light CHEVROLET ASTRO 1996 Repair Manual

12 18 24
c57 c7 E7 c7 11 17 23
4
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3 9 15 21 C7 E7 E7 C7
2
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FuseKircuit Usage
Breaker
1
2
3
Stop/Turn/Hazard Lamps, CHMSL,
Chime Module
No Fuse-Resistor
Courtesy Lamps, Power Outside Mirrors, Glove Box Lamp, Dome
Reading Lamps, Vanity Mirror Lamps
10
11
12
13
FuseKircuit Usage
Breaker
4 DRL Relay, DRL Module, Chime
Headlamp Switch, Keyless Entry,
Cluster, Overhead Console
Not Used
Cruise Module, Cruise
Activator Switch
Power Outlets, ALDL,
Subwoofer Amplifier
Not Used
License Plate Lamp, Taillamps,
Parking Lamps, Ashtray Lamp, Panel
Lights, Trailer Taillamps, Front and Rear Sidemarker Lamps, Door Switch
Illumination, Headlamp Switch
Illumination, RSA Illumination
Air Bag System
Wiper Motor, Washer Pump
L, M 1, M2 Blower Motor, Rear A/C
Relay Coil, Front Cont, Temp. Door
Motor, Hi Blower Relay, Defogger
Timer Coil, Upfitter Relay Coil
Cigarette Lighter, Door Lock Relay
i
5
6
7
8
9
6-62

Fuse
UPFIT-BATT .......
UPFIT-IGN . .
Spare .....
Fuse Puller*
Spare
.............
Spare .............
ECM-B ............
..
..
HORN ......
A/C COMP ...
RR DEFOG .......
ENG-I ......
IGN-E
..
..
Usage
Upfitter Battery
Power Stud, Trailer Wiring
Harness Upfitter Ignition Relay
Not Used
Not Used Not Used
Fuel Pump Relay,
VCM, Oil Pressure
Switch/Sender
Horn Relay
A/C Enable Relay
Heater-A/C Control Selector Switch
Oxygen Sensors 1-4,
Camshaft Position Sensor,
Mass Air Flow Sensor,
Evaporative Emission
Canister Purge Solenoid
Valve, Linear EGR Valve
Solenoid, VCM
A/C Enable Relay
Fuse
ECM-I ..... .....
LIGHTING .....
BATT I/P .......
IGN A .............
IGN B .............
ABS ..............
AIC ...............
RR HTR/AC ........
Spare .............
Usage
Fuel Injectors 1-6,
Crankshaft Position Sensor,
VCM, Distributor Ignition
Control Module Park Lamps Fuse,
DRL Fuse, Headlamp and
Panel Dimmer Switch
Fuse Block Fuses,
Power Seat CB,
Stop/Hazard Fuse,
Auxiliary Power Fuse,
Cigarette Lighter Fuse,
Radio, Battery Fuse
Starter Relay, Ignition Switch
Ignition Switch
Brake Pressure Module Valve Blower Motor Resistor,
Blower Relay
Auxiliary Heater A/C Relay
Not Used
* A fuse puller is included in the underhood electrical
center. You
will also find spare fuses.
6-65

At Least Twice a Year
Restraint System Check
Make sure the safety belt reminder light and all your
belts, buckles, latch plates, retractors and anchorages are
working properly.
Look for any other loose or damaged
safety belt system parts. If you see anything that might
keep a safety belt system from doing its job, have it
repaired. Have any torn or frayed safety belts replaced.
Also look for any opened or broken air bag covers, and
have them repaired or replaced, (The air bag system
does not need regular maintenance.)
Automatic Transmission Check
Check the transmission fluid level; add if needed. See
“Automatic Transmission’’ in the Index. A fluid
loss
may indicate a problem. Check the system and repair
if needed.
At Least Once a Year
Key Lock Cylinders Service
Lubricate the key lock cylinders with the lubricant
specified in Part
D.
Body Lubrication Service
Lubricate all body door hinges, the body hood, fuel door
and rear compartment hinges, latches and locks
including interior glove box and console doors, and
any
moving seat hardware. Lubricate the hood safety lever
pivot and prop rod pivot. Part
D tells you what to use.
More frequent lubrication may be required
when
exposed to a corrosive environment.
7-42

