2005 CHEVROLET ASTRO CARGO VAN service

Security Light
This light will come on
briey when you turn the
ignition key to START.
The light will stay on until the engine starts. If the light
ashes, the Passlock
®System has entered a tamper
mode. If the vehicle fails to start, seePasslock®
on page 2-16.
If the light comes on continuously while driving and
stays on, there may be a problem with the Passlock
®
System. Your vehicle will not be protected by Passlock®,
and you should see your GM dealer.
Highbeam On Light
This light will come on
when the high-beam
headlamps are in use.
SeeHeadlamp High/Low-Beam Changer on page 3-9.
Service All-Wheel Drive Light
This light should come on
briey when you turn on
the ignition, as a check to
show you it is working.
3-35

The SERVICE AWD light comes on to indicate that
there may be a problem with the drive system and
service is required. Malfunctions can be indicated by the
system before any problem is apparent, which may
prevent serious damage to the vehicle. This system is
also designed to assist your service technician in
correctly diagnosing a malfunction.
Tow/Haul Mode Light
This light should come on
when the tow/haul mode
has been selected.
For more information, see “Tow/Haul Mode” inTowing a
Trailer on page 4-34.
Check Gages Warning Light
The CHECK GAGES light
will come on briey when
you are starting the engine.
If the light comes on and stays on while you are driving,
check your coolant temperature and engine oil
pressure gages to see if they are in the warning zones.
3-36

Reduce your speed according to your speedometer, not
to your sense of motion. After driving for any distance
at higher speeds, you may tend to think you are
going slower than you actually are.
Before Leaving on a Long Trip
Make sure you are ready. Try to be well rested. If you
must start when you are not fresh — such as after
a day’s work — do not plan to make too many miles that
rst part of the journey. Wear comfortable clothing
and shoes you can easily drive in.
Is your vehicle ready for a long trip? If you keep it
serviced and maintained, it is ready to go. If it needs
service, have it done before starting out. Of course, you
will nd experienced and able service experts in GM
dealerships all across North America. They will be ready
and willing to help if you need it.Here are some things you can check before a trip:
Windshield Washer Fluid:Is the reservoir full?
Are all windows clean inside and outside?
Wiper Blades:Are they in good shape?
Fuel, Engine Oil, Other Fluids:Have you checked
all levels?
Lamps:Are they all working? Are the lenses clean?
Tires:They are vitally important to a safe,
trouble-free trip. Is the tread good enough for
long-distance driving? Are the tires all inated to the
recommended pressure?
Weather Forecasts:What is the weather outlook
along your route? Should you delay your trip a
short time to avoid a major storm system?
Maps:Do you have up-to-date maps?
4-20

Highway Hypnosis
Is there actually such a condition as highway hypnosis?
Or is it just plain falling asleep at the wheel? Call it
highway hypnosis, lack of awareness, or whatever.
There is something about an easy stretch of road with
the same scenery, along with the hum of the tires on the
road, the drone of the engine, and the rush of the
wind against the vehicle that can make you sleepy.
Do not let it happen to you! If it does, your vehicle can
leave the road in less than a second, and you could
crash and be injured.
What can you do about highway hypnosis? First, be
aware that it can happen.
Then here are some tips:
Make sure your vehicle is well ventilated, with a
comfortably cool interior.
Keep your eyes moving. Scan the road ahead and
to the sides. Check your mirrors and your
instruments frequently.
If you get sleepy, pull off the road into a rest,
service, or parking area and take a nap, get some
exercise, or both. For safety, treat drowsiness
on the highway as an emergency.
Hill and Mountain Roads
Driving on steep hills or mountains is different from
driving in at or rolling terrain.
If you drive regularly in steep country, or if you are
planning to visit there, here are some tips that can make
your trips safer and more enjoyable.
Keep your vehicle in good shape. Check all uid
levels and also the brakes, tires, cooling system,
and transmission. These parts can work hard
on mountain roads.
4-21

