transmission dipstick is located near the center of the engine compartment and will be labeled with this graphic shown. See EngineCompartment Overviewonpage5-12 for more information on location. • Flip the handle up and then pull out the dipstick and wipe it with a clean rag or paper towel. • Push it back in all the way, wait three seconds and then pull it back out again. 5-24 • Check both sides of the dipstick, and read the lower level. The ﬂuid level must be in the COLD area for a cold check or in the HOT area or cross-hatched area for a hot check. Be sure to keep the dipstick pointed down to get an accurate reading. • If the ﬂuid level is in the acceptable range, push the dipstick back in all the way; then ﬂip the handle down to lock the dipstick in place. How to Add Fluid Refer to the Maintenance Schedule to determine what kind of transmission ﬂuid to use. See PartD: RecommendedFluidsandLubricantsonpage6-30. Using a funnel, add ﬂuid down the transmission dipstick tube only after checking the transmission ﬂuid while it is hot. (A cold check is used only as a reference.) If the ﬂuid level is low, add only enough of the proper ﬂuid to bring the level up to the HOT area for a hot check. It doesn’t take much ﬂuid, generally less than one pint (0.5 L). Don’toverﬁll. Notice: We recommend you use only ﬂuid labeled DEXRON® -III, because ﬂuid with that label is made especially for your automatic transmission. Damage caused by ﬂuid other than DEXRON® -III is not covered by your new vehicle warranty. • After adding ﬂuid, recheck the ﬂuid level as described under † How to Check.† • When the correct ﬂuid level is obtained, push the dipstick back in all the way; then ﬂip the handle down to lock the dipstick in place. Engine Coolant The cooling system in your vehicle is ﬁlled with DEX-COOL® engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs ﬁrst, if you add only DEX-COOL® extended life coolant. The following explains your cooling system and how to add coolant when it is low. If you have a problem with engine overheating, see EngineOverheatingon page5-28. A 50/50 mixture of clean, drinkable water and DEX-COOL® coolant will: • Give freezing protection down to - 34°F (- 37°C). • Give boiling protection up to 265°F (129°C). • Protect against rust and corrosion. • Help keep the proper engine temperature. • Let the warning lights and gages work as they should. 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 ﬁrst. Any repairs would not be covered by your warranty. Always use DEX-COOL®(silicate-free) coolant in your vehicle. 5-25 What to Use Use a mixture of one-half clean,drinkablewater and one-half DEX-COOL® coolant which won’t damage aluminum parts. If you use this coolant mixture, you don’t need to add anything else. {CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle’s coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch ﬁre and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and the proper coolant. Notice: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. 5-26 If you have to add coolant more than four times a year, have your dealer check your cooling system. Notice: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Checking Coolant The engine coolant tank is located in the engine compartment on the passenger’s side at the front. See Engine CompartmentOverviewon page5-12 for more information on location. The vehicle must be on a level surface. When your engine is cold, the coolant level should be at ADD, or a little higher. When your engine is warm, the level should be up to FULL HOT, or a little higher. Adding Coolant If you need more coolant, add the proper DEX-COOL® coolant mixtureatthecoolantrecoverytank. {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. Add coolant mixture at the recovery tank, but be careful not to spill it. {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, see CoolingSystemonpage5-30. Radiator Pressure Cap The radiator pressure cap is located in the engine compartment on the passenger’s side of the vehicle. 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. 5-27 Engine Overheating You will ﬁnd an engine coolant temperature gage on your vehicle’s instrument panel. See EngineCoolant TemperatureGageonpage3-30. If Steam Is Coming From Your Engine {CAUTION: Steam from an overheated engine can burn you badly, even if you just open the hood. Stay away from the engine if you see or hear steam coming from it. Just turn it off and get everyone away from the vehicle until it cools down. Wait until there is no sign of steam or coolant before you open the hood. If you keep driving when your engine is overheated, the liquids in it can catch ﬁre. You or others could be badly burned. Stop your engine if it overheats, and get out of the vehicle until the engine is cool. Notice: If your engine catches ﬁre because you keep driving with no coolant, your vehicle can be badly damaged. The costly repairs would not be covered by your warranty. 