0 FREE Locksmith/Key Service (when keys are lost
on the road or locked inside)
0 FREE Flat Tire Service (spare installed on the road)
0 FREE Jump Start (at home or on the road)
0 FREE Fuel Delivery ($5 of fuel delivered on
the road)
Chevrolet/Geo offers Courtesy Transportation for
customers needing warranty service. Courtesy
Transportation will be offered in conjunction with
the coverage provided by the Bumper to Bumper
New Vehicle Limited Warranty to eligible purchasers
of 1996 Chevrolet/Geo passenger car and light duty
trucks. (Please see your selling dealer for details.)
Note:
Courtesy Care is available to Retail and Retail Lease
Customers operating
1996 and newer ChevroletlGeo
vehicles for a period
of 36 months/36,000 miles,
whichever occurs first.
All Courtesy Care services
must be pre-arranged by Chevrolet Roadside
or dealer
Service Management.
Basic Care and Courtesy Care are not part of or
included
in the coverage provided by the New Vehicle
Limited Warranty. Chevrolet reserves the right to
modify or discontinue
Basic C~re and Courtesy Care
at any time. For
complete program details, see your Chevrolet/Geo
dealer to obtain
a Roadside Assistance Center brochure.
The Roadside Assistance Center uses companies that
will provide
you with quality and priority service. When
roadside services are required, our advisors will explain
any payment obligations that may be incurred for
utilizing outside services.
For prompt assistance when calling, please have the
following available to give
to the advisor:
Vehicle Identification Number (VIN)
License plate number
0 Vehicle color
0 Vehicle location
0 Telephone number where you can be reached
Vehicle mileage
0 Description of problem
Please refer
to the Roadside Assistance brochure
inside your owner information portfolio for
full
program details.
8-5

Canadian Roadside Assistance
Vehicles purchased in Canada have afi extensive
Roadside Assistance program accessible from anywhere
in Canada or the United States. Please refer
to the
separate brochure provided by the dealer or call
1-800-268-6800 for emergency services.
Courtesy Transportation
Chevrolet/Geo offers Courtesy Transportation for
customers needing warranty service. Courtesy
Transportation will be offered in conjunction with the
coverage provided by the Bumper to Bumper New
Vehicle Limited Warranty to retail purchasers of
1996 Chevrolet/Geo passenger cars and light duty
trucks (please see your selling dealer for details).
Courtesy Transportation includes:
One way shuttle ride for any warranty repair
completed during the same day.
0 Up to $30 maximum daily vehicle rental allowance for
any overnight warranty repair up to five days,
OR
Up to $30 maximum daily cab, bus or other
transportation allowance in lieu of rental for any
overnight warranty repair up
to five days, OR
Up to $10 daily fuel allowance for rides provided by
another person (Le., friend, neighbor, etc.) in
lieu of rental
for
any overnight warranty repair up to five days.
Note: All Courtesy Transportation arrangements will
be administered by your Chevrolet/Geo dealer
service management. Claim amounts should reflect
all actual costs.
Chevrolet/Geo Courtesy Transportation is not part
of the Bumper
to Bumper New Vehicle Limited
Warranty. Chevrolet/Geo reserves the right
to make
any changes or discontinue Courtesy Transportation
at any time without notification.
I
For additional program details, contact your
Chevrolet/Geo dealer.
In Canada, please consult your
GM dealer for
information on Courtesy Transportation.
Some state insurance regulations make it impractical to
rent vehicles to people under 21 years of age.
If you are
under
21 and have difficulty renting a vehicle, Chevrolet
will reimburse
up to $30/day for documented
transportation
you receive.
8-6

