2003 CHEVROLET ASTRO service

Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition
to notifying General
Motors of Canada Limited. You may write to:
Transport Canada 330 Sparks Street
Tower C Ottawa, Ontario K1A ON5
Reporting Safety Defects to
General Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you’ll notify us.
Please call us at 1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors
of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
Transmission, Transaxle, Transfer
Case Unit Repair Manual
This manual provides information on unit repair service
procedures, adjustments, and specifications for GM
transmissions, transaxles, and transfer cases.
RETAIL SELL PRICE: $50.00
7-1
1

Service Bulletins
Service Bulletins give technical service information needed to knowledgeably service General Motors cars
and trucks. Each bulletin contains instructions to
assist in the diagnosis and service of your vehicle.
In Canada, information pertaining to Product Service
Bulletins can be obtained by contacting your General
Motors dealer or by calling 1-800-GM-DRIVE
(1 -800-463-7483).
Owner’s Information
Owner publications are written specifically for owners
and intended to provide basic operational information
about the vehicle. The owner’s manual will include
the Maintenance Schedule for all models.
In-Portfolio: Includes a Portfolio, Owner’s Manual, and
Warranty Booklet.
RETAIL SELL PRICE:
$35.00
Without Portfolio: Owner’s Manual only.
RETAIL SELL PRICE:
$25.00
Current and Past Model Order Forms
Service Publications are available for current and
past model GM vehicles. To request an order form,
please specify year and model name of the vehicle.
ORDER TOLL FREE: 1-800-551-4123
Monday-Friday 8:OO
AM - 6:OO PM
Eastern Time
For Credit Card Orders Only
(VISA-Mastercard-Discover), visit Helm, Inc.
on the
World Wide Web at: www.helminc.com
Or you can write to:
Helm, Incorporated
P.
0. Box 07130
Detroit, MI 48207
Prices are subject to change without notice and without
incurring obligation. Allow ample time for delivery.
Note to Canadian Customers: All listed prices are
quoted in
U.S. funds. Canadian residents are to make
checks payable
in U.S. funds.
7-1 2

Accessory Power Outlets ................................. 3-16
Activating the Theft-Deterrent Feature
................ 3-48
Adding Equipment to Your Air Bag-Equipped
Vehicle
....................................................... 1-70
Adding Washer Fluid
....................................... 5-41
Additional Program Information
......................... 7-1 0
Additives, Fuel ................................................. 5-6
Add-On Electrical Equipment
............................ 5-92
Add-on Equipment
.......................................... 4-31
Adjusting the Speakers (Balance/Fade)
........ 3-40, 3-43
Air Bag
Readiness Light
.......................................... 3-26
Air Bag System
.............................................. 1-62
Adding Equipment to Your
Air Bag-Equipped Vehicle
...................... 1-70
How Does an Air Bag Restrain?
.................... 1-67
Servicing Your Air Bag-Equipped Vehicle
......... 1-69
What Will You See After an Air Bag inflates?
...... 1-68
When Should an Air Bag Inflate?
................... 1-66
Where Are the Air Bags?
.............................. 1-64
All Overseas Locations
...................................... 7-5
All-Wheel Drive
............................................... 5-52
All-Wheel Drive (AWD) System
......................... 2-26
All-Wheel-Drive Service Light
............................ 3-35
Aluminum Wheels
........................................... 5-88
What
Makes an Air Bag Inflate?
.................... 1-67
Air CleanedFiIter, Engine
... ...................... 5-24
AM
............................................................... 3-50 AM-FM Radio
...................... ................ 3-39
Antenna, Fixed Mast
....................................... 3-50
Anti-lock Brake System
..................................... 4-7
Anti-Lock Brake, System Warning Light
.............. 3-29
Appearance Care
............................................ 5-83
Care of Safety Belts
.................................... 5-86
Chemical Paint Spotting
............................... 5-89
Cleaning the Inside of Your Vehicle
................ 5-83
Finish Damage
............................................ 5-88
Sheet Metal Damage
................................... 5-88
Underbody Maintenance
............................... 5-89
Weatherstrips
.............................................. 5-86
Ashtrays
........................................................ 3-17
Audio System(s)
............................................. 3-38
Audio Systems
AM-FM Radio
............................................. 3-39
Care of Your CD Player
............................... 3-50
Care of Your CDs
........................................ 3-50
Fixed Mast Antenna
..................................... 3-50
Radio with CQ
............................................ 3-41
Rear Seat Audio (RSA)
................................ 3-46
Setting the Time for Radios with HR and
MN Buttons
............................................. 3-38
Setting the Time for Radios with the
Set Button
.............................................. 3-38
Theft-Deterrent Feature
................................ 3-47
Understanding Radio Reception
..................... 3-50
Cleaning
the Outside of Your Vehicle
.............. 5-86
GM Vehicle Care/Appearance Materials
.......... 5-89
1

