2005 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 cannot 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 3-19.
If you have air outlets on or under the
instrument panel, open them all the way.
SeeEngine Exhaust on page 2-26.
2-12

LWindshield Washer. SeeWindshield Washer
on page 3-10.
Cruise Control (Option). SeeCruise Control on
page 3-11.
For information on the exterior lamps, seeExterior
Lamps on page 3-14.
Turn and Lane-Change Signals
The turn signal has two upward (for right) and two
downward (for left) positions. These positions allow you
to signal a turn or a lane change.
To signal a turn, move the lever all the way up or down.
When the turn is nished, the lever will return
automatically.
An arrow on the instrument
panel cluster will ash in
the direction of the
turn or lane change.
To signal a lane change, just raise or lower the lever
until the arrow starts to ash. Hold it there until you
complete your lane change. The lever will return by itself
when you release it.As you signal a turn or a lane change, if the arrows
ash faster, a signal bulb may be burned out and other
drivers will not see your turn signal.
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 5-93.
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.
3-8

Airbag Readiness Light
There is an airbag readiness light on the instrument
panel, which shows AIR BAG or the airbag symbol.
The system checks the airbag’s electrical system
for malfunctions. The light tells you if there is an
electrical problem. The system check includes the airbag
sensor, the airbag modules, the wiring and the crash
sensing and diagnostic module. For more information on
the airbag system, seeAirbag System on page 1-60.
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 airbag readiness light stays on after you start the
vehicle or comes on when you are driving, your
airbag system may not work properly. Have your vehicle
serviced right away.{CAUTION:
If the airbag readiness light stays on after you
start your vehicle, it means the airbag system
may not be working properly. The airbags 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 airbag
readiness light stays on after you start your
vehicle.
The airbag 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
3-27

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 2-26.
Safety Chains
You should always attach chains between your vehicle
and your trailer. Cross the safety chains under the tongue
of the trailer to help prevent the tongue from contacting
the road if it becomes separated from the hitch.
Instructions about safety chains may be provided by the
hitch manufacturer or by the trailer manufacturer. Followthe manufacturer’s recommendation for attaching safety
chains and do not attach them to the bumper. Always
leave just enough slack so you can turn with your rig.
Never allow safety chains to drag on the ground.
Trailer Brakes
If your trailer weighs more than 1,000 lbs (450 kg)
loaded, then it needs its own brakes — and they must
be adequate. Be sure to read and follow the instructions
for the trailer brakes so you’ll be able to install, adjust
and maintain them properly.
Your trailer brake system can tap into your vehicle’s
hydraulic brake system, except:
Don’t tap into your vehicle’s brake system if the
trailer’s brake system will use more than 0.02 cubic
inch (0.3 cc) of uid from your vehicle’s master
cylinder. If it does, both braking systems won’t work
well. You could even lose your brakes.
Will the trailer parts take 3,000 psi (20 650 kPa) of
pressure? If not, the trailer brake system must not
be used with your vehicle.
If everything checks out this far, then make the
brake uid tap at the port on the master cylinder that
sends uid to the rear brakes. But don’t use
copper tubing for this. If you do, it will bend and
nally break off. Use steel brake tubing.
4-40

Passing
You’ll need more passing distance up ahead when
you’re towing a trailer. And, because you’re a good deal
longer, you’ll need to go much farther beyond the
passed vehicle before you can return to your lane.
Backing Up
Hold the bottom of the steering wheel with one hand.
Then, to move the trailer to the left, just move that hand
to the left. To move the trailer to the right, move your
hand to the right. Always back up slowly and, if possible,
have someone guide you.
Making Turns
Notice:Making very sharp turns while trailering
could cause the trailer to come in contact with the
vehicle. Your vehicle could be damaged. Avoid
making very sharp turns while trailering.
When you’re turning with a trailer, make wider turns
than normal. Do this so your trailer won’t strike
soft shoulders, curbs, road signs, trees or other objects.
Avoid jerky or sudden maneuvers. Signal well in
advance.
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).
4-42

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

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

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, see
Servicing Your Airbag-Equipped Vehicle on page 1-66.
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.
5-92