5-28 If No Steam Is Coming From Your Engine If you get an engine overheat warning but see or hear no steam, the problem may not be too serious. Sometimes the engine can get a little too hot when you: • Climb a long hill on a hot day. • Stop after high-speed driving. • Idle for long periods in traffic. • Tow a trailer. See † Driving on Grades” in Towinga Traileronpage4-35. If you get the overheat warning with no sign of steam, try this for a minute or so: 1. In heavy traffic, let the engine idle in NEUTRAL (N) while stopped. If it is safe to do so, pull off the road, shift to PARK (P) or NEUTRAL (N) and let the engine idle. 2. Turn on your heater to full hot at the highest fan speed and open the window as necessary. If you no longer have the overheat warning, you can drive. Just to be safe, drive slower for about 10 minutes. If the warning doesn’t come back on, you can drive normally. If the warning continues and you have not stopped, pull over, stop, and park your vehicle right away. If there’s still no sign of steam, you can push down the accelerator until the engine speed is about twice as fast as normal idle speed for at least three minutes while you’re parked. If you still have the warning,turnoffthe engineandgeteveryoneoutofthevehicle until it cools down. You may decide not to lift the hood but to get service help right away. 5-29 Cooling System When you decide it’s safe to lift the hood, here’s what you’ll see: If the coolant inside the coolant recovery tank is boiling, don’t 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 it isn’t, 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. A. Coolant Recovery Tank B. Radiator Pressure Cap C. Engine Cooling Fan 5-30 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 ﬁrst. Any repairs would not be covered by your warranty. Always use DEX-COOL®(silicate-free) coolant in your vehicle. {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 ﬁre, and you could be burned. Get any leak ﬁxed 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 doesn’t, your vehicle needs service. Turn off the engine. 5-31 How to Add Coolant to the Coolant Recovery Tank If you haven’t found a problem yet, but the coolant level isn’t at the ADD mark, add a 50/50 mixture of clean drinkablewater, and DEX-COOL® engine coolant at the coolant recovery tank. See EngineCoolanton page5-25 for more information. {CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle’s coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch ﬁre and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL® coolant. Notice: In cold weather, water can freeze and crack the engine, radiator, heater core and other parts. Use the recommended coolant and the proper coolant mixture. 5-32 {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. When the coolant in the coolant recovery tank is at the ADD mark, start your vehicle. If the overheat warning continues, there’s 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. 5-33 2. Then keep turning the pressure cap, but now push down as you turn it. Remove the pressure cap. How to Add Coolant to the Radiator You can remove the radiator pressure cap when the cooling system, including the radiator pressure cap and upper radiator hose, is no longer hot. 1. Turn the pressure cap slowly counterclockwise until it ﬁrst stops. (Don’t 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. 5-34 3. Fill the radiator with the proper DEX-COOL® coolant mixture, up to the base of the ﬁller neck. See EngineCoolantonpage5-25 for more information about the proper coolant mixture. 4. Then ﬁll the coolant recovery tank to the ADD mark. 5. Put the cap back on the coolant recovery tank, but leave the pressure cap off. 5-35 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. 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. 5-36 Power Steering Fluid When to Check Power Steering Fluid It is not necessary to regularly check power steering ﬂuid unless you suspect there is a leak in the system or you hear an unusual noise. A ﬂuid loss in this system could indicate a problem. Have the system inspected and repaired. See EngineCompartmentOverview onpage5-12 for reservoir location. How to Check Power Steering Fluid Turn the key off, let the engine compartment cool down, wipe the cap and the top of the reservoir clean, then unscrew the cap and wipe the dipstick with a clean rag. Replace the cap and completely tighten it. Then remove the cap again and look at the ﬂuid level on the dipstick. The level should be at the FULL COLD mark. If necessary, add only enough ﬂuid to bring the level up to the mark. What to Use To determine what kind of ﬂuid to use, see PartD: RecommendedFluidsandLubricantsonpage6-30. Always use the proper ﬂuid. Failure to use the proper ﬂuid can cause leaks and damage hoses and seals. 5-37 Windshield Washer Fluid What to Use When you need windshield washer ﬂuid, be sure to read the manufacturer’s instructions before use. If you will be operating your vehicle in an area where the temperature may fall below freezing, use a ﬂuid that has sufficient protection against freezing. Adding Washer Fluid Open the cap with the washer symbol on it. Add washer ﬂuid until the tank is full. Notice: • When using concentrated washer ﬂuid, follow the manufacturer’s instructions for adding water. • Do not mix water with ready-to-use washer ﬂuid. Water can cause the solution to freeze and damage your washer ﬂuid tank and other parts of the washer system. Also, water does not clean as well as washer ﬂuid. • Fill your washer ﬂuid tank only three-quarters full when it is very cold. This allows for expansion if freezing occurs, which could damage the tank if it is completely full. • Do not use engine coolant (antifreeze) in your windshield washer. It can damage your washer system and paint. 5-38 Brakes Brake Fluid Your brake master cylinder reservoir is ﬁlled with DOT-3 brake ﬂuid. See EngineCompartmentOverviewon page5-12 for the location of the reservoir. There are only two reasons why the brake ﬂuid level in the reservoir might go down. The ﬁrst is that the brake ﬂuid goes down to an acceptable level during normal brake lining wear. When new linings are put in, the ﬂuid level goes back up. The other reason is that ﬂuid is leaking out of the brake system. If it is, you should have your brake system ﬁxed, since a leak means that sooner or later your brakes will not work well, or will not work at all. So, it is not a good idea to “top off” your brake ﬂuid. Adding brake ﬂuid will not correct a leak. If you add ﬂuid when your linings are worn, then you will have too much ﬂuid when you get new brake linings. You should add (or remove) brake ﬂuid, as necessary, only when work is done on the brake hydraulic system. {CAUTION: If you have too much brake ﬂuid, it can spill on the engine. The ﬂuid will burn if the engine is hot enough. You or others could be burned, and your vehicle could be damaged. Add brake ﬂuid only when work is done on the brake hydraulic system. See “Checking Brake Fluid” in this section. Refer to the Maintenance Schedule to determine when to check your brake ﬂuid. See PartC:Periodic MaintenanceInspectionsonpage6-28. 