. .. I. .
Section 9 Index
Accessory'power Outlet ......................... 2-49
Add-on Equipment
............................. 4-28
AirBag
....................................... 1-24
Adding Equipment
............................ 1-30
How Does it Restrain
.......................... 1-28
How it Works
................................ 1-26
Location
.................................... 1-26
Readiness Light
......................... 1.25. 2.54
What Makes it Inflate
.......................... 1-27
What Will
You See After it Inflates .... : .......... 1-28
When Should it Inflate
......................... 1-27
Aircleaner
.................................... 6-19
Air Conditioning
................................ 3-5
Air Conditioning Refrigerants
..................... 6-68
Alignment and Balance. Tire
...................... 6-47
All-Wheel Drive
.......................... 2.21. 6.23
Aluminum Wheels. Cleaning
....................... 6-55
Antenna. Fixed
................................. 3-28
Antifreeze
...................................... 6-25
Anti-Lock
Brake System Warning Light
................ 2-57. 4-6
Brakes
...................................... 4-6
knti-Theft. Radio
.............................. 3-23
Appearance Care
............................... 6-49
Appearance Care Materials
....................... 6-58
Arbitration Program
.............................. 8-7
Servicing
................................... 1-29
Ashtrays
...................................... 2-48
Audio Equipment. Adding
. : ...................... 3-2t
Automatic Audio Systems
.................................. 3-8
Transmission Check
........................... 7-42
Transmission Operation
........................ 2-18
Axle Front
....................................... 6-24
LockingRear
................................ 2-21
Rear
....................................... 6-25
Battery
...................................... 6-35
Jump Starting
................................. 5-2
Replacement. Remote Keyless Entry ............... 2-8
Warnings
...................................... 5-2
BBB Auto Line ................................. 8-7
Better Business Bureau Mediation
................... 8-5
Brake
Adjustment
...................... ........... 6-35
Fluid
..................................... ;.6-32
Master Cylinder
.............................. 6-32
Parking
..................................... 2-21
PedalTravel .................................. 6-32
Replacing System Parts
........................ 6-32
Trailer
...................................... 4-3:
Transmission Shift Interlock Check
............... 7-42
Wear
............................. : ......... 6-3'
9-1

Brakes. Anti-Lock ............................... 4-6
Braking
........................................ 4-5
Braking
in Emergencies ........................... 4-8
Break-In. New Vehicle
.......................... 2- 13
BTSICheck ................................... 7-43
Bulb Replacement
.............................. 6-36
Canadian Roadside Assistance
.................... 8-6
Capacities and Specifications
...................... 6-67
Carbon Monoxide
............... 2.26.4.25.4.32. 4.33
Cassette Deck Service
........................... 7-41
Cassette Tape Player
.................. 3- 10. 3. 12. 3.20
Cassette Tape Player Care
........................ 3-27
Center Passenger Position
........................ 1-34
Chains. Safety
................................. 4-32
Chains. Tire
................................... 6-49
Changing a Flat Tire
............................. 5-23
Charging System Light
.......................... 2-55
Check Gages Light
.............................. 2-63
Check Oil Light
................................ 2-61
Checking
Your Restraint Systems .................. 1-52
Chemical Paint Spotting
.......................... 6-57
Child Restraints
................................ 1-4 I
Securing in a Rear Outside Seat Position ........... 1-43
Securing
in the Center Seat Position .............. 1-45
Securing
in the Right Front Seat Position .......... 1-46
TopStrap
................................... 1-42
Where to Put
........................... 1-4 I. 1-42
Cigarette Lighter
............................... 2-48
Circuit Breakers and Fuses
....................... 6-61
Cleaner. Air ................................... 6-19 Cleaning
Aluminum Wheels ............................ 6-55
Fabric
...................................... 6-50
Glass
....................................... 6-53
Inside
of Your Vehicle ......................... 6-50
Instrument Panel
............................. 6-53
Leather
..................................... 6-52
Outside
of Your Vehicle ........................ 6-54
Special Problems
............................. 6-51
Stains
...................................... 6-51
Tires
....................................... 6-56
Vinyl ....................................... 6-52
Wheels
..................................... 6-55
Windshield and Wiper Blades
................... 6-53
Clock. Setting the
................................ 3-8
Comfort Controls
................................ 3-1
Compact Disc Care
............................. 3-28
Compact Disc Player
............................ 3-16
Compact Spare Tire
............................. 5-36
Control of a Vehicle .............................. 4-5
ConvenienceNet
............................... 2-46
Convex Outside Mirror
.......................... 2-39
Coolant
....................................... 6-25
Heater. Engine
............................... 2-16
RecoveryTank
............................... 5-15
Courtesy Lamps
................................ 2-37
Courtesy Transportation
........................... 8-6
Cruise Control
................................. 2-32
Customer Assistance for Text Telephone Users
......... 8-3
Customer
Assistance Information ................... 8-1
Customer Satisfaction Procedure .................... 8-1
Cooling System
................................ 5-15
9-2

