2003 CHEVROLET ASTRO CARGO VAN fuel

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-2
Rear Seats
............................................... 1-7
Safety Belts
.............................................1-13
Child Restraints
.......................................1-35
Air Bag System
.......................................1-62
Restraint System Check
............................1-71
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-16
Theft-Deterrent Systems
............................2-18
Starting and Operating Your Vehicle
...........2-19
Mirrors
....................................................2-32
HomeLink
žTransmitter
.............................2-34
Storage Areas
.........................................2-38
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-2
Climate Controls
......................................3-18
Warning Lights, Gages and Indicators
.........3-23
Audio System(s)
.......................................3-38
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2Towing
....................................................4-29
Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under the Hood
...............5-11
All-Wheel Drive
........................................5-52
Rear Axle
...............................................5-53
Front Axle
...............................................5-54
Bulb Replacement
....................................5-55
Windshield Wiper Blade Replacement
.........5-62
Tires
......................................................5-63
Appearance Care
.....................................5-83
Vehicle Identi®cation
.................................5-91
Electrical System
......................................5-92
Capacities and Speci®cations
.....................5-99
Normal Maintenance Replacement Parts
....5-101
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance Information.................... 7-1
Customer Assistance Information
.................. 7-2
Reporting Safety Defects
...........................7-10
Index.................................................................1
2003 Chevrolet Astro Owner ManualM

Theft-Deterrent Systems
Vehicle theft is a big business, especially in some cities.
Although your vehicle has a number of theft-deterrent
features, we know that nothing we put on it can make it
impossible to steal. However, there are ways you
can help.
Passlockž
Your vehicle is equipped with the Passlockž
theft-deterrent system.
Passlock
žis a passive theft-deterrent system. Passlockž
enables fuel if the ignition lock cylinder is turned with
a valid key. If a correct key is not used or the ignition
lock cylinder is tampered with, fuel is disabled.During normal operation, the SECURITY light will go off
approximately ®ve seconds after the key is turned
to RUN.
If the engine stalls and the SECURITY light ¯ashes,
wait until the light stops ¯ashing before trying to restart
the engine. Remember to release the key from
START as soon as the engine starts.
If the engine is running and the SECURITY light comes
on, you will be able to restart the engine if you turn
the engine off. However, your Passlock
žsystem is not
working properly and must be serviced by your
dealer. Your vehicle is not protected by Passlock
žat
this time. You may also want to check the fuse.
See
Fuses and Circuit Breakers on page 5-93. See your
dealer for service.
2-18

Starting Your Engine
Move your shift lever to PARK (P) or NEUTRAL (N).
Your engine won't start in any other position ± that's a
safety feature. To restart when you're already moving,
use NEUTRAL (N) only.
Notice:Don't try to shift to PARK (P) if your
vehicle is moving. If you do, you could damage the
transmission. Shift to PARK (P) only when your
vehicle is stopped.
1. With your foot off the accelerator pedal, turn the
ignition key to START. When the engine starts,
let go of the key. The idle speed will go down as
your engine gets warm.
Notice:Holding your key in START for longer than
15 seconds at a time will cause your battery to
be drained much sooner. And the excessive heat
can damage your starter motor. Wait about 15
seconds between each try to help avoid draining
your battery or damaging your starter.
2. If it doesn't start within 10 seconds, push the
accelerator pedal all the way to the ¯oor, while you
hold the ignition key in START. When the engine
starts, let go of the key and let up on the accelerator
pedal. Wait about 15 seconds between each try.When starting your engine in very cold weather
(below 0ÉF or-18ÉC), do this:
1. With your foot off the accelerator pedal, turn the
ignition key to START and hold it there up to
15 seconds. When the engine starts, let go of
the key.
2. If your engine still won't start (or starts but then
stops), it could be ¯ooded with too much gasoline.
Try pushing your accelerator pedal all the way to the
¯oor and holding it there as you hold the key in
START for about three seconds. When the engine
starts, let go of the key and accelerator. If the
vehicle starts brie¯y but then stops again, do the
same thing, but this time keep the pedal down
for ®ve or six seconds. This clears the extra
gasoline from the engine.
Notice:Your engine is designed to work with the
electronics in your vehicle. If you add electrical
parts or accessories, you could change the way the
engine operates. Before adding electrical equipment,
check with your dealer. If you don't, your engine
might not perform properly.
Fuel Regulator
You have a fuel regulator that shuts the fuel off when
the engine reaches 5,600 rpm.
2-21