Automatic Headlamp System ..................
Automatic Transmission
Fluid
................................................
Automatic Transmission Check ................
Automatic Transmission Shift Lock Control
System Check
...................................
Operation .........................................
......... 3-13
......... 5-25
......... 2-23
......... 6-27
......... 6-28
Backing Up
.................................................... 4-38
Battery
.......................................................... 5-46
Battery Replacement
......................................... 2-6
Battery Run-Down Protection
............................ 3-1 6
Before Leaving on a Long Trip
......................... 4-21
Bench Seat
............................................ 1-1 1, 1-57
Body Lubrication Service
.................................. 6-27
Brake Parking
...................................................... 2-26
System Inspection
....................................... 6-31
System Warning Light
.................................. 3-28
Brake Adjustment
............................................ 5-45
Brake Fluid
.................................................... 5-42
Brake Pedal Travel
......................................... 5-45
Brake Wear
................................................... 5-45
Brakes
.......................................................... 5-42
Braking in Emergencies
..................................... 4-9
Break-In, New Vehicle
..................................... 2-19
Braking
........................................................... 4-6
Bucket Seats, Rear
......................................... 1-12 Bulb
Replacement
........................................... 5-55
Halogen Bulbs ............................................ 5-55
Headlamps
............................ ......... 5-55
Replacement Bulbs
.............................. 5-61
Taillamps
.................................................... 5-60
Front
Turn Signal Lamps
.............................. 5-59
Buying New Tires
................................... 5-66
C
California Fuel .................................................. 5-6
Canada
........................................................... 7-5
Canadian Owners
................................................ ii
Canadian Roadside Assistance ............ ....... 7-7
Cancelling the Sliding Door
Security Lock
.......................................... 2-12
Capacities and Specifications
........................ 5-99
Carbon Monoxide
............... ..... 4-24, 4-31, 2-30
Care of
Safety Belts
.... ~ ~ ~ ~ ..................... 5-86
Care of Your
CD Player
.......... ...., ............ ..... 3-50
CDS
.......................................................... 3-50
Cargo Vans
........................................... 1-41, 1-48
Center Passenger Position, Safety Belts
............. 1-27
Chains, Tires
..................................... ..... 5-70
Charging System Light
....................... ..... 3-27
Engine Light
.............................. , ..... 3-30
Check
Gages Warning Light
................................... 3-36
2

