service CHEVROLET ASTRO 2003 Owners Manual

The 2003 Chevrolet Astro Owner Manual
Seats and Restraint Systems ........................... I-!
Front Seats ............................................... 1-2
Rear Seats
............................................... 1-7
Safety Belts
............................................. 1-13
Child Restraints
....................................... 1-35
Air Bag System
....................................... 1-62
Restraint System Check
............................ 1-71
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
................................................. 2-1 6
Theft-Deterrent Systems
............................ 2-1 8
Mirrors
.................................................... 2-32
HomeLink@ Transmitter
............................. 2-34
Features and Controls ..................................... 2-1
Starting and Operating Your Vehicle
........... 2-19
Storage Areas
Instrument Panel .
Instrument Panel
Climate Controls
......................................... 2-38
........................................... 3-1
Overview .......................... 3-2
...................................... 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
................................................... 4-29
Service and Appearance Care .......................... 5-1
Service ..................................................... 5-3
Fuel
......................................................... 5-5
All-Wheel Drive
........................................ 5-52
Rear Axle ............................................... 5-53
Front Axle
............................................... 5-54
Bulb Replacement
.................................... 5-55
Windshield Wiper Blade Replacement ......... 5-62
Tires
...................................................... 5-63
Appearance Care
..................................... 5-83
Vehicle Identification
................................. 5-91
Electrical System
...................................... 5-92
Capacities and Specifications
..................... 5-99
Normal Maintenance Replacement Parts
...... 5-1 01
Maintenance Schedule ..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance Information .................... 7-1
Customer Assistance Information
.................. 7-2
Reporting Safety Defects ........................... 7-10
Checking Things Under
the Hood
............... 5-11
Index ................................................................ 1

These are some examples of vehicle symbols you may find on your vehicle:
POSSIBLE A
CAUTION INJURY
PROTECT EYES BY
SHIELDING
CAUSTIC
BATTERY
KID COULD
CAUSE
BURNS
AVOID
SPARKS OR FLAMES
SPARK OR COULD
EXPLODE FLAME
\\I/'
BAlTERY I
LATCH BOTH LAP AND
SHOULDER BELTS TO
PROTECT OCCUPANT
*&: @
DO NOT TWIST SAFETY
BELT WHEN AlTACHING
FASTEN SEAT
BELTS
MOVE SEAT FULLY
\!$!
REARWARD /a
SECURE
CHILD
SEAT
PULL BELT
COMPLETELY
rHEN SECURE CHILD SEAT
POWER
WINDOW DO NOT INSTALL
A REAR-FACING
CHILD RESTRAINT IN THIS SEATING POSITION
DO NOT INSTALL A
'ORWARD-FACING CHILD RESTRAINT IN THIS SEATING POSITION
DOOR LOCK UNLOCK LIGHTING
- MASTER SWITCH u- 0 ,
SIGNALS
TURN
LAMPS
Pf
RUNNING ***o
DAYTIME 0.0
LAMPS ea.
LAMPS $0
ENGINE
COOLANT
cc
TEMP
CHARGING
I-1
BATTERY SYSTEM
BRAKE
(a)
ENGINE OIL PRESSURE
Wb
ANTI-LOCK (@)
BRAKES COOLANT
FAN
OWNERS MANUAL
SERVICE
MANUAL
V

e
e
e
Air bags are designed to inflate only once. After they
inflate, 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 inflation and driver’s safety belt
usage at deployment. The module also records
speed, engine rpm, brake and throttle data.
Let only qualified 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
inflate 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 Informqtion on page
7-1 1.
For up to 10 minutes after the ignition key is
turned off and the battery is disconnected, an
air bag can
still inflate during improper service.
You can be injured if you are close to an air bag
when
it inflates. 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
qualified to do so.
The air bag system does not need regular maintenance.
1-69

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:
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.
Changes or modifications 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.
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 2-5.
If you are still having trouble, see your dealer or a
qualified technician for service.
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.
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 five seconds after the key is turned
to RUN.
If the engine stalls and the SECURITY light flashes, wait
until the light stops flashing 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.
See
Fuses and Circuit Breakers on page 5-93.
See your dealer for service.
2-1 8