5-39 Checking Brake Fluid You can check the brake ﬂuid without taking off the cap. Just look at the brake ﬂuid reservoir. The ﬂuid level should be above MIN. If it is not, have your brake system checked to see if there is a leak. After work is done on the brake hydraulic system, make sure the level is above the MIN but not over the MAX mark. 5-40 What to Add When you do need brake ﬂuid, use only DOT-3 brake ﬂuid. Use new brake ﬂuid from a sealed container only. See PartD:RecommendedFluidsandLubricants onpage6-30. Always clean the brake ﬂuid reservoir cap and the area around the cap before removing it. This will help keep dirt from entering the reservoir. {CAUTION: With the wrong kind of ﬂuid in your brake system, your brakes may not work well, or they may not even work at all. This could cause a crash. Always use the proper brake ﬂuid. Notice: • Using the wrong ﬂuid 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 ﬂuid. • If you spill brake ﬂuid on your vehicle’s painted surfaces, the paint ﬁnish can be damaged. Be careful not to spill brake ﬂuid on your vehicle. If you do, wash it off immediately. See Appearance Careonpage5-86. 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 ﬁrmly). {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 ﬁrst 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 speciﬁcations. Brake linings should always be replaced as complete axle sets. See BrakeSystemInspectiononpage6-29. Brake Pedal Travel See your dealer if the brake pedal does not return to normal height, or if there is a rapid increase in pedal travel. This could be a sign of brake trouble. Brake Adjustment Every time you make a brake stop, your disc brakes adjust for wear. 5-41 Replacing Brake System Parts The braking system on a vehicle is complex. Its many parts have to be of top quality and work well together if the vehicle is to have really good braking. Your vehicle was designed and tested with top-quality GM brake parts. When you replace parts of your braking system — for example, when your brake linings wear down and you need new ones put in — be sure you get new approved GM replacement parts. If you do not, your brakes may no longer work properly. For example, if someone puts in brake linings that are wrong for your vehicle, the balance between your front and rear brakes can change — for the worse. The braking performance you have come to expect can change in many other ways if someone puts in the wrong replacement brake parts. Battery Your new vehicle comes with a maintenance free ACDelco® battery. When it is time for a new battery, get one that has the replacement number shown on the original battery’s label. We recommend an ACDelco® battery. See EngineCompartmentOverviewon page5-12 for battery location. Warning: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Vehicle Storage If you are not going to drive your vehicle for 25 days or more, remove the black, negative (- ) cable from the battery. This will help keep your battery from running down. {CAUTION: Batteries have acid that can burn you and gas that can explode. You can be badly hurt if you are not careful. See JumpStartingon page5-43 for tips on working around a battery without getting hurt. Contact your dealer to learn how to prepare your vehicle for longer storage periods. Also, for your audio system, see Theft-Deterrent Featureonpage3-47. 5-42 Jump Starting If your battery has run down, you may want to use another vehicle and some jumper cables to start your vehicle. But please follow the numbered steps to do it safely. {CAUTION: Batteries can hurt you. They can be dangerous because: • They contain acid that can burn you. • They contain gas that can explode or • They contain enough electricity to ignite. burn you. If you do not follow these steps exactly, some or all of these things can hurt you. Notice: Ignoring these steps could result in costly damage to your vehicle that would not be covered by your warranty. Trying to start your vehicle by pushing or pulling it will not work, and it could damage your vehicle. 1. Check the other vehicle. It must have a 12–-volt battery with a negative ground system. Notice: If the other vehicle’s system is not a 12-volt system with a negative ground, both vehicles can be damaged. Only use vehicles with 12-volt systems with negative grounds to jump start your vehicle. 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 ﬁrmly 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! 5-43 Notice: If you leave your radio or other accessories on during the jump starting procedure, they could be damaged. The repairs would not be covered by your warranty. Always turn off your radio and other accessories when jump starting your vehicle. 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 ﬂashlight if you need more light. Be sure the battery has enough water. You do not need to add water to the ACDelco® battery installed in your new vehicle. But if a battery has ﬁller caps, be sure the right amount of ﬂuid is there. If it is low, add water to take care of that ﬁrst. If you do not, explosive gas could be present. Battery ﬂuid contains acid that can burn you. Do not get it on you. If you accidentally get it in your eyes or on your skin, ﬂush the place with water and get medical help immediately. 