2004 CHEVROLET ASTRO CARGO VAN wiring

To fully open the rear
doors, push in on the
clip and lift the check
assembly up off the
mounting bracket.
Do this on each door. Replace the check assemblies
on the mounting brackets before closing the doors.
{CAUTION:
It can be dangerous to drive with the rear
glass open because carbon monoxide (CO)
gas can come into your vehicle. You can not
see or smell CO. It can cause
unconsciousness and even death. If you must
drive with the rear glass open or if electrical
wiring or other cable connections must pass
through the seal between the body and the
rear glass:
Make sure all other windows are shut.
Turn the fan on your heating or cooling
system to its highest speed and select the
control setting that will force outside air
into your vehicle. SeeClimate Control
System on page 3-17.
If you have air outlets on or under the
instrument panel, open them all the way.
SeeEngine Exhaust on page 2-29.
2-13

If a bulb is burned out, replace it to help avoid an
accident. If the arrows don’t go on at all when you signal
a turn, check for burned-out bulbs and a blown fuse.
SeeFuses and Circuit Breakers on page 5-101.
If you have a trailer towing option with added wiring for
the trailer lamps, a different turn signal asher is
used. With this asher installed, the signal indicator will
ash even if a turn signal bulb is burned out. Check
the front and rear turn signal lamps regularly to make
sure they are working.
Turn Signal On Chime
If your turn signal is left on for more than 3/4 of a mile
(1.2 km), a chime will sound at each ash of the
turn signal. To turn off the chime, move the turn signal
lever to the center position.
Headlamp High/Low-Beam Changer
To change the headlamps from low beam to high or
high to low, pull the multifunction lever all the way
toward you. Then release it.When the high beams
are on, this indicator
light located on the
instrument panel cluster
also will be on.
Flash-to-Pass
This feature lets you use your high-beam headlamps
to signal a driver in front of you that you want to pass.
It works even if your headlamps are in automatic.
To use it, pull the turn signal lever toward you, but not
so far that you hear a click.
If your headlamps are in automatic or on low beam,
your high-beam headlamps will turn on. They’ll stay
on as long as you hold the lever toward you and
the high-beam indicator located on the cluster comes
on. Release the lever to return to normal operation.
3-7

Air Bag Readiness Light
There is an air bag readiness light on the instrument
panel, which shows AIR BAG or the air bag symbol.
The system checks the air bag’s electrical system
for malfunctions. The light tells you if there is an
electrical problem. The system check includes the air
bag sensor, the air bag modules, the wiring and
the crash sensing and diagnostic module. For more
information on the air bag system, seeAir Bag System
on page 1-62.
This light will come on when you start your vehicle,
and it will ash for a few seconds. Then the light should
go out. This means the system is ready.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 inate in a crash, or they
could even inate 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. United States
Canada
3-25

Hitches
It’s important to have the correct hitch equipment.
Crosswinds, large trucks going by and rough roads
are a few reasons why you’ll need the right hitch.
Weight-Distributing Hitches and Weight
Carrying Hitches
When using a weight-distributing hitch, the hitch
must be adjusted so that the distance (A) remains the
same both before and after coupling the trailer to the
tow vehicle.If you use a step-bumper hitch, your bumper could be
damaged in sharp turns. Make sure you have ample
room when turning to avoid contact between the trailer
and the bumper.
If you’ll be pulling a trailer that, when loaded, will weigh
more than 2,000 lbs. (900 kg.), be sure to use a
properly mounted, weight-distributing hitch and sway
control of the proper size. This equipment is very
important for proper vehicle loading and good handling
when you’re driving. You should always use a sway
control if your trailer will weigh more than these limits.
You can ask a hitch dealer about sway controls.
Will you have to make any holes in the body of your
vehicle when you install a trailer hitch?
If you’re using the wiring provided with the
factory-installed trailering package, you should not
need to make any holes in the body of your vehicle.
However, if you have an aftermarket hitch installed,
you may need to make holes in the body.
If you do, then be sure to seal the holes later when
you remove the hitch. If you don’t seal them, deadly
carbon monoxide (CO) from your exhaust can get into
your vehicle as well as dirt and water. See “Carbon
Monoxide” underEngine Exhaust on page 2-29. (A) Body to Ground Distance, (B) Front of Vehicle
4-39

