2004 CHEVROLET ASTRO CARGO VAN manual transmission

Keys...............................................................2-2
Remote Keyless Entry System.........................2-4
Remote Keyless Entry System Operation...........2-5
Doors and Locks.............................................2-7
Power Door Locks..........................................2-8
Programmable Automatic Door Locks................2-8
Leaving Your Vehicle......................................2-9
Sliding Side Door...........................................2-9
Rear Doors..................................................2-12
Windows........................................................2-15
Manual Windows..........................................2-15
Power Windows............................................2-16
Sun Visors...................................................2-16
Theft-Deterrent Systems..................................2-17
Passlock
®....................................................2-17
Starting and Operating Your Vehicle................2-18
New Vehicle Break-In....................................2-18
Ignition Positions..........................................2-18
Starting Your Engine.....................................2-20
Engine Coolant Heater..................................2-21Automatic Transmission Operation...................2-22
All-Wheel Drive............................................2-25
Parking Brake..............................................2-25
Shifting Into Park (P).....................................2-26
Shifting Out of Park (P).................................2-28
Parking Over Things That Burn.......................2-29
Engine Exhaust............................................2-29
Running Your Engine While
You Are Parked........................................2-30
Mirrors...........................................................2-31
Manual Rearview Mirror.................................2-31
Outside Manual Mirror...................................2-31
Outside Power Mirrors...................................2-31
Outside Convex Mirror...................................2-32
HomeLink®Transmitter...................................2-32
Programming the HomeLink®Transmitter.........2-33
Storage Areas................................................2-36
Overhead Console........................................2-38
Luggage Carrier...........................................2-43
Convenience Net..........................................2-43
Section 2 Features and Controls
2-1

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:Spinning the tires or holding the vehicle
in one place on a hill using only the accelerator
pedal may damage the transmission. If you
are stuck, do not spin the tires. When stopping
on a hill, use the brakes to hold the vehicle in place.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. SeeTow/Haul Mode Light
on page 3-34for more information.
2-24

There is a delay in the transition between the daytime
and nighttime operation of the Daytime Running
Lamps (DRL) and the automatic headlamp systems so
that driving under bridges or bright overhead street
lights does not affect the system. The DRL and
automatic headlamp system will only be affected when
the light sensor sees a change in lighting lasting
longer than the delay.
To idle your vehicle with the automatic headlamp
system off, set the parking brake while the ignition is off.
Then start your vehicle. The automatic headlamp
system will stay off until you release the parking brake.
You may be able to turn off your automatic headlamp
system. See “Daytime Running Lamps (DRL)” later
in this section for more information.
As with any vehicle, you should turn on the regular
headlamps when you need them.
Lamps On Reminder
A reminder tone will sound when your headlamps or
parking lamps are manually turned on and your ignition
is in OFF, LOCK or ACCESSORY. To disable the
tone, turn the instrument panel brightness thumbwheel
all the way down. In the automatic mode, the
headlamps turn off once the ignition key is in OFF.
Daytime Running Lamps (DRL)
Daytime Running Lamps (DRL) can make it easier
for others to see the front of your vehicle during the day.
DRL can be helpful in many different driving conditions,
but they can be especially helpful in the short periods
after dawn and before sunset. Fully functional daytime
running lamps are required on all vehicles rst sold
in Canada.
The DRL system will make your headlamps come on
at a reduced brightness when the following conditions
are met:
The ignition is on,
the exterior lamp control is off.
the automatic transmission is not in PARK (P),
the light sensor determines it is daytime and
the parking brake is released.
When the DRL are on, only your DRL lamps will be on.
The taillamps, sidemarker and other lamps won’t be
on. Your instrument panel won’t be lit up either.
When it begins to get dark, the automatic headlamp
system will switch from DRL to the headlamps or the last
chosen headlamp setting that was used.
3-13