Engine Coolant Heater
If your vehicle has this
feature, in very cold
weather, 0ÉF (-8ÉC) or
colder, the engine coolant
heater can help. You'll
get easier starting
and better fuel economy
during engine warm-up.
Usually, the coolant heater should be plugged in a
minimum of four hours prior to starting your vehicle.
At temperatures above 32ÉF (0ÉC), use of the coolant
heater is not required.
To Use the Engine Coolant Heater
1. Turn off the engine.
2. Open the hood and unwrap the electrical cord.
The engine coolant heater cord is located on the
driver's side of the engine compartment, near
the power steering ¯uid reservoir.3. Plug it into a normal, grounded 110-volt AC outlet.
{CAUTION:
Plugging the cord into an ungrounded outlet
could cause an electrical shock. Also, the
wrong kind of extension cord could overheat
and cause a ®re. You could be seriously
injured. Plug the cord into a properly grounded
three-prong 110-volt AC outlet. If the cord
won't reach, use a heavy-duty three-prong
extension cord rated for at least 15 amps.
4. Before starting the engine, be sure to unplug and
store the cord as it was before to keep it away
from moving engine parts. If you don't, it could be
damaged.
How long should you keep the coolant heater plugged
in? The answer depends on the outside temperature, the
kind of oil you have, and some other things. Instead
of trying to list everything here, we ask that you contact
your dealer in the area where you'll be parking your
vehicle. The dealer can give you the best advice for that
particular area.
2-22

REVERSE (R):Use this gear to back up.
Notice:Shifting to REVERSE (R) while your vehicle
is moving forward could damage your transmission.
Shift to REVERSE (R) only after your vehicle is
stopped.
To rock your vehicle back and forth to get out of snow,
ice or sand without damaging your transmission,
see If You Are Stuck: In Sand, Mud, Ice or Snow on
page 4-28.
NEUTRAL (N):In this position, your engine doesn't
connect with the wheels. To restart when you're already
moving, use NEUTRAL (N) only. Also, use
NEUTRAL (N) when your vehicle is being towed.
{CAUTION:
Shifting into a drive gear while your engine is
ªracingº (running at high speed) is dangerous.
Unless your foot is ®rmly on the brake pedal,
your vehicle could move very rapidly. You
could lose control and hit people or objects.
Don't shift into a drive gear while your engine
is racing.
Notice:Damage to your transmission caused by
shifting out of PARK (P) or NEUTRAL (N) with
the engine racing isn't covered by your warranty.
DRIVE (D):This position is for normal driving. If
you need more power for passing, and you're:
·Going less than about 35 mph (55 km/h), push your
accelerator pedal about halfway down.
·Going about 35 mph (55 km/h) or more, push the
accelerator pedal all the way down. You'll shift
down to the next gear and have more power.
DRIVE (D) should be used for normal towing.
THIRD (3):This position is also used for normal driving,
however it offers more power and lower fuel economy
than DRIVE (D). You should use THIRD (3) when
carrying a heavy load or driving on steep hills.
SECOND (2):This position gives you more power but
lower fuel economy. You can use SECOND (2) on
hills. It can help control your speed as you go down
steep mountain roads, but then you would also want to
use your brakes off and on.
2-24

