2004 CHEVROLET ASTRO 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
.......................................1-63
Restraint System Check
............................1-70
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-6
Windows
.................................................2-14
Theft-Deterrent Systems
............................2-16
Starting and Operating Your Vehicle
...........2-17
Mirrors
....................................................2-30
HomeLink
žTransmitter
.............................2-31
Storage Areas
.........................................2-34
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
..... 4-2
Towing
...................................................4-29Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-4
Checking Things Under the Hood
................. 5-9
All-Wheel Drive
........................................5-47
Rear Axle
...............................................5-48
Front Axle
...............................................5-48
Bulb Replacement
....................................5-49
Windshield Wiper Blade Replacement
.........5-56
Tires
......................................................5-56
Appearance Care
.....................................5-86
Vehicle Identi®cation
.................................5-95
Electrical System
......................................5-95
Capacities and Speci®cations
...................5-102
Normal Maintenance Replacement Parts
....5-104
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-10
Index................................................................ 1
2004 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

This vehicle has one
double-sided key for the
ignition and door locks. It
will ®t with either side up.
When a new vehicle is delivered, the dealer provides
the owner with a pair of identical keys and a
bar-coded tag.
The bar-coded tag has a code on it that tells your
dealer or a quali®ed locksmith how to make extra keys.
Keep this tag in a safe place. If you lose your keys,
you'll be able to have new ones made easily using
this tag.
Notice:If you ever lock your keys in your vehicle,
you may have to damage the vehicle to get in.
Be sure you have spare keys.
If you ever do get locked out of your vehicle, call GM
Roadside Assistance Center. See
Roadside Assistance
Program on page 7-6.
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:
3. This device may not cause interference, and
4. 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.
2-3

·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 the battery replacement is
necessary. See ``Battery Replacement'' under
Remote Keyless Entry System Operation on
page 2-4.
·If you are still having trouble, see your dealer or a
quali®ed technician for service.
Remote Keyless Entry System
Operation
If your vehicle has this feature, you can lock and unlock
your doors from about 3 feet (1 m) up to 30 feet
(9 m) away using the remote keyless entry transmitter
supplied with your vehicle.
UNLOCK:Press UNLOCK once for the driver's door to
unlock, the parking lamps to ¯ash and the interior
lights to go on.
If you press UNLOCK again within three seconds, all
doors will unlock.
LOCK:Press LOCK to lock all the doors. Press LOCK
again within three seconds and the horn will chirp.REAR 2X:Press the REAR button twice within three
seconds to unlock the rear hatch or cargo doors.
The parking lamps will ¯ash and the interior lights will
go on. If the engine is running, the automatic
transmission must be in PARK (P) or NEUTRAL (N) for
the REAR 2X button to operate.
L(Panic Alarm):Press this button for the horn to
sound and the headlamps and taillamps to ¯ash for up to
30 seconds. This can be turned off by pressing the
panic button again, waiting for 30 seconds, or starting
the vehicle.
Matching Transmitter(s) to Your
Vehicle
Each remote keyless entry transmitter is coded to
prevent another transmitter from unlocking your vehicle.
If a transmitter is lost or stolen, a replacement can
be purchased through your dealer. Remember to bring
any remaining transmitters with you when you go to
your dealer. When the dealer matches the replacement
transmitter to your vehicle, any remaining transmitters
must also be matched. Once your dealer has coded the
new transmitter, the lost transmitter will not unlock
your vehicle. Each vehicle can have a maximum of four
transmitters matched to it.
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 5-89. See your
dealer for service.
2-16

Notice:Lengthy operation of features such as the
radio in the accessory ignition position may
drain the battery and prevent your vehicle from
starting. Do not operate your vehicle in the
accessory ignition position for a long period
of time.
B (LOCK):This position locks your ignition 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:Using a tool to force the key from the
ignition switch could cause damage or break the
key. Use the correct key and turn the key only with
your hand. Make sure the key is all the way in. If
none of this works, then your vehicle needs service.C (OFF):This position lets you turn off the engine. 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.
2-18

Outside Convex Mirror
Your passenger's side mirror is convex. A convex
mirror's surface is curved so you can see more from the
driver's seat.
{CAUTION:
A convex mirror can make things (like other
vehicles) look farther away than they really are.
If you cut too sharply into the right lane, you
could hit a vehicle on your right. Check your
inside mirror or glance over your shoulder
before changing lanes.
HomeLinkžTransmitter
HomeLink, a 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 information 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.
Programming the HomeLinkž
Transmitter
Do not use the HomeLinkžTransmitter with any garage
door opener that does not have the ªstop and reverseº
feature. This includes any garage door opener model
manufactured before April 1, 1982. If you have a newer
garage door opener with rolling codes, please be
sure to follow steps 6 through 8 to complete the
programming of your HomeLink
žTransmitter.
Read the instructions completely before attempting to
program the HomeLink
žTransmitter. Because of the
steps involved, it may be helpful to have another person
available to assist you in programming the transmitter.
2-31

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
Outlet Adjustment.........................................3-20
Rear Heating System....................................3-21
Rear Air Conditioning System.........................3-21
Warning Lights, Gages and Indicators.............3-23
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
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