2003 CHEVROLET ASTRO maintenance

The 2003 Chevrolet Astro Owner Manual
Seats and Restraint Systems ........................... I-!
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
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
................................................. 2-1 6
Theft-Deterrent Systems
............................ 2-1 8
Mirrors
.................................................... 2-32
HomeLink@ Transmitter
............................. 2-34
Features and Controls ..................................... 2-1
Starting and Operating Your Vehicle
........... 2-19
Storage Areas
Instrument Panel .
Instrument Panel
Climate Controls
......................................... 2-38
........................................... 3-1
Overview .......................... 3-2
...................................... 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
........ 4-2
Towing
................................................... 4-29
Service and Appearance Care .......................... 5-1
Service ..................................................... 5-3
Fuel
......................................................... 5-5
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 Identification
................................. 5-91
Electrical System
...................................... 5-92
Capacities and Specifications
..................... 5-99
Normal Maintenance Replacement Parts
...... 5-1 01
Maintenance Schedule ..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance Information .................... 7-1
Customer Assistance Information
.................. 7-2
Reporting Safety Defects ........................... 7-10
Checking Things Under
the Hood
............... 5-11
Index ................................................................ 1

e
e
e
Air bags are designed to inflate only once. After they
inflate, 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 inflation and driver’s safety belt
usage at deployment. The module also records
speed, engine rpm, brake and throttle data.
Let only qualified 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
inflate 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 Informqtion on page
7-1 1.
For up to 10 minutes after the ignition key is
turned off and the battery is disconnected, an
air bag can
still inflate during improper service.
You can be injured if you are close to an air bag
when
it inflates. 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
qualified to do so.
The air bag system does not need regular maintenance.
1-69

Restraint System Check
Checking Your Restraint Systems
Now and then, make sure the safety belt reminder light
and all your belts, buckles, latch plates, retractors
and anchorages are working properly. Look for any other
loose
or damaged safety belt system parts. If you see
anything that might keep a safety belt system from doing
its job, have it repaired.
Torn or frayed safety belts may not protect you in a
crash. They can rip apart under impact forces.
If a belt
is torn or frayed, get a new one right away.
Also look for any opened or broken air bag covers, and
have them repaired or replaced. (The air bag system
does not need regular maintenance.)
Replacing Restraint System Parts
After a Crash
A crash can damage the restraint systems in
your vehicle. A damaged restraint system
may not properly protect the person using
it,
resulting in serious injury or even death in a
crash.
To help make sure your restraint
systems are working properly after a crash, have them inspected and any necessary
replacements made as
soon as possible.
1-71

This system is called OBD II (On-Board Diagnostics-
Second Generation) and is intended to assure that
emissions are at acceptable levels for the life of
the vehicle, helping to produce a cleaner environment.
The SERVICE ENGINE SOON or CHECK ENGINE
light comes on and a chime will sound to indicate that
there is a problem and service is required. Malfunctions
often will be indicated by the system before any
problem is apparent. This may prevent more serious
damage to your vehicle. This system is also designed to
assist your service technician in correctly diagnosing
any malfunction.
Notice: If you keep driving your vehicle with this
light on, after a while, your emission controls
may not work as well, your fuel economy may not
be as good and your engine may not run as
smoothly. This could lead to costly repairs that
may not be covered by your warranty.
Notice: Modifications made to the engine,
transmission, exhaust, intake or fuel system of
your vehicle
or the replacement of the original tires
with other than those of the same Tire Performance
Criteria (TPC) can affect your vehicle’s emission
controls and may cause
this light to come on. Modifications to these systems could lead to costly
repairs not covered by your warranty. This may
also result
in a failure to pass a required Emission
Inspection/Maintenance test.
This light should come on, as a check to show you
it
is working, when the ignition is on and the engine is not
running.
If the light doesn’t come on, have it repaired.
This light will also come on during a malfunction in one
of two ways:
e
e Light Flashing - A misfire condition has been
detected.
A misfire increases vehicle emissions
and may damage the emission control system on
your vehicle. Dealer or qualified service center
diagnosis and service may be required.
Light On Steady
- An emission control system
malfunction has been detected on your vehicle.
Dealer or qualified service center diagnosis
and service may be required.
3-31