Checking Brake Fluid .................................. 5-43
Checking Coolant ............................................ 5-29
Checking Engine Oil ........................................ 5-15
Checking Things Under the Hood ...................... 5-1 1
Checking Your Restraint Systems ...................... 1-71
Chemical Paint Spotting ................................... 5-89
Child Restraints
Child Restraint Systems
............................... 1-44
Infants and Young Children ........................... 1-38
Lower Anchorages and Top Tethers for
Children (LATCH System)
.......................... 1-52
Older Children ............................................. 1-35
Securing a Child Restraint Designed for
the LATCH System
................................ 1-54
Securing a Child Restraint in a Center
Seat Position
....................................... 1-57
Securing a Child Restraint in a Rear
Outside Seat Position
............................... 1-54
Securing a Child Restraint in the Right
Front Seat Position
................................... 1-59
Top Strap ................................................... 1-48
Top Strap Anchor Location ............................ 1-50
Where to Put the Restraint ........................... 1-47
Cigarette Lighter ............................................. 3-1 7
Cleaning
Inside of Your Vehicle
.................................. 5-83
Outside of Your Vehicle ................................ 5-86
Underbody Maintenance ............................... 5-89
Weatherstrips .............................................. 5-86
Cleaning Exterior Lamps/Lenses ....................... 5-86
Climate Control System ................................... 3-18
Rear .......................................................... 3-21
Rear Heating System ................................... 3-19
Compact Disc Messages .................................. 3-45
Compact Spare Tire ........................................ 5-82
Composite Headlamps ..................................... 5-56
Control of a Vehicle .......................................... 4-6
Convenience Net ............................................ 2-45
Coolant
Engine Temperature Gage
............................ 3-30
Heater, Engine ............................................ 2-22
Cooling System .............................................. 5-33
Cruise Control ................................................ 3-10
Current and Past Model Order Forms ................ 7-12
Customer Assistance Information
Customer Assistance for Text
Customer Assistance
Off ices ........................... 7-4
Customer Satisfaction Procedure ..................... 7-2
GM Mobility Program for Persons with
Disabilities
................................................ 7-5
Reporting Safety Defects to General Motors ....... 7-11
Reporting Safety Defects to the
Canadian Government
.............................. 7-11
Reporting Safety Defects to the United States Government
......................... 7-10
Roadside Assistance Program ......................... 7-6
Service Publications Ordering Information ........ 7-11
Rear Air Conditioning System ........................ 3-20
Courtesy Transportation ......... ...... 7-8
Telephone (TTY) Users ............................... 7-4
3

Daytime Running Lamps (DRL) ...................... 3-14
Defensive Driving
............................................. 4-2
Defogging and Defrosting
................................. 3-1 9
Directing the Airflow
........................................ 3-20
Disabling the Theft-Deterrent Feature
................. 3-49
Doing Your Own Service Work
........................... 5-3
Dome Lamps
.......................................... ~ ~~~ 3-16
Door Front Doors
............................................... 2-8
Locks
.......................................................... 2-7
Power Door Locks
......................................... 2-8
Programmable Automatic Door Locks
............... 2-9
Rear Doors
................................................. 2-13
Sliding Side Door
........................................ 2-10
Position, Safety Belt
..................................... 1-1 8
Driver Information System
................................ 2-42
At Night
..................................................... 4-14
City
........................................................... 4-19
Defensive
..................................................... 4-2
Drunken
....................................................... 4-3
Freeway
..................................................... 4-20
Hill and Mountain Roads
.............................. 4-22
In Rain and on Wet Roads ........................... 4-16
Winter
........................................................ 4-24
Driving On Grades
.......................................... 4-39
Driving on Snow or Ice
.................................... 4-24
Driver
Driving Driving
Through Deep Standing Water
............... 4-18
Driving Through Flowing Water
......................... 4-18
Driving with a Trailer
....................................... 4-37
E
Electrical System
Add-on Equipment
...................................... 5-92
Headlamp Wiring
......................................... 5-92
Fuses and
Circuit Breakers
........................... 5-93
Power Windows and Other Power Options
......... 5-92
Windshield Wiper Fuses
............................... 5-92
Emissions Inspection and
Engine Maintenance Programs
................................. 3-33
Air Cleaner/Filter
......................................... 5-24
Battery
....................................................... 5-46
Check and Service Engine Soon Light
............ 3-30
Coolant
...................................................... 5-28
Coolant Heater
............................................ 2-22
Coolant Temperature Gage
........................... 3-30
Cooling System Inspection
............................ 6-30
Cover
........................................................ 5-20
Engine Compartment Overview
...................... 5-14
Exhaust
..................................................... 2-30
Fan Noise
.................................................. 5-39
Oil
............................................................. 5-15
Starting
...................................................... 2-21
Overheating
................................................ 5-31
4