Parking on Hills
{CAUTION:
You really should not park your vehicle, with
a trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.
But if you ever have to park your rig on a hill, here’s
how to do it:
1. Apply your regular brakes, but don’t shift into
PARK (P) yet.
2. Have someone place chocks under the
trailer wheels.
3. When the wheel chocks are in place, release
the regular brakes until the chocks absorb
the load.
4. Reapply the regular brakes. Then apply
your parking brake, and shift to PARK (P).
5. Release the regular brakes.
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 uid
(don’t overll), engine oil, axle lubricant, belt, cooling
system and brake system. Each of these is covered
in this manual, and the Index will help you nd
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.
4-44

{CAUTION:
Batteries can hurt you. They can be
dangerous because:
They contain acid that can burn you.
They contain gas that can explode
or ignite.
They contain enough electricity to
burn you.
If you do not follow these steps exactly,
some or all of these things can hurt you.
Notice:Ignoring these steps could result in costly
damage to your vehicle that would not be covered
by your warranty.
Trying to start your vehicle by pushing or pulling it
will not work, and it could damage your vehicle.
1. Check the other vehicle. It must have a 12 - volt
battery with a negative ground system.Notice:If the other vehicle’s system is not a 12-volt
system with a negative ground, both vehicles can
be damaged. Only use vehicles with 12-volt systems
with negative grounds to jump start your vehicle.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles are not touching
each other. If they are, it could cause a ground
connection you do not want. You would not be able
to start your vehicle, and the bad grounding
could damage the electrical systems.
To avoid the possibility of the vehicles rolling, set
the parking brake rmly on both vehicles involved
in the jump start procedure. Put an automatic
transmission in PARK (P) and a manual
transmission in NEUTRAL before setting the
parking brake.
5-45

Capacities and Specications (cont’d)
ApplicationCapacities
English Metric
Transmission Fluid (Drain and Rell) 5.0 quarts 4.7 L
Wheel Nut Torque 140 ft lb 190Y
All capacities are approximate. When adding, be sure to ll to the appropriate level, as recommended in this
manual. Recheck the uid level after lling. See refrigerant charge label under the hood for charge capacity
information and requirements.
Engine Specications
Engine RPO Transmission Spark Plug Gap Firing Order
“Vortec” 4300 V6 MFI* LU3 Automatic0.060 inches
(1.52 mm)1–6–5–4–3–2
*Micro Fuel Injection
5-108

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 specications
for GM transmissions, transaxles, and transfer cases.
RETAIL SELL PRICE: $50.00
7-12

Hood
Checking Things Under.................................. 5-9
Release.....................................................5-10
Horn............................................................... 3-5
How to Add Coolant to the Coolant
Recovery Tank............................................5-33
How to Add Coolant to the Radiator..................5-35
How to Add Fluid............................................5-25
How to Check Lubricant...................................5-51
How to Check Power Steering Fluid..................5-38
How to Inspect the Engine Air Cleaner/Filter.......5-22
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-18
Hydroplaning..................................................4-16
I
If No Steam Is Coming From Your Engine..........5-30
If Steam Is Coming From Your Engine...............5-29
If the Light Is Flashing.....................................3-30
If the Light Is On Steady.................................3-30
If You Are Caught in a Blizzard.........................4-26
If You Are Stuck in Sand, Mud, Ice or Snow.......4-28
If You Do Decide To Pull A Trailer.....................4-35
Ignition Positions.............................................2-18Ignition Transmission Lock Check......................6-25
Infants and Young Children, Restraints...............1-38
Ination - Tire Pressure...................................5-70
Inspection
Brake System.............................................6-27
Engine Cooling System................................6-26
Exhaust System..........................................6-26
Fuel System...............................................6-26
Part C - Periodic Maintenance.......................6-26
Steering, Suspension and Front Drive
Axle Boot and Seal..................................6-26
Throttle System...........................................6-27
Transfer Case and Front Axle
(All-Wheel Drive)......................................6-27
Installing a Garage Door Opener.......................2-39
Instrument Panel
Cluster.......................................................3-23
Overview..................................................... 3-2
Instrument Panel Brightness Control..................3-14
Instrument Panel Fuse Block..........................5-101
Interior Lamps................................................3-14
J
Jump Starting.................................................5-44
7