If you manually select SECOND (2), the transmission
will drive in second gear. You may use this feature
for reducing torque to the rear wheels when you
are trying to start your vehicle from a stop on slippery
road surfaces.
FIRST (1):This position gives you even more power
(but lower fuel economy) than SECOND (2). You
can use it on very steep hills, or in deep snow or mud.
If the shift selector lever is put in FIRST (1), the
transmission won't shift into ®rst gear until the vehicle is
going slow enough.
Notice:If your wheels won't turn, don't try to drive.
This might happen if you were stuck in very deep
sand or mud or were up against a solid object. You
could damage your transmission. Also, if you
stop when going uphill, don't hold your vehicle there
with only the accelerator pedal. This could overheat
and damage the transmission. Use your brakes
or shift into PARK (P) to hold your vehicle in
position on a hill.
Tow/Haul Mode Button
Your vehicle is equipped with a tow/haul button. The
button is located on the end of the column shift
lever. You can use this feature to assist when towing or
hauling a heavy load.
To select the tow/haul mode, press in the button. The
TOW/HAUL light on the instrument panel cluster
will come on. To go back to normal operation, press the
button again. The indicator light on the instrument
panel cluster will go out. See
Tow/Haul Mode Light on
page 3-36for more information.
2-25

If this happens, follow these instructions to set the
variance for your particular location:
1. Find your location on the zone map. Record your
zone number.
2. Press and hold both the US/MET and the MODE
buttons while in the COMP/TEMP mode.
3. After ®ve seconds, the compass will acknowledge
the variation mode by displaying the current zone
number. When it does, release both buttons.4. Press US/MET until your zone number appears on
the display.
5. Press MODE to enter your zone number. Your
variance is now set and the display will return to
the COMP/TEMP mode.
TRIP:Once in the TRIP mode, pressing the MODE
button will take you through the following TRIP functions:
·AVG ECON (Average Economy):The average
fuel economy since the last reset is displayed.
·INST ECON (Instantaneous Economy):
Instantaneous fuel economy for the last second of
driving is displayed.
·RANGE:The display indicates the estimated
distance that can be travelled with the remaining
fuel in the tank, based on the fuel economy for the
last few hours of driving.
·FUEL USED:The fuel used since the last reset is
displayed.
·AVG SPEED (Average Speed):The average
speed since the last reset is displayed.
To reset the trip computer, press the MODE and
US/MET buttons simultaneously for at least two
seconds. All functions will be displayed brie¯y once the
system is reset. Reset can only be performed in the
AVG ECON, FUEL USED and AVG SPEED modes.
All three modes are reset simultaneously.
2-43

Instrument Panel Overview...............................3-2
Hazard Warning Flashers................................3-4
Other Warning Devices...................................3-5
Horn.............................................................3-5
Tilt Wheel.....................................................3-5
Turn Signal/Multifunction Lever.........................3-6
Exterior Lamps.............................................3-12
Interior Lamps..............................................3-15
Accessory Power Outlets...............................3-16
Ashtrays and Cigarette Lighter........................3-17
Climate Controls............................................3-18
Climate Control System.................................3-18
Rear Heating System....................................3-19
Rear Air Conditioning System.........................3-20
Rear Climate Control System.........................3-21
Warning Lights, Gages and Indicators.............3-23
Instrument Panel Cluster................................3-24
Speedometer and Odometer...........................3-25
Safety Belt Reminder Light.............................3-26
Air Bag Readiness Light................................3-26
Charging System Light..................................3-27
Voltmeter Gage............................................3-28
Brake System Warning Light..........................3-28Anti-Lock Brake System Warning Light.............3-29
Engine Coolant Temperature Gage..................3-30
Malfunction Indicator Lamp.............................3-30
Oil Pressure Gage........................................3-34
Security Light...............................................3-35
Service All-Wheel Drive Light.........................3-35
Tow/Haul Mode Light....................................3-36
Check Gages Warning Light...........................3-36
Fuel Gage...................................................3-36
Low Fuel Warning Light.................................3-37
Audio System(s).............................................3-38
Setting the Time for Radios with
the Set Button..........................................3-38
Setting the Time for Radios with
HR and MN Buttons..................................3-38
AM-FM Radio...............................................3-39
Radio with CD..............................................3-41
Rear Seat Audio (RSA).................................3-46
Theft-Deterrent Feature..................................3-47
Understanding Radio Reception......................3-50
Care of Your CDs.........................................3-50
Care of Your CD Player................................3-50
Fixed Mast Antenna......................................3-50
Section 3 Instrument Panel
3-1