5-44 {CAUTION: Fans or other moving engine parts can injure you badly. Keep your hands away from moving parts once the engine is running. 5. Check that the jumper cables don’t have loose or missing insulation. If they do, you could get a shock. The vehicles could be damaged too. Before you connect the cables, here are some basic things you should know. Positive (+) will go to positive (+) or to a remote positive (+) terminal if the vehicle has one. Negative (- ) will go to a heavy, unpainted metal engine part, or to a negative (- ) terminal if the vehicle has one. Don’t connect positive (+) to negative (- ) or you’ll get a short that would damage the battery and maybe other parts, too. And don’t connect the negative (- ) cable to the negative (- ) terminal on the dead battery because this can cause sparks. 6. Connect the red positive (+) cable to the positive (+) terminal of the vehicle with the dead battery. Use a remote positive (+) terminal if the vehicle has one. 7. Don’t let the other end touch metal. Connect it to the positive (+) terminal of the good battery. Use a remote positive (+) terminal if the vehicle has one. 8. Now connect the black negative (- ) cable to the negative (- ) terminal of the good battery. Use a remote negative (- ) terminal if the vehicle has one. Don’t let the other end touch anything until the next step. The other end of the negative (- ) cable does not go to the dead battery. It goes to a heavy, unpainted metal engine part, or to a remote negative (- ) terminal on the vehicle with the dead battery. 5-45 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 won’t start after a few tries, it probably needs service. Notice: If the jumper cables are removed in the wrong order, electrical shorting may occur and damage the vehicle. The repairs would not be covered by your warranty. Remove the jumper cables in the correct order, making sure that the cables do not touch each other or other metal. 5-46 Jumper Cable Removal A. Heavy, Unpainted Metal Engine Part B. Good Battery C. Dead Battery To disconnect the jumper cables from both vehicles, do the following: 1. Disconnect the black negative (- ) cable from the vehicle that had the dead battery. 2. Disconnect the black negative (- ) cable from the vehicle with the good battery. 3. Disconnect the red positive (+) cable from the vehicle with the good battery. 4. Disconnect the red positive (+) cable from the other vehicle. All-Wheel Drive Lubricant checks in this section also apply to these vehicles. However, there are two additional systems that need lubrication. Transfer Case When to Check Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant. See PartC:Periodic MaintenanceInspectionsonpage6-28. 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 ﬁller plug hole, you’ll need to add some lubricant. Add enough lubricant to raise the level to the bottom of the ﬁller plug hole. Use care not to overtighten the plug. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See PartD:Recommended FluidsandLubricantsonpage6-30. 5-47 Rear Axle When to Check Lubricant Refer to the Maintenance Schedule to determine how often to check the lubricant. See PartA:Scheduled MaintenanceServicesonpage6-4. How to Check Lubricant To get an accurate reading, the vehicle should be on a level surface. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See PartD:Recommended FluidsandLubricantsonpage6-30. 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 PartA:ScheduledMaintenanceServicesonpage6-4. 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 ﬁller plug hole, you’ll need to add some lubricant. Add enough lubricant to raise the level to the bottom of the ﬁller plug hole. 5-48 If the level is below the bottom of the ﬁller plug hole, you may need to add some lubricant. Bulb Replacement For any bulb changing procedure not listed in this section, contact your dealer. For the type of bulbs, see ReplacementBulbson page5-55. When the differential is cold, add enough lubricant to raise the level to 1/2 inch (12 mm) below the ﬁller plug hole. When the differential is at operating temperature (warm), add enough lubricant to raise the level to the bottom of the ﬁller plug hole. What to Use Refer to the Maintenance Schedule to determine what kind of lubricant to use. See PartD:Recommended FluidsandLubricantsonpage6-30. Halogen Bulbs {CAUTION: Halogen bulbs have pressurized gas inside and can burst if you drop or scratch the bulb. You or others could be injured. Be sure to read and follow the instructions on the bulb package. 5-49 Headlamps Sealed Beam Headlamp 1. Remove the four retainer screws and the retainer. 2. Pull the connector out and unplug the lamp. 3. Plug the new lamp into the connector. 4. Reverse Steps 1 and 2 to reinstall the headlamp. 5-50 Composite Headlamps 1. Open the hood. 2. Remove the two screws from the sidemarker/turn signal lamp. 3. Completely remove the sidemarker/turn signal lamp by pulling out the assembly and disconnecting the sidemarker/turn signal lamp sockets from the lamp. 5-51 4. Remove the screw located behind the corner reﬂector to remove the entire corner reﬂector. 5. Remove the remaining three screws, the ﬁrst one from the corner reﬂector pocket and the two remaining from the composite assembly. 6. Remove the composite assembly. 5-52 7. Turn the halogen bulb counterclockwise to remove it from the assembly. 3. Squeeze the tab on the side of the lamp socket while turning the socket counterclockwise. 8. Install the new bulb into the composite assembly by turning it clockwise until it is completely tightened. 9. Reinstall the composite assembly by installing and tightening all of the screws previously removed. Front Turn Signal Lamps 1. Remove the two screws at the inside edge of the parking/turn signal lamp assembly. 