Inspection (cont.) Exhaust System
........................ ....... 6-30
Fuel System
............................................... 6-30
Part C
- Periodic Maintenance ....................... 6-30
Steering, Suspension and Front Drive Axle
Boot and Seal
......................................... 6-30
Throttle System
........................................... 6-31
Installing a Garage Door Opener
....................... 2-40
Instrument Panel Cluster
....................................................... 3-24
Overview
.................................................. 3-2
Instrument Panel Brightness Control
.............. 3-1 5
Instrument Panel Fuse Block ............................ 5-93
Interior Lamps
................................................ 3-15
Interior Plastic Components
.............................. 5-85
Introduction Transfer Case (All-Wheel Drive) Inspection
........ 6-31
Jump Starting
....................................... ... 5-47
Key Lock Cylinders Service
.............................. 6-27
Keys
............................................................... 2-2
Keyless Entry System
....................................... 2-4
L
Lamps
Exterior
...................................................... 3-12
Interior
....................................................... 3-15
Lap Belt
........................................................ 1-27
Lap-Shoulder Belt
................................... 1-18, 1-29
LATCH System
Child Restraints
........................................... 1-52
Securing a Child Restraint Designed for
the LATCH System
........................... . 1-54
Latches, Seatback
............................................ 1-6
Leather
......................................................... 5-85
Leaving Your Vehicle
....................................... 2-10
Leaving Your Vehicle With the
Engine Running
.......................................... 2-28
Light
Air Bag Readiness
....................................... 3-26
Brake System Warning
................................. 3-28
Charging System
......................................... 3-27
Check Gages Warning
................................. 3-36
Low Fuel Warning
....................................... 3-37
Malfunction Indicator
.................................... 3-30
Safety Belt Reminder
................................... 3-26
Security
.............................................. 3-35
Service All-Wheel-Drive
......................... 3-35
Tow/Haul Mode
........................................... 3-36
Lamps On Reminder
....................................... 3-14
Anti-Lock Brake System Warning
................... 3-29
7

Loading Your Vehicle ....................................... 4-29
Locks Door
........................................................... 2-7
Front Doors
.................................................. 2-8
Leaving Your Vehicle
.................................... 2-10
Power Door
.................................................. 2-8
Programmable Automatic Door Locks
............... 2-9
Long Trip/Highway Definition
.............................. 6-6
Long Trip/Highway Intervals
............................... 6-6
Long Trip/Highway Scheduled Maintenance
........ 6-1 8
Loss
of Control ............................................... 4-1 3
Low Fuel Warning Light
................................... 3-37
Lumbar
Luggage
Carrier
.............................................. 2-44
Manual Controls
............................................ 1-3
M
Maintenance. Normal Replacement Parts .......... 5-1 01
Maintenance Schedule At Each Fuel Fill
......................................... 6-26
At Least Once a Month
................................ 6-26
At Least Once a Year
.................................. 6-27
At Least Twice a Year
.................................. 6-26
Brake System Inspection
.............................. 6-31
Engine Cooling System Inspection
................. 6-30
Fuel System Inspection
................................ 6-30
How This Section is Organized
....................... 6-3
Exhaust System
Inspection
........................... 6-30 Maintenance Schedule (cont.)
Introduction
.................................................. 6-2
Long Trip/Highway Scheduled Maintenance
..... 6-18
Maintenance Requirements
............................. 6-2
Part A
. Scheduled Maintenance Services ......... 6-4
Part B
. Owner Checks and Services ............. 6-26
Part C
. Periodic Maintenance Inspections ...... 6-30
Part D
- Recommended Fluids and
Lubricants
............................................... 6-32
Part E
. Maintenance Record ........................ 6-34
Selecting the Right Schedule
.......................... 6-5
Short Trip/City Scheduled Maintenance
............. 6-7
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection
.......................... 6-30
Using Your
................................................... 6-4
Your Vehicle and the Environment
................... 6-2
Maintenance When Trailer Towing
..................... 4-40
Throttle
System Inspection
............................ 6-31
Making Turns
................................................. 4-38
Malfunction Indicator Light
................................ 3-30
Manual Lumbar Controls
.................................... 1-3
Manual Seats
................................................... 1-2
Manual Windows
........................................ 2-16
Mirrors Manual Rearview Mirror
................................ 2-32
Outside Convex Mirror
................................. 2-33
Outside Manual Mirrors
................................ 2-32
Outside Power Mirrors
.................................. 2-32
Model Reference
............................................ vi
8