If you experience one or more of these conditions,
change the fuel brand you use.
it will require at least
one full tank of the proper fuel to turn the light
off.
If none of the above steps have made the light turn off,
have your dealer or qualified service center check
the vehicle. Your dealer has the proper test equipment
and diagnostic tools to fix any mechanical or electrical
problems that may have developed.
Emissions Inspection and
Maintenance Programs
Some state/provincial and local governments have or
may begin programs to inspect the emission control
equipment on your vehicle. Failure to pass this
inspection could prevent you from getting a vehicle
registration. Here are
some things you need to know to help your
vehicle pass an inspection:
Your vehicle will not pass this inspection
if the SERVICE
ENGINE SOON or CHECK ENGINE light is on or not
working properly.
Your vehicle will not pass this inspection
if the OBD
(on-board diagnostic) system determines that critical
emission control systems have not been completely
diagnosed by the system. The vehicle would be
considered not ready for inspection. This can happen
if you have recently replaced your battery or if your
battery has run down. The diagnostic system is
designed to evaluate critical emission control systems
during normal driving. This may take several days
of routine driving.
If you have done this and your
vehicle still does not pass the inspection for lack of
OBD system readiness, see your dealer or qualified
service center to prepare the vehicle for inspection.
3-33

Payload
The Payload Capacity is shown on the CertificationiTire
label. This is the maximum load capacity that your
vehicle can carry. Be sure to include the weight of the
people inside as part of your load.
If you added any
accessories or equipment after your vehicle left
the factory, remember to subtract the weight of these
things from the payload. Your dealer can help you
with this.
Towing a Trailer
Trailering Package
There is a load rating which includes the weight of the
vehicle and the trailer it tows. This rating is called
the Gross Combination Weight Rating (GCWR).
When
you weigh your trailer, be sure to include the
weight of everything you put in it. And, remember
to figure the weight of the people inside the vehicle
as part of your load.
Add-on Equipment
When you carry removable items, you may need to put
a limit on how many people you carry inside your
vehicle. Be sure to weigh your vehicle before you buy
and install the new equipment. If
)“J don’t use the correct equipment and
drive properly, you can lose control when you pull a trailer. For example, if the trailer
is too
heavy, the brakes may not work well
- or
even at all. You and your passengers could be
seriously injured. Pull a trailer only if you have
followed all the steps in this section.
Ask your
dealer for advice and information about towing
a trailer with your vehicle.
Notice: Pulling a trailer improperly can damage
your vehicle and result in costly repairs not covered by your warranty.
To pull a trailer correctly, follow
the advice
in this part, and see your dealer for
important information about towing a trailer with
your vehicle. Additional rear axle maintenance is required for a vehicle used to tow a trailer. See
“Scheduled Maintenance Services”
in the Index.
To identify what the vehicle trailering capacity is for your
vehicle, you should read the information in “Weight of
the Trailer” that appears later in this section.
4-3 1

When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you:
start your engine,
shift into a gear, and
release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the
chocks.
Maintenance When Trailer Towing
Your vehicle will need service more often when you’re
pulling a trailer. See the Maintenance Schedule for more
on this. Things that are especially important in trailer
operation are automatic transmission fluid (don’t overfill),
engine oil, axle lubricant, belt, cooling system and
brake system. Each
of these is covered in this manual,
and the Index will help you find them quickly.
If you’re
trailering, it’s a good idea to review these sections
before you start your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
4-40

Section 5 Service and Appearance Care
Appearance Care ............................................ 5.83
Care
of Safety Belts ...................................... 5-86
Weatherstrips
............................................... 5-86
Sheet Metal Damage
..................................... 5-88
Finish Damage
............................................. 5-88
Underbody Maintenance
................................ 5-89
Chemical Paint Spotting
................................. 5-89
GM Vehicle Care/Appearance Materials ........... 5-89
Vehicle Identification ...................................... 5-91
Vehicle Identification Number (VIN)
................. 5-91
Service Parts Identification Label
..................... 5-91
Cleaning the Inside of Your Vehicle ................. 5-83
Cleaning the Outside
of Your Vehicle ................. 5-86
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 Specifications ......................... 3-99
Capacities and Specifications
......................... 5-99
Normal Maintenance Replacement Parts ......... 5-101
5-2