2. Remove the lamp assembly. 4. Pull the socket out of the lamp assembly. 5. Pull the bulb from the socket. 6. Gently push the new bulb into the socket. 7. Put the socket back into the lamp assembly and turn it clockwise until it locks. 8. Put the parking/turn signal lamp assembly back into the vehicle and tighten the screws. 5-53 Taillamps 1. Open the rear door. 2. Remove the two screws from behind the door. 5-54 3. Pull out the taillamp assembly so you can see the socket. 4. Press the tab and turn the socket counterclockwise to remove the socket from the bezel. If the socket does not have a tab, turn the socket counterclockwise to remove the socket from the bezel. 5. Remove the old bulb from the socket and replace it with a new one. 6. Reverse Steps 1 through 4 to reinstall the taillamp. Replacement Bulbs Exterior Lamp Bulb Number 1156 9005 (High Beam) 9006 (Low Beam) Back-Up Lamps Halogen Headlamps Composite Halogen Headlamps Composite Halogen Headlamps Sealed Beam Parking, Turn Signal Lamps Rear,Stoplamps Sidemarker Lamps For any bulb not listed here, contact your dealer. 3157NA 2057 194 H6054 5-55 Windshield Wiper Blade Replacement Windshield wiper blades should be inspected at least twice a year for wear and cracking. See “Wiper Blade Check” in AtLeastTwiceaYearonpage6-24 for more information. 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’s Manual. To replace your windshield wiper blade inserts, do the following: {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. See “Loading Your Vehicle” in the Index. • Underinﬂated 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. CAUTION: (Continued) 1. Lift the wiper arm away from the windshield. 2. Pinch the two tabs on the wiper arm and slide the insert out of the blade. 3. Slide the new one in place. Make sure the tabs are locked into position. See Normal MaintenanceReplacementPartsonpage5-104 for the proper type of replacement blade. 5-56 CAUTION: (Continued) • Overinﬂated 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. Tire Sidewall Labeling Useful information about a tire is molded into its sidewall. The following illustrations are examples of a typical P-Metric and a LT-Metric tire sidewall. P-Metric Tire 5-57 (A) Tire Size Code: The tire size code is a combination of letters and numbers used to deﬁne a particular tire’s width, height, aspect ratio, construction type and service description. See the “Tire Size Code” illustration later in this section for more detail. (B) Tire Performance Criteria Speciﬁcation (TPC Spec): Original equipment tires designed to GM’s speciﬁc tire performance criteria have a TPC speciﬁcation code molded onto the sidewall. GM’s TPC speciﬁcations meet or exceed all federal safety guidelines. (C) Department of Transportation (DOT): The Department of Transportation (DOT) code indicates that the tire is in compliance with the U.S. Department of Transportation Motor Vehicle Safety Standards. (D) Tire Identiﬁcation Number (TIN): The letters and numbers following DOT code are the Tire Identiﬁcation 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. (E) Tire Ply Material: The type of cord and number of plies in the sidewall and under the tread. (F) Uniform Tire Quality Grading (UTQG): Tire manufacturers are required to grade tires based on three performance factors: treadwear, traction and temperature resistance. For more information, see UniformTireQualityGradingonpage5-71. (G) Maximum Cold Inﬂation Load Limit: Maximum load that can be carried and the maximum pressure needed to support that load. For information on recommended tire pressure see Inﬂation-TirePressure onpage5-66and LoadingYourVehicleonpage4-30. 5-58 (A) Tire Size: The tire size code is a combination of letters and numbers used to deﬁne 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) Tire Performance Criteria Speciﬁcation (TPC Spec): Original equipment tires designed to GM’s speciﬁc tire performance criteria have a TPC speciﬁcation code molded onto the sidewall. GM’s TPC speciﬁcations meet or exceed all federal safety guidelines. (C) Dual Tire Maximum Load: Maximum load that can be carried and the maximum pressure needed to support that load when used in a dual conﬁguration. For information on recommended tire pressure see Inﬂation-TirePressureonpage5-66 and LoadingYour Vehicleonpage4-30. LT-Metric Tire 5-59 (D) Department of Transportation (DOT): The Department of Transportation (DOT) code indicates that the tire is in compliance with the U.S. Department of Transportation Motor Vehicle Safety Standards. (E) Tire Identiﬁcation Number (TIN): The letters and numbers following DOT code are the Tire Identiﬁcation 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. (F) Tire Ply Material: The type of cord and number of plies in the sidewall and under the tread. (G) Single Tire Maximum Load: Maximum load that can be carried and the maximum pressure needed to support that load when used as a single. For information on recommended tire pressure see Inﬂation -TirePressureonpage5-66 and LoadingYour Vehicleonpage4-30. 