Damage. Finish ........................ . . 6-56
Damage. Sheet Metal
............................ 6-56
Daytime Running Lamps
......................... 2-36
Daytime Running Lamps Indicator Light
............ 2-62
Dead Battery
................................... 5-2
Defects. Reporting Safety
......................... 8-8
Defensive Driving ............................... 4- 1
Defogger. Rear Window .......................... 3-7
Defrosting
..................................... 3-6
Dimensions. Vehicle
............................ 6-69
Dome Lamps
.................................. 2-37
Door Locks
....................................... 2-5
Sliding ...................................... 2-9
DrivePosition
................................. 2-20
DriverPosition
................................. 1-16
Driving City
........................................ 4-17
Defensive
.................................... 4-1
Drunken ..................................... 4-2
Freeway
.................................... 4-18
InaBlizzard ................................. 4-24
In Foreign Countries ........................... 6-4
In the Rain .................................. 4-14
Night
...................................... 4-13
OnCurves
................................... 4-8
On Grades While Towing
a Trailer ............... 4-35
On Hill and Mountain Roads
.................... 4-20
On Snow and Ice
............................. 4-22
Through Water
................... ....... 4-16
WetRoads
.................................. 4-14
Winter ...................................... 4-22
With a Trailer ................................ 4-33
Drunken Driving
................................ 4-2 Electrical
Equipment. Adding
........ 2- 16. 3.26. 6-60
Electrical System
............................... 6-60
Engine ........................................ 4-9
Coolant
..................................... 6-25
Coolant Heater
............................... 2-16
Coolant Level Check
.......................... 7-41
Cooling System Capacity
....................... 6-67
Cover
...................................... 6-15
Exhaust
..................................... 2-26
FuseBlocks
............................ 6-61. 6-64
Identification
................................ 6-59
OilLevelCheck
.............................. 7-41
Overheating
................................. 5-13
Running While Parked
......................... 2-26
Specifications
................................ 6-67
Starting
..................................... 2-15
Temperature Gage
............................ 2-62
Engineoil
.................................... 6-11
Adding
..................................... 6-12
Additives
................................... 6-14
Checking
................................... 6-12
Pressure Gage
........................... .... 2-60
Used
....................................... 6-15
Whentochange .............................. 6-14
Exhaust. Engine
................................ 2-26
Express-Down Window
........................ 2-28
Fabric Cleaning
............................... 6-50
Fiberglass Springs
.............................. 6-57
Filling Your Tank
................................ 6-5
Filter. Air
..................................... 6-69
Filter. Engine Oil
............................... 6-69
Finish Care
.................................... 6-54
9-3

