2005 CHEVROLET ASTRO service

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-3
Rear Seats
............................................... 1-7
Safety Belts
.............................................1-18
Child Restraints
.......................................1-38
Airbag 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
...........2-16
Mirrors
....................................................2-28
HomeLink
®Transmitter
.............................2-29
Storage Areas
.........................................2-33
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-19
Warning Lights, Gages, and Indicators
........3-23
Driver Information Center (DIC)
..................3-37
Audio System(s)
.......................................3-39Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-33
Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under the Hood
...............5-10
All-Wheel Drive
........................................5-47
Rear Axle
...............................................5-48
Front Axle
...............................................5-49
Bulb Replacement
....................................5-50
Windshield Wiper Blade Replacement
.........5-57
Tires
......................................................5-58
Appearance Care
.....................................5-84
Vehicle Identication
.................................5-93
Electrical System
......................................5-94
Capacities and Specications
...................5-101
Normal Maintenance Replacement Parts
....5-102
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-11
Index................................................................ 1
2005 Chevrolet Astro Owner ManualM

Airbags are designed to inate only once. After an
airbag inates, you will need some new parts for
your airbag system. If you do not get them,
the airbag system will not be there to help protect
you in another crash. A new system will include
airbag 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 after
a crash. SeeVehicle Data Collection and Event
Data Recorders on page 7-10.
Let only qualied technicians work on your airbag
system. Improper service can mean that your
airbag system will not work properly. See your
dealer for service.
Notice:If you damage the covering for the driver’s
or the right front passenger’s airbag, the bag
may not work properly. You may have to replace
the airbag module in the steering wheel or both
the airbag module and the instrument panel for
the right front passenger’s airbag. Do not open or
break the airbag coverings.
Servicing Your Airbag-Equipped
Vehicle
Airbags affect how your vehicle should be serviced.
There are parts of the airbag system in several places
around your vehicle. You don’t want the system to inate
while someone is working on your vehicle. Your dealer
and the service manual have information about servicing
your vehicle and the airbag system. To purchase a
service manual, seeService Publications Ordering
Information on page 7-12.
{CAUTION:
For up to 10 minutes after the ignition key is
turned off and the battery is disconnected, an
airbag can still inate during improper service.
You can be injured if you are close to an
airbag when it inates. Avoid wires wrapped
with yellow tape or yellow connectors. They
are probably part of the airbag system. Be sure
to follow proper service procedures, and make
sure the person performing work for you is
qualied to do so.
The airbag 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 qualied 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. SeeRoadside 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.
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:
1. This device may not cause interference.
2. This device must accept any interference received,
including interference that may cause undesired
operation of the device.
Changes or modications to this system by other than
an authorized service facility could void authorization to
use this equipment.
2-3

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.
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 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 qualied 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.
2-4

Theft-Deterrent Systems
Vehicle theft is 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.
Passlock®
Your vehicle is equipped with the Passlock®
theft-deterrent system.
Passlock
®is a passive theft-deterrent system. Passlock®
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. SeeSecurity Light on page 3-34.
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
®system is not
working properly and must be serviced by your dealer.
Your vehicle is not protected by Passlock
®at this time.You may also want to check the fuse. SeeFuses and
Circuit Breakers on page 5-95. See your dealer for
service.
Starting and Operating
Your Vehicle
New Vehicle Break-In
Notice:Your vehicle does not need an elaborate
break-in. But it will perform better in the long run if
you follow these guidelines:
Keep your speed at 55 mph (88 km/h) or less
for the rst 500 miles (805 km).
Do not drive at any one speed — fast or
slow — for the rst 500 miles (805 km).
Do not make full-throttle starts.
Avoid making hard stops for the rst 200 miles
(322 km) or so. During this time your new brake
linings are not yet broken in. Hard stops with new
linings can mean premature wear and earlier
replacement. Follow this breaking-in guideline
every time you get new brake linings.
Do not tow a trailer during break-in. SeeTowing a
Trailer on page 4-34for more information.
2-16