5-60 Compact Spare Tire Example (A) Temporary Use Only: The compact spare tire or temporary use tire has a tread life of approximately 3,000 miles (5 000 km) and should not be driven at speeds over 65 mph (105 km/h). The compact spare tire is for emergency use when a regular road tire has lost air and gone ﬂat. See CompactSpareTireon page5-86 and IfaTireGoesFlatonpage5-74. (B) Tire Ply Material: The type of cord and number of plies in the sidewall and under the tread. (E) Tire Inﬂation: The temporary use tire or compact spare tire should be inﬂated to 60 psi (420 kPa). For more information on tire pressure and inﬂation see Inﬂation-TirePressureonpage5-66. (F) Tire Size: A combination of letters and numbers deﬁne a tire’s width, height, aspect ratio, construction type and service description. The letter “T” as the ﬁrst character in the tire size means the tire is for temporary use only. (C) Tire Identiﬁcation Number (TIN): The Tire Identiﬁcation 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. (G) Tire Performance Criteria Speciﬁcation (TPC Spec): Original equipment tires designed to GM’s speciﬁc tire performance criteria have a TPC speciﬁcation code molded onto the sidewall. GM’s TPC speciﬁcations meet or exceed all federal safety guidelines. (D) Maximum Cold Inﬂation Load Limit: Maximum load that can be carried and the maximum pressure needed to support that load. See CompactSpareTire onpage5-86 and LoadingYourVehicleonpage4-30. 5-61 (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 “75,” as shown in item “C” of the illustration, it would mean that the tire’s sidewall is 75% as high as it is wide. (D) Construction Code: A letter code is used to indicate the type of ply construction in the tire. The letter “R” means radial ply construction; the letter “D” means diagonal or bias ply construction; and the letter “B” means belted-bias ply construction. (E) Rim Diameter: Diameter of the wheel in inches. (F) Service Description: The service description indicates the load range and speed rating of a tire. The load index can range from 1 to 279. Speed ratings range from “A” to “Z”. Tire Size The following examples show the different parts of a tire size. Passenger (P-Metric) Tire (A) Passenger (P-Metric) Tire: The United States version of a metric tire sizing system. The letter “P” as the ﬁrst character in the tire size means a passenger vehicle tire engineered to standards set by the U.S. Tire and Rim Association. 5-62 Light Truck (LT-Metric) Tire (A) Light Truck (LT-Metric) Tire: The United States version of a metric tire sizing system. The letter “LT” as the ﬁrst two characters in the tire size means a light truck 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 “75,” as shown in item “C” of the illustration, it would mean that the tire’s sidewall is 75% as high as it is wide. (D) Construction Code: A letter code is used to indicate the type of ply construction in the tire. The letter “R” means radial ply construction; the letter “D” means diagonal or bias ply construction; and the letter “B” means belted-bias ply construction. (E) Rim Diameter: Diameter of the wheel in inches. (F) Service Description: The service description indicates the load range and speed rating of a tire. The load index can range from 1 to 279. Speed ratings range from “A” to “Z”. The light truck tire size example above shows dual or single tire conﬁgurations. Tire Terminology and Deﬁnitions Air Pressure: The amount of air inside the tire pressing outward on each square inch of the tire. Air pressure is expressed in pounds per square inch (psi) or kilopascal (kPa). Accessory Weight: This means the combined weight of optional accessories. Some examples of optional accessories are, automatic transmission, power steering, power brakes, power windows, power seats, and air conditioning. Aspect Ratio: The relationship of a tire’s height to its width. 5-63 Belt: A rubber coated layer of cords that is located between the plies and the tread. Cords may be made from steel or other reinforcing materials. Bead: The tire bead contains steel wires wrapped by steel cords that hold the tire onto the rim. Bias Ply Tire: A pneumatic tire in which the plies are laid at alternate angles less than 90 degrees to the centerline of the tread. Cold Inﬂation Pressure: The amount of air pressure in a tire, measured in pounds per square inch (psi) or kilopascals (kPa) before a tire has built up heat from driving. See Inﬂation-TirePressureonpage5-66. Curb Weight: This means the weight of a motor vehicle with standard and optional equipment including the maximum capacity of fuel, oil and coolant, but without passengers and cargo. DOT Markings: A code molded into the sidewall of a tire signifying that the tire is in compliance with the U.S. Department of Transportation motor vehicle safety standards. The DOT code includes the Tire Identiﬁcation Number (TIN), an alphanumeric designator which can also identify the tire manufacturer, production plant, brand and date of production. GVWR: Gross Vehicle Weight Rating, see Loading YourVehicleonpage4-30. GAWR FRT: Gross Axle Weight Rating for the front axle, see LoadingYourVehicleonpage4-30. GAWR RR: Gross Axle Weight Rating for the rear axle, see LoadingYourVehicleonpage4-30. Intended Outboard Sidewall: The side of an asymmetrical tire, that must always face outward when mounted on a vehicle. Kilopascal (kPa): The metric unit for air pressure. There are 6.9 kPa’s to one psi. Light Truck (LT-Metric) Tire: A tire used on light duty trucks and some multipurpose passenger vehicles. Load Index: An assigned number ranging from 1 to 279 that corresponds to the load carrying capacity of a tire. Maximum Inﬂation Pressure: The maximum air pressure to which a cold tire may be inﬂated. The maximum air pressure is molded onto the sidewall. Maximum Load Rating: The load rating for a tire at the maximum permissible inﬂation pressure for that tire. 5-64 Maximum Loaded Vehicle Weight: The sum of curb weight; accessory weight; vehicle capacity weight; and production options weight. Radial Ply tire: A pneumatic tire in which the ply cords that extend to the beads are laid at 90 degrees to the centerline of the tread. Normal Occupant Weight: The number of occupants a vehicle is designed to seat multiplied by 150 pounds (68 kg). See LoadingYourVehicleonpage4-30. Occupant Distribution: Designated seating