2003 CHEVROLET ASTRO CARGO VAN headlamp

Service............................................................5-3
Doing Your Own Service Work.........................5-3
Adding Equipment to the Outside
of Your Vehicle...........................................5-4
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Speci®cations....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling Your Tank............................................5-8
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-11
Hood Release..............................................5-11
Engine Compartment Overview.......................5-14
Engine Oil...................................................5-15
Engine Cover...............................................5-20
Engine Air Cleaner/Filter................................5-24
Automatic Transmission Fluid.........................5-25
Engine Coolant.............................................5-28
Radiator Pressure Cap..................................5-30
Engine Overheating.......................................5-31Cooling System............................................5-33
Engine Fan Noise.........................................5-39
Power Steering Fluid.....................................5-40
Windshield Washer Fluid................................5-41
Brakes........................................................5-42
Battery........................................................5-46
Jump Starting...............................................5-47
All-Wheel Drive..............................................5-52
Rear Axle.......................................................5-53
Front Axle......................................................5-54
Bulb Replacement..........................................5-55
Halogen Bulbs..............................................5-55
Headlamps..................................................5-55
Front Turn Signal Lamps...............................5-59
Taillamps.....................................................5-60
Replacement Bulbs.......................................5-61
Windshield Wiper Blade Replacement..............5-62
Tires..............................................................5-63
In¯ation Ð Tire Pressure...............................5-64
Tire Inspection and Rotation...........................5-64
When It Is Time for New Tires.......................5-66
Section 5 Service and Appearance Care
5-1

Buying New Tires.........................................5-66
Uniform Tire Quality Grading..........................5-67
Wheel Alignment and Tire Balance..................5-69
Wheel Replacement......................................5-69
Tire Chains..................................................5-70
If a Tire Goes Flat........................................5-70
Changing a Flat Tire.....................................5-71
Compact Spare Tire......................................5-82
Appearance Care............................................5-83
Cleaning the Inside of Your Vehicle.................5-83
Care of Safety Belts......................................5-86
Weatherstrips...............................................5-86
Cleaning the Outside of Your Vehicle.................5-86
Sheet Metal Damage.....................................5-88
Finish Damage.............................................5-88
Underbody Maintenance................................5-89
Chemical Paint Spotting.................................5-89
Vehicle Care/Appearance Materials..................5-89Vehicle Identi®cation......................................5-91
Vehicle Identi®cation Number (VIN).................5-91
Service Parts Identi®cation Label.....................5-91
Electrical System............................................5-92
Add-On Electrical Equipment..........................5-92
Headlamp Wiring..........................................5-92
Windshield Wiper Fuses................................5-92
Power Windows and Other
Power Options..........................................5-92
Fuses and Circuit Breakers............................5-93
Capacities and Speci®cations..........................5-99
Capacities and Speci®cations.........................5-99
Normal Maintenance Replacement Parts.........5-101
Section 5 Service and Appearance Care
5-2

Bulb Replacement
For any bulb changing procedure not listed in this
section, contact your dealer.
For the type of bulbs, see
Replacement Bulbs on
page 5-61.
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.
Headlamps
Sealed Beam Headlamp
1. Remove the four
retainer screws and
the retainer.
5-55

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.Composite Headlamps
1. Open the hood.
2. Remove the two
screws from the
sidemarker/turn
signal lamp.
5-56

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
Halogen Headlamps Sealed
BeamH6054
Halogen Headlamps Composite 9006 (Low Beam)
Halogen Headlamps Composite 9005 (High Beam)
Parking, Turn Signal Lamps 3157NA
Rear,Stoplamps 2057
Sidemarker Lamps 194
Back-Up Lamps 1156
For any bulb not listed here, contact your dealer.
5-61

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.
Your dealer will know the kind of wheel you need.
Each new wheel should have the same load-carrying
capacity, diameter, width, offset and be mounted
the same way as the one it replaces.If you need to replace any of your wheels, wheel bolts
or wheel nuts, replace them only with new GM
original equipment parts. This way, you will be sure to
have the right wheel, wheel bolts and wheel nuts
for your vehicle.
{CAUTION:
Using the wrong replacement wheels, wheel
bolts or wheel nuts on your vehicle can be
dangerous. It could affect the braking and
handling of your vehicle, make your tires lose
air and make you lose control. You could have
a collision in which you or others could be
injured. Always use the correct wheel, wheel
bolts and wheel nuts for replacement.
Notice:The wrong wheel can also cause problems
with bearing life, brake cooling, speedometer or
odometer calibration, headlamp aim, bumper height,
vehicle ground clearance and tire or tire chain
clearance to the body and chassis.
See
Changing a Flat Tire on page 5-71for more
information.
5-69

Electrical System
Add-On Electrical Equipment
Notice:Don't add anything electrical to your
vehicle unless you check with your dealer ®rst.
Some electrical equipment can damage your vehicle
and the damage wouldn't be covered by your
warranty. Some add-on electrical equipment can
keep other components from working as they
should.
Your vehicle has an air bag system. Before attempting
to add anything electrical to your vehicle, see
Servicing Your Air Bag-Equipped Vehicle on page 1-69.
Headlamp Wiring
The headlamp wiring is protected by a circuit breaker in
the lamp switch. An electrical overload will cause the
lamps to ¯icker on and off, or in some cases to remain
off. If this happens, have your headlamp wiring
checked right away.
Windshield Wiper Fuses
The windshield wiper motor is protected by a circuit
breaker and a fuse. If the motor overheats due to heavy
snow, etc., the wiper will stop until the motor cools.
Although the circuit is protected from electrical overload,
overload due to heavy snow, etc., may cause wiper
linkage damage. Always clear ice and heavy snow from
the windshield before using the windshield wipers.
If the overload is caused by some electrical problem and
not snow, etc., be sure to get it ®xed.
Power Windows and Other
Power Options
Circuit breakers in the fuse panel protect the power
windows and other power accessories. When the current
load is too heavy, the circuit breaker opens and
closes, protecting the circuit until the problem is ®xed or
goes away.
5-92

Fuse/Circuit
BreakerUsage
1Stop/Turn/Hazard Lamps, Center
High Mounted Stop Lamp, Anti-Lock
Brakes
2Radio Accy, Rear Seat Audio
ControlsFuse/Circuit
BreakerUsage
3Courtesy Lamps, Glove Box Lamp,
Dome Reading Lamps, Vanity Mirror
Lamps, Courtesy Lamps
4Daytime Running Lamps Relay,
Instrument Panel Cluster
5 Rear Defogger
6Cruise Module, Truck Body Control
Module, Instrument Panel Cluster,
Cruise Control Switch,
Electrochromic Mirror
7Power Outlets, DLC, Subwoofer
Ampli®er
8Crank Circuit Fuse, Park/Neutral
Switch, Starter Enabler Relay
9License Plate Lamp, Tailamps,
Parking Lamps, Ashtray Lamp,
Panel Lights, Trailer Taillamps, Front
and Rear Sidemarker Lamps, Door
Switch Illumination, Headlamp
Switch Illumination, Rear Seat Audio
Illumination, Truck Body
Control Module
5-94