Instrumentpanel ............................... 2-50
Brightness Control
.................... i ....... 2-35
Cleaning
.................................... 6-53
Cluster
..................................... 2-52
FuseBlock
.................................. 6-61
Interior Lamps
................................. 2-37 Charging System
........................... 2-55
Check Gages
................................ 2-63
Check Oil
................................... 2-61
Daytime Running Lamps Indicator
............... 2-62
Safety Belt Reminder
..................... 1 - 12. 2-54
Service Engine Soon
.......................... 2-58
Loading Your Vehicle
........................... 4-26 .
J
Locks
ack. Tire .................................... 5-24
Cylinders ................................... 7-42
Jump Starting ................................... 5-2
Door ........................................ 2-5
Key Lock Cylinders Service
..................... 7-42
Keyless Entry System
............................ 2-7
Keys
.......................................... 2-1
Key Lock Cylinder Service ..................... 7-42
PowerDoor
.................................. 2-6
Sliding Door Child Security
..................... 2-10
Steering Column Lock Check
................... 7-44
Lubricants and Fluids
............................ 7-47
Lubrication Service. Body
........................ 7-42
Luggagecarrier
................................ 2-47
Certificationflire
............................. 4-26 Lumbar Controls ................................ 1-2
Service Parts Identification ..................... 6-59
Tire-Loading Information
...................... 4-26
Vehicle Identification Number
................... 6-59
Lamps ........................................ 2-35
Dome
...................................... 2-37
Interior
..................................... 2-37
OnReminder
................................ 2-36
Latches. Seatback ................................ 1-5
Leaving Your Vehicle ............................. 2-6
Leaving Your Vehicle with the Engine Running
....... 2-24
Lighter
....................................... 2-48
Lights
Air Bag Readiness ....................... 1-25. 2-54
Anti-Lock Brake System Warning
............ 2-57. 4-6
Brake System Warning
......................... 2-57 Maintenance.
Normal Replacement Parts
........... 6-69
Maintenance Record
............................ 7-49
Maintenance Schedule
............................ 7-1
Long Trip/Highway Definition
................... 7-5
Long TripMighway Intervals
..................... 7-5
Owner Checks and Services
..................... 7-41
Periodic Maintenance Inspections
................ 7-45
Recommended Fluids and Lubricants
............. 7-47
Scheduled Maintenance Services
.................. 7-2
Short Trip/City Definition
....................... 7-4
Short Trip/City Intervals ........................ 7-4
Maintenance. Underbody ......................... 6-X
9-5

Rear Air Conditioning System
.................... 3-4
Axle
....................................... 6-25
Heating System
............................... 3-4
Outside Seat Position
.......................... 1-3 I
Safety Belt Comfort Guides ..................... 1-36
SeatAudio
.................................. 3-22
Seatpassengers
.............................. 1-31
Storage
..................................... 2-40
Towing
................................ 5.11. 5.12
Window Defogger
............................. 3-7
Windshield Washer
........................... 2-3 I
Rearview Mirror ................................ 2-38
Reclining Front Seatbacks
......................... 1-3
Recovery Tank, Coolant
.......................... 5- 15
Refrigerants. Air Conditioning
.................... 6-68
Regulator.
Fuel ................................. 2- 16
Removable Rear Seats ............................ 1-8
Replacement Bulbs
...................................... 6-66
Parts
....................................... 6-69
Wheel
...................................... 6-47
Replacing Safety Belts
........................... 1-52
Reporting Safety Defects
.......................... 8-8
Restraints Checking
................................... 1-52
Child ....................................... 1-41
Head
........................................ 1-5
Replacing Parts After
a Crash ................... 1-52
Systemcheck
................................ 7-42
Reverse
....................................... 2-19
Right Front Passenger Position
.................... 1-3 I
Roadside Assistance .............................. 8-4 Roadside Assistance. Canadian
......... ....... 8-6
Rocking Your Vehicle
........................... 5-37
Rotation. Tires
...................... ...... 6-44
Safety Belt Extender
............................ 1-51
Safety Belt Comfort Guides
....................... 1-36
Safety Belts
................................... 1 . 11
Adults ...................................... 1-16
Care
....................................... 6-53
Center Passenger Position
...................... 1-34
Children
.................................... 1-38
Driver Position
............................... 1-16
Extender
.................................... 1-51
How
to Wear Properly ......................... 1-16
Incorrect Usage
.................... 1.19. 1-50, 1-51
LapBelt
.................................... 1-34
Lap-Shoulder
........................... 1 . 16, 1-3 1
Questions and Answers ........................ 1 . 15
Rear Seat Outside Passenger Positions
............ 1-31
Rear Seat Passengers
.......................... 1-31
Reminder Light
......................... 1 - 12. 2-54
Replacing Atter
a Crash ........................ 1-52
Right Front Passenger Position .................. 1-31
Shoulder Belt Height Adjuster
................... 1 . 18
Smaller Children and Babies. Cargo Vans .......... 1-40
Smaller Children and Babies. Except Cargo Vans
.... 1-38
Use During Pregnancy
......................... 1-30
WhyThey Work
.............................. 1-12
Safety Defects. Reporting ......................... 8-8
Safety Warnings and Symbols
....................... 111
Scheduled Maintenance Services .................... 7-3
Larger Children
.............................. 1-49
Safety Chains
.................................. 4-32
...
9-7