positions. Outward Facing Sidewall: The side of a asymmetrical tire that has a particular side that faces outward when mounted on a vehicle. The side of the tire that contains a whitewall, bears white lettering or bears manufacturer, brand and or model name molding that is higher or deeper than the same moldings on the other sidewall of the tire. Passenger (P-Metric) Tire: A tire used on passenger cars and some light duty trucks and multipurpose vehicles. Recommended Inﬂation Pressure: Vehicle manufacturer’s recommended tire inﬂation pressure and shown on the tire placard. See Inﬂation-TirePressure onpage5-66and LoadingYourVehicleonpage4-30. Rim: A metal support for a tire and upon which the tire beads are seated. Sidewall: The portion of a tire between the tread and the bead. Speed Rating: An alphanumeric code assigned to a tire indicating the maximum speed at which a tire can operate. Traction: The friction between the tire and the road surface. The amount of grip provided. Tread: The portion of a tire that comes into contact with the road. Treadwear Indicators: Narrow bands, sometimes called “wear bars,” that show across the tread of a tire when only 2/32 inch of tread remains. See WhenIt IsTimeforNewTiresonpage5-69. 5-65 Notice: Don’t let anyone tell you that underinﬂation or overinﬂation is all right. It’s not. If your tires don’t have enough air (underinﬂation), you can get the following: • Too much ﬂexing • Too much heat • Tire overloading • Bad wear • Bad handling • Bad fuel economy If your tires have too much air (overinﬂation), you can get the following: • Unusual wear • Bad handling • Rough ride • Needless damage from road hazards UTQGS: Uniform Tire Quality Grading Standards, a tire information system that provides consumers with ratings for a tire’s traction, temperature and treadwear. Ratings are determined by tire manufacturers using government testing procedures. The ratings are molded into the sidewall of the tire. See UniformTireQuality Gradingonpage5-71. Vehicle Capacity Weight: The number of designated seating positions multiplied by 150 lbs. (68 kg) plus the rated cargo load. See LoadingYourVehicle onpage4-30. Vehicle Maximum Load on the Tire: Load on an individual tire due to curb weight, accessory weight, occupant weight and cargo weight. Vehicle Placard: A label permanently attached to a vehicle showing the original equipment tire size and recommended inﬂation pressure. See LoadingYour Vehicleonpage4-30. Inﬂation - Tire Pressure The Certiﬁcation/Tire label or Tire and Loading Information label shows the correct inﬂation pressures for your tires when they’re cold. “Cold” means your vehicle has been sitting for at least three hours or driven no more than 1 mile (1.6 km). See LoadingYour Vehicleonpage4-30. 5-66 When to Check Check your tires once a month or more. Also, check the tire pressure of the compact spare tire. It should be at 60 psi (420 kPa). How to Check Use a good quality pocket-type gage to check tire pressure. You can’t tell if your tires are properly inﬂated simply by looking at them. Radial tires may look properly inﬂated even when they’re underinﬂated. Remove the valve cap from the tire valve stem. Press the tire gage ﬁrmly onto the valve to get a pressure measurement. If the cold tire inﬂation pressure is low, add air until you reach the recommended pressure on the Certiﬁcation/Tire label or the Tire and Loading Information label. If you overﬁll the tire, release air by pushing on the metal stem in the center of the tire valve. Recheck the tire pressure with the tire gage. Be sure to put the valve caps back on the valve stems. They help prevent leaks by keeping out dirt and moisture. 5-67 Tire Inspection and Rotation Tires should be rotated every 5,000 to 8,000 miles (8 000 to 13 000 km). Any time you notice unusual wear, rotate your tires as soon as possible and check wheel alignment. Also check for damaged tires or wheels. See WhenItIsTime forNewTiresonpage5-69 and WheelReplacement onpage5-72 for more information. Make sure the spare tire is stored securely. Push, pull, and then try to rotate or turn the tire. If it moves, use the ratchet/wheel wrench to tighten the cable. See ChangingaFlatTireonpage5-75. The purpose of regular rotation is to achieve more uniform wear for all tires on the vehicle. The ﬁrst rotation is the most important. See PartA:Scheduled MaintenanceServicesonpage6-4. 5-68 When rotating your tires, always use the correct rotation patterns shown here. Don’t include the compact spare tire in your tire rotation. After the tires have been rotated, adjust the front and rear inﬂation pressures as shown on the Certiﬁcation/Tire label or Tire and Loading Information label. See Inﬂation-TirePressureonpage5-66 and LoadingYourVehicleonpage4-30. Make certain that all wheel nuts are properly tightened. See “Wheel Nut Torque” under CapacitiesandSpeciﬁcations onpage5-102. {CAUTION: Rust or dirt on a wheel, or on the parts to which it is fastened, can make wheel nuts become loose after a time. The wheel could come off and cause an accident. When you change a wheel, remove any rust or dirt from places where the wheel attaches to the vehicle. In an emergency, you can use a cloth or a paper towel to do this; but be sure to use a scraper or wire brush later, if you need to, to get all the rust or dirt off. See “Changing a Flat Tire” in the Index. When It Is Time for New Tires One way to tell when it’s time for new tires is to check the treadwear indicators, which will appear when your tires have only 1/16 inch (1.6 mm) or less of tread remaining. Some commercial truck tires may not have treadwear indicators. You need a new tire if any of the following statements are true: • You can see the indicators at three or more places • You can see cord or fabric showing through the around the tire. tire’s rubber. • The tread or sidewall is cracked, cut or snagged deep enough to show cord or fabric. • The tire has a bump, bulge or split. • The tire has a puncture, cut or other damage that can’t be repaired well because of the size or location of the damage. 