Ignition Positions
With the key in the ignition, you can turn it to
ve different positions.
A (ACCESSORY):This position lets you use things
like the radio, power windows and windshield wipers
when the engine is off. To get into ACCESSORY,
push in the key and turn it toward you.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 is 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 it is, turn the steering wheel left and right while
you turn the key hard. 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.
2-17

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 modications to this system by other than
an authorized service facility could void authorization
to use this equipment.
Programming the HomeLink®
Transmitter
Do not use the HomeLink®Transmitter with any garage
door opener that does not have the “stop and reverse”
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
®Transmitter.
Read the instructions completely before attempting to
program the HomeLink
®Transmitter. Because of
the steps involved, it may be helpful to have another
person available to assist you in programming the
transmitter.Keep the original transmitter for use in other vehicles as
well as for future HomeLink
®programming. It is also
recommended that upon the sale of the vehicle,
the programmed HomeLink
®buttons should be erased
for security purposes. Refer to “Erasing HomeLink®
Buttons” or, for assistance, contact HomeLink®on the
internet at: www.homelink.com or by calling
1-800-355-3515.
Be sure that people and objects are clear of the garage
door or gate operator you are programming. When
programming a garage door, it is advised to park outside
of the garage.
It is recommended that a new battery be installed in
your hand-held transmitter for quicker and more
accurate transmission of the radio frequency.
Programming HomeLink®
Your vehicle’s engine should be turned off while
programming the transmitter. Follow these steps to
program up to three channels:
1. Press and hold down the two outside buttons,
releasing only when the indicator light begins to
ash, after 20 seconds. Do not hold down the
buttons for longer than 30 seconds and do not
repeat this step to program a second and/or third
transmitter to the remaining two HomeLink
®buttons.
2-30

Instrument Panel Overview...............................3-4
Hazard Warning Flashers................................3-6
Other Warning Devices...................................3-6
Horn.............................................................3-6
Tilt Wheel.....................................................3-6
Turn Signal/Multifunction Lever.........................3-7
Turn and Lane-Change Signals........................3-7
Headlamp High/Low-Beam Changer..................3-8
Flash-to-Pass.................................................3-8
Windshield Wipers..........................................3-9
Windshield Washer.......................................3-10
Cruise Control..............................................3-11
Exterior Lamps.............................................3-14
Headlamps on Reminder................................3-14
Daytime Running Lamps (DRL).......................3-15
Automatic Headlamp System..........................3-16
Instrument Panel Brightness...........................3-16
Dome Lamps...............................................3-16
Entry Lighting...............................................3-17
Exit Lighting.................................................3-17
Battery Run-Down Protection..........................3-17
Accessory Power Outlets...............................3-17
Ashtrays and Cigarette Lighter........................3-18Climate Controls............................................3-19
Climate Control System.................................3-19
Outlet Adjustment.........................................3-21
Rear Heating System....................................3-21
Rear Air Conditioning System.........................3-22
Warning Lights, Gages, and Indicators............3-23
Instrument Panel Cluster................................3-24
Speedometer and Odometer...........................3-25
Trip Odometer..............................................3-25
Safety Belt Reminder Light.............................3-25
Airbag Readiness Light..................................3-26
Charging System Light..................................3-27
Voltmeter Gage............................................3-27
Brake System Warning Light..........................3-28
Anti-Lock Brake System Warning Light.............3-29
Engine Coolant Temperature Gage..................3-29
Malfunction Indicator Lamp.............................3-30
Oil Pressure Gage........................................3-33
Security Light...............................................3-34
Highbeam On Light.......................................3-34
Service All-Wheel Drive Light.........................3-34
Tow/Haul Mode Light....................................3-35
Check Gages Warning Light...........................3-35
Fuel Gage...................................................3-36
Low Fuel Warning Light.................................3-36
Section 3 Instrument Panel
3-1