Turn Signals When Towing a Trailer
When you tow a trailer, your vehicle has to have extra
wiring (included in the optional trailering package).
The arrows on your instrument panel will ash whenever
you signal a turn or lane change. Properly hooked up,
the trailer lamps will also ash, telling other drivers
you’re about to turn, change lanes or stop.
When towing a trailer, the arrows on your instrument
panel will ash for turns even if the bulbs on the trailer
are burned out. Thus, you may think drivers behind
you are seeing your signal when they are not. It’s
important to check occasionally to be sure the trailer
bulbs are still working.
Driving On Grades
Reduce speed and shift to a lower gearbeforeyou
start down a long or steep downgrade. If you don’t shift
down, you might have to use your brakes so much
that they would get hot and no longer work well.
You can tow in DRIVE (D). You may want to shift the
transmission to THIRD (3) or, if necessary, a lower
gear selection if the transmission shifts too often
(e.g., under heavy loads and/or hilly conditions).
When towing at high altitude on steep uphill grades,
consider the following: Engine coolant will boil at a lower
temperature than at normal altitudes. If you turn your
engine off immediately after towing at high altitude
on steep uphill grades, your vehicle may show signs
similar to engine overheating. To avoid this, let the
engine run while parked (preferably on level ground)
with the automatic transmission in PARK (P) for a
few minutes before turning the engine off. If you do
get the overheat warning, seeEngine Overheating
on page 5-29.
4-43

Trailer Wiring Harness
If you have the optional trailering package, your vehicle
will have an eight-wire harness, including the center
high-mounted stoplamp battery feed wire. The harness
is stored on the passenger’s side of the vehicle near
the rear wheel well. This harness has a 30 amp battery
feed wire and no connector, and should be wired by
a qualied electrical technician. After choosing an
aftermarket trailer mating connector pair, have the
technician attach one connector to the eight-wire trailer
harness and the other connector to the wiring harness
on the trailer. Be sure the wiring harness on the trailer
is taped or strapped to the trailer’s frame rail and
leave it loose enough so the wiring doesn’t bend or
break, but not so loose that it drags on the ground.
The eight-wire harness must be routed out of your
vehicle between the rear door and the oor, with enough
of the harness left on both sides so that the trailer or
the body won’t pull it. If you do not have the optional
trailering package, your vehicle will still have a trailering
harness. The harness is located near the passenger’s
side rear wheel well. It consists of six wires that may be
used by after-market trailer hitch installers.The technician can use the following color code chart
when connecting the wiring harness to your trailer.Brown: Rear lamps.
Yellow: Left stoplamp and turn signal.
Dark Green: Right stoplamp and turn signal.
White (Heavy Gage): Ground.
Light Green: Back-up lamps.
White (Light Gage): Center High-Mounted Stoplamp.
Blue: Auxiliary circuit (eight-wire harness only).
Orange: Fused auxiliary (eight-wire harness only).
Store the harness in its original place. Wrap the
harness together and tie it neatly so it won’t
be damaged.
4-45

Appearance Care............................................5-91
Cleaning the Inside of Your Vehicle.................5-92
Care of Safety Belts......................................5-94
Weatherstrips...............................................5-94
Cleaning the Outside of Your Vehicle.................5-95
Sheet Metal Damage.....................................5-97
Finish Damage.............................................5-97
Underbody Maintenance................................5-97
Chemical Paint Spotting.................................5-97
Vehicle Care/Appearance Materials..................5-98
Vehicle Identication......................................5-99
Vehicle Identication Number (VIN).................5-99
Service Parts Identication Label.....................5-99Electrical System..........................................5-100
Add-On Electrical Equipment.........................5-100
Headlamp Wiring........................................5-100
Windshield Wiper Fuses...............................5-100
Power Windows and Other Power Options......5-100
Fuses and Circuit Breakers..........................5-101
Capacities and Specications........................5-107
Normal Maintenance Replacement Parts.........5-109
Engine Drive Belt Routing............................5-110
Section 5 Service and Appearance Care
5-2

Electrical System
Add-On Electrical Equipment
Notice:Don’t add anything electrical to your
vehicle unless you check with your dealer rst.
Some electrical equipment can damage your
vehicle and the damage wouldn’t be covered by
your warranty. Some add-on electrical equipment
can keep other components from working as
they should.
Your vehicle has an air bag system. Before
attempting to add anything electrical to your vehicle,
seeServicing Your Air Bag-Equipped Vehicle
on page 1-67.
Headlamp Wiring
The headlamp wiring is protected by a circuit breaker in
the lamp switch. An electrical overload will cause the
lamps to icker on and off, or in some cases to remain
off. If this happens, have your headlamp wiring
checked right away.
Windshield Wiper Fuses
The windshield wiper motor is protected by a circuit
breaker and a fuse. If the motor overheats due to heavy
snow, etc., the wiper will stop until the motor cools.
Although the circuit is protected from electrical overload,
overload due to heavy snow, etc., may cause wiper
linkage damage. Always clear ice and heavy snow from
the windshield before using the windshield wipers. If
the overload is caused by some electrical problem and
not snow, etc., be sure to get it xed.
Power Windows and Other
Power Options
Circuit breakers in the fuse panel protect the power
windows and other power accessories. When the current
load is too heavy, the circuit breaker opens and
closes, protecting the circuit until the problem is xed
or goes away.
5-100