Notice: Don’t operate accessories in the
ACCESSORY position for long periods of time.
Prolonged operation of accessories in the
ACCESSORY position could drain your battery
and prevent you from starting your vehicle.
B (LOCK): This position locks your ignition, steering
wheel 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: If your key seems stuck in LOCK and you
can’t turn
it, be sure you are using the correct key;
if
so, is it all the way in? If it is, then turn the
steering wheel left and right while you turn the key hard. Turn the key only with your hand. Using a
tool to force
it could break the key or the ignition
switch. If none of this works, then your vehicle needs service.
C (OFF): This position lets you turn off the engine but
still turn the steering wheel. 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.
2-20

HomeLink@ Transmitter
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 1-800-355-351
5.
If your vehicle is equipped with the HomeLink@
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 modifications
to this system by other than
an authorized service facility could void authorization
to use this equipment.
2-34

Section 3 Instrument Panel
Instrument Panel Overview ............................... 3.2
Hazard Warning Flashers
................................ 3-4
Other Warning Devices
................................... 3-5
Horn
............................................................. 3-5
Tilt Wheel
..................................................... 3-5
Turn SignaVMultifunction 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
Rear Heating System
................................... -3-1 9
Rear Air Conditioning System ......................... 3.20
Rear Climate Control System
......................... 3.21
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
.......................... 3.28 Anti-Lock
Brake System Warning Light
............. 3.29
Engine Coolant Temperature Gage
= = =. ~ = = ~ ~ ~ = i. 3-39
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
Fuel Gage
................................................... 3.36
Low Fuel Warning Light
................................. 3.37
Audio System@) ............................................. 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
Theft-Deterrent Feature
........... ................ 3.47
Understanding Radio Reception
................... 3.50
Care of Your CDs
......................................... 3-50
Care of Your CD Player
................................ 3-50
Fixed Mast Antenna
...................................... 3.50
Check Gages Warning
Light
........................... 3-36
Rear Seat Audio (RSA)
. . .... ............ 3.46
3-
1

If the air bag readiness light stays on after you start the
vehicle or comes on when
you are driving, your air
bag system may not work properly. Have your vehicle
s iced right away.
Charging System
If the air bag readiness light stays on after you
start your vehicle,
it means the air bag system
may not be working properly. The air bags in
your vehicle may not inflate
in a crash, or they
could even inflate without a crash. To help avoid
injury to yourself or others, have your vehicle
serviced right away if the air bag readiness light
stays on after you start your vehicle.
The air bag readiness light should flash for a few
seconds when you turn the ignition key to
RUN.
If the light doesn’t come on then, have it fixed so
it will be ready to warn you if there is a problem.
Light
This light should come on
briefly when you turn on
the ignition, before starting the engine, as a check
to show you it is working.
After the engine starts, the light should go out.
if it stays
on or comes on while you are driving, you may have
a problem with your charging system. It could indicate a
problem with the generator drive belt, or some other
charging system problem. Have it checked right away.
Driving while this light is on could drain your battery.
If you must drive a short distance with this light
on,
it helps to turn off all your accessories, such as
the radio and air conditioner.
3-27

Voltmeter Gage
When your engine is not
running, but the ignition is
on (in the RUN position),
the gage shows your
battery’s state of charge
in
DC volts.
When the engine is running, the gage shows the
condition of the charging system. Readings between
the low and high warning zones indicate the normal
operating range.
Readings in the low warning zone may occur when a
large number of electrical accessories are operating in
the vehicle and the engine is left at an idle for an
extended period. This condition
is normal since the
charging system
is not able to provide full power at engine
idle.
As engine speeds are increased, this
condition should correct itself as higher engine speeds
allow the charging system to create maximum power.
You can only drive for a short time with the readings
in either warning zone.
If you must drive, turn off
all unnecessary accessories.
Readings in either warning zone indicate a possible
problem in the electrical system. Have the vehicle
serviced as soon as possible.
Brake System Warning Light
When the ignition is on, the brake system warning
light will come on when you set your parking brake.
The light will stay on
if your parking brake doesn’t
release fully.
If it stays on after your parking brake is
fully released, it means you have a brake problem.
Your vehicle’s hydraulic brake system is divided into
two parts.
If one part isn’t working, the other part can
still work and stop you. For good braking, though,
you need both parts working well.
If the warning light comes on, there could be a brake
problem. Have your brake system inspected right away.
3-28