5-69 Buying New Tires To ﬁnd out what kind and size of tires you need, look at the Certiﬁcation/Tire label or the Tire and Loading Information label. See Loading Your Vehicle on page4-30, for examples of the labels and where they can be found on your vehicle. The tires installed on your vehicle when it was new had a Tire Performance Criteria Speciﬁcation (TPC Spec) number on each tire’s sidewall. When you get new tires, GM recommends that you get tires with that same TPC Spec number. That way your vehicle will continue to have tires that are designed to give proper endurance, handling, speed rating, traction, ride and other things during normal service on your vehicle. If your tires have an all-season tread design, the TPC number will be followed by an “MS” (for mud and snow). If you ever replace your tires with those not having a TPC Spec number, make sure they are the same size, load range, speed rating and construction type (bias, bias-belted or radial) as your original tires. 5-70 {CAUTION: Mixing tires could cause you to lose control while driving. If you mix tires of different sizes or types (radial and bias-belted tires), the vehicle may not handle properly, and you could have a crash. Using tires of different sizes may also cause damage to your vehicle. Be sure to use the same size and type tires on all wheels. It’s all right to drive with your compact spare temporarily, it was developed for use on your vehicle. See “Compact Spare Tire” in the index. {CAUTION: If you use bias-ply tires on your vehicle, the wheel rim ﬂanges could develop cracks after many miles of driving. A tire and/or wheel could fail suddenly, causing a crash. Use only radial-ply tires with the wheels on your vehicle. Uniform Tire Quality Grading Quality grades can be found where applicable on the tire sidewall between tread shoulder and maximum section width. For example: Treadwear 200 Traction AA Temperature A The following information relates to the system developed by the United States National Highway Traffic Safety Administration, which grades tires by treadwear, traction and temperature performance. (This applies only to vehicles sold in the United States.) The grades are molded on the sidewalls of most passenger car tires. The Uniform Tire Quality Grading system does not apply to deep tread, winter-type snow tires, space-saver or temporary use spare tires, tires with nominal rim diameters of 10 to 12 inches (25 to 30 cm), or to some limited-production tires. While the tires available on General Motors passenger cars and light trucks may vary with respect to these grades, they must also conform to federal safety requirements and additional General Motors Tire Performance Criteria (TPC) standards. Treadwear The treadwear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions on a speciﬁed government test course. For example, a tire graded 150 would wear one and a half (1.5) times as well on the government course as a tire graded 100. The relative performance of tires depends upon the actual conditions of their use, however, and may depart signiﬁcantly from the norm due to variations in driving habits, service practices and differences in road characteristics and climate. Traction – AA, A, B, C The traction grades, from highest to lowest, are AA, A, B, and C. Those grades represent the tire’s ability to stop on wet pavement as measured under controlled conditions on speciﬁed government test surfaces of asphalt and concrete. A tire marked C may have poor traction performance. Warning: The traction grade assigned to this tire is based on straight-ahead braking traction tests, and does not include acceleration, cornering, hydroplaning, or peak traction characteristics. 5-71 Temperature – A, B, C The temperature grades are A (the highest), B, and C, representing the tire’s resistance to the generation of heat and its ability to dissipate heat when tested under controlled conditions on a speciﬁed indoor laboratory test wheel. Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive temperature can lead to sudden tire failure. The grade C corresponds to a level of performance which all passenger car tires must meet under the Federal Motor Vehicle Safety Standard No. 109. Grades B and A represent higher levels of performance on the laboratory test wheel than the minimum required by law. Warning: The temperature grade for this tire is established for a tire that is properly inﬂated and not overloaded. Excessive speed, underinﬂation, or excessive loading, either separately or in combination, can cause heat buildup and possible tire failure. Wheel Alignment and Tire Balance The wheels on your vehicle were aligned and balanced carefully at the factory to give you the longest tire life and best overall performance. Scheduled wheel alignment and wheel balancing are not needed. However, if you notice unusual tire wear or your vehicle pulling one way or the other, the alignment may need to be reset. If you notice your vehicle vibrating when driving on a smooth road, your wheels may need to be rebalanced. Wheel Replacement Replace any wheel that is bent, cracked or badly rusted or corroded. If wheel nuts keep coming loose, the wheel, wheel bolts and wheel nuts should be replaced. If the wheel leaks air, replace it (except some aluminum wheels, which can sometimes be repaired). See your dealer if any of these conditions exist. 5-72

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2004 Chevrolet Astro Owners Manual