2003 CHEVROLET ASTRO CARGO VAN service

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

·Air bags are designed to in¯ate only once. After
they in¯ate, you'll need some new parts for your
air bag system. If you don't get them, the air
bag system won't be there to help protect you in
another crash. A new system will include air
bag modules and possibly other parts. The service
manual for your vehicle covers the need to
replace other parts.
·Your vehicle is equipped with a crash sensing and
diagnostic module, which records information
about the air bag system. The module records
information about the readiness of the system, when
the system commands air bag in¯ation and
driver's safety belt usage at deployment. The
module also records speed, engine rpm, brake and
throttle data.
·Let only quali®ed technicians work on your air bag
system. Improper service can mean that your air
bag system won't work properly. See your dealer for
service.
Notice:If you damage the covering for the driver's
or the right front passenger's air bag, the bag
may not work properly. You may have to replace the
air bag module in the steering wheel or both the
air bag module and the instrument panel for
the right front passenger's air bag. Do not open or
break the air bag coverings.
Servicing Your Air Bag-Equipped
Vehicle
Air bags affect how your vehicle should be serviced.
There are parts of the air bag system in several places
around your vehicle. You don't want the system to
in¯ate while someone is working on your vehicle. Your
dealer and the service manual have information
about servicing your vehicle and the air bag system.
To purchase a service manual, see
Service Publications
Ordering Information on page 7-11.
{CAUTION:
For up to 10 minutes after the ignition key is
turned off and the battery is disconnected, an
air bag can still in¯ate during improper
service. You can be injured if you are close to
an air bag when it in¯ates. Avoid wires
wrapped with yellow tape or yellow
connectors. They are probably part of the air
bag system. Be sure to follow proper service
procedures, and make sure the person
performing work for you is quali®ed to do so.
The air bag system does not need regular maintenance.
1-69

Remote Keyless Entry System
If equipped, the keyless entry system operates on a
radio frequency subject to Federal Communications
Commission (FCC) Rules and with Industry Canada.
This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
1. This device may not cause interference, and
2. This device must accept any interference received,
including interference that may cause undesired
operation of the device.
This device complies with RSS-210 of Industry Canada.
Operation is subject to the following two conditions:
1. This device may not cause interference, and
2. This device must accept any interference received,
including interference that may cause undesired
operation of the device.
Changes or modi®cations to this system by other than
an authorized service facility could void authorization to
use this equipment.At times you may notice a decrease in range. This is
normal for any remote keyless entry system. If the
transmitter does not work or if you have to stand closer
to your vehicle for the transmitter to work, try this:
·Check the distance. You may be too far from your
vehicle. You may need to stand closer during
rainy or snowy weather.
·Check the location. Other vehicles or objects may
be blocking the signal. Take a few steps to the
left or right, hold the transmitter higher, and
try again.
·Check to determine if battery replacement is
necessary. See ªBattery Replacementº under
Remote Keyless Entry System Operation on
page 2-5.
·If you are still having trouble, see your dealer or a
quali®ed technician for service.
2-4

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

Notice:Don't operate accessories in the
ACCESSORY position for long periods of time.
Prolonged operation of accessories in the
ACCESSORY position could drain your battery and
prevent you from starting your vehicle.
B (LOCK):This position locks your ignition, steering
wheel and transmission. It's a theft-deterrent feature.
You will only be able to remove your key when the
ignition is turned to LOCK.
Notice:If your key seems stuck in LOCK and you
can't turn it, be sure you are using the correct key; if
so, is it all the way in? If it is, then turn the steering
wheel left and right while you turn the key hard.
Turn the key only with your hand. Using a tool
to force it could break the key or the ignition switch.
If none of this works, then your vehicle needs
service.C (OFF):This position lets you turn off the engine but
still turn the steering wheel. Use OFF if you must
have your vehicle in motion while the engine is off (for
example, if your vehicle is being towed).
D (RUN):This is the position for driving.
E (START):This position starts your engine.
Retained Accessory Power (RAP)
Your vehicle is equipped with a Retained Accessory
Power (RAP) feature which will allow certain features on
your vehicle to continue to work up to 20 minutes
after the ignition key is turned to OFF.
Your radio, power windows and overhead console will
work when the ignition key is in RUN or ACCESSORY.
Once the key is turned from RUN to OFF, these
features will continue to work for up to 20 minutes or
until a door is opened.
2-20

HomeLinkžTransmitter
HomeLink,ža combined universal transmitter and
receiver, provides a way to replace up to three
hand-held transmitters used to activate devices such as
gate operators, garage door openers, entry door
locks, security systems and home lighting. Additional
HomeLink,
žinformation can be found on the internet at
www.homelink.com or by calling 1-800-355-3515.If your vehicle is equipped with the HomeLink
ž
Transmitter, it complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
(1) this device may not cause harmful interference, and
(2) this device must accept any interference received,
including interference that may cause undesired
operation.
This device complies with RSS-210 of Industry Canada.
Operation is subject to the following two conditions: (1)
this device may not cause interference, and (2) this
device must accept any interference, including
interference that may cause undesired operation of the
device.
Changes and modi®cations to this system by other than
an authorized service facility could void authorization
to use this equipment.
2-34

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

If the air bag readiness light stays on after you start the
vehicle or comes on when you are driving, your air
bag system may not work properly. Have your vehicle
serviced right away.
{CAUTION:
If the air bag readiness light stays on after you
start your vehicle, it means the air bag system
may not be working properly. The air bags in
your vehicle may not in¯ate in a crash, or they
could even in¯ate without a crash. To help
avoid injury to yourself or others, have your
vehicle serviced right away if the air bag
readiness light stays on after you start your
vehicle.
The air bag readiness light should ¯ash for a few
seconds when you turn the ignition key to RUN. If the
light doesn't come on then, have it ®xed so it will
be ready to warn you if there is a problem.
Charging System Light
This light should come on
brie¯y when you turn on
the ignition, before starting
the engine, as a check
to show you it is working.
After the engine starts, the light should go out. If it stays
on or comes on while you are driving, you may have
a problem with your charging system. It could indicate a
problem with the generator drive belt, or some other
charging system problem. Have it checked right away.
Driving while this light is on could drain your battery.
If you must drive a short distance with this light
on, it helps to turn off all your accessories, such as the
radio and air conditioner.
3-27