Towing
Towing Your Vehicle
Consult your dealer or a professional towing service if
you need to have your disabled vehicle towed. See
Roadside Assistance Program on page 7-5.
If you want to tow your vehicle behind another vehicle
for recreational purposes (such as behind a motorhome),
see “Recreational Vehicle Towing” following.
Recreational Vehicle Towing
Recreational vehicle towing means towing your vehicle
behind another vehicle — such as behind a motorhome.
The two most common types of recreational vehicle
towing are known as “dinghy towing” (towing your vehicle
with all four wheels on the ground) and “dolly towing”
(towing your vehicle with two wheels on the ground and
two wheels up on a device known as a “dolly”).
Notice:Towing an all-wheel-drive vehicle with all
four wheels on the ground, or even with only two of
its wheels on the ground, will damage drivetrain
components. Do not tow an all-wheel-drive vehicle if
any of its wheels will be on the ground.Your vehicle was not designed to be towed with any of
its wheels on the ground. If your vehicle must be
towed, it should be placed on a platform trailer.
Towing a Trailer
{CAUTION:
If you do not 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 that would
not be covered by your warranty. Always follow
the instructions in this section and check with your
dealer for more information about towing a trailer
with your vehicle.
4-34

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.
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 harnessmust 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.
4-44

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-6
Filling the Tank..............................................5-7
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood....................5-10
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Cover...............................................5-17
Engine Air Cleaner/Filter................................5-21
Automatic Transmission Fluid.........................5-23
Engine Coolant.............................................5-25
Radiator Pressure Cap..................................5-28
Engine Overheating.......................................5-28
Cooling System............................................5-30
Engine Fan Noise.........................................5-34Power Steering Fluid.....................................5-35
Windshield Washer Fluid................................5-36
Brakes........................................................5-37
Battery........................................................5-40
Jump Starting...............................................5-41
All-Wheel Drive..............................................5-45
Rear Axle.......................................................5-46
Front Axle......................................................5-47
Bulb Replacement..........................................5-48
Halogen Bulbs..............................................5-48
Headlamps and Sidemarker Lamps.................5-48
Front Turn Signal and Parking Lamps..............5-52
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-52
Replacement Bulbs.......................................5-54
Windshield Wiper Blade Replacement..............5-54
Tires..............................................................5-55
Tire Sidewall Labelling...................................5-56
Tire Terminology and Denitions.....................5-59
Ination - Tire Pressure.................................5-61
Tire Inspection and Rotation...........................5-63
When It Is Time for New Tires.......................5-64
Buying New Tires.........................................5-65
Section 5 Service and Appearance Care
5-1

Uniform Tire Quality Grading..........................5-66
Wheel Alignment and Tire Balance..................5-67
Wheel Replacement......................................5-67
Tire Chains..................................................5-68
If a Tire Goes Flat........................................5-69
Changing a Flat Tire.....................................5-70
Removing the Spare Tire and Tools................5-71
Removing the Flat Tire and Installing the
Spare Tire................................................5-74
Storing a Flat or Spare Tire and Tools............5-80
Compact Spare Tire......................................5-82
Appearance Care............................................5-82
Cleaning the Inside of Your Vehicle.................5-83
Fabric/Carpet...............................................5-84
Leather.......................................................5-85
Instrument Panel, Vinyl, and Other Plastic
Surfaces..................................................5-85
Care of Safety Belts......................................5-86
Weatherstrips...............................................5-86
Washing Your Vehicle...................................5-86
Cleaning Exterior Lamps/Lenses.....................5-86
Finish Care..................................................5-87Windshield and Wiper Blades.........................5-87
Aluminum Wheels.........................................5-88
Tires...........................................................5-88
Sheet Metal Damage.....................................5-89
Finish Damage.............................................5-89
Underbody Maintenance................................5-89
Chemical Paint Spotting.................................5-89
Vehicle Care/Appearance Materials..................5-90
Vehicle Identication......................................5-91
Vehicle Identication Number (VIN).................5-91
Service Parts Identication Label.....................5-91
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
Instrument Panel Fuse Block..........................5-93
Underhood Fuse Block..................................5-96
Capacities and Specications..........................5-99
Normal Maintenance Replacement Parts.........5-101
Section 5 Service and Appearance Care
5-2