fuel cap CHEVROLET ASTRO 2005 Owners Manual

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

This light should come on, as a check to show you
it is working, when the ignition is on and the engine is
not running. If the light does not come on, have it
repaired. This light will also come on during a
malfunction in one of two ways:
Light Flashing— A misre condition has been
detected. A misre increases vehicle emissions
and may damage the emission control system on
your vehicle. Diagnosis and service may be
required.
Light On Steady— An emission control system
malfunction has been detected on your vehicle.
Diagnosis and service may be required.
If the Light Is Flashing
The following may prevent more serious damage
to your vehicle:
Reducing vehicle speed
Avoiding hard accelerations
Avoiding steep uphill grades
If you are towing a trailer, reduce the amount of
cargo being hauled as soon as it is possible
If the light stops ashing and remains on steady, see
“If the Light Is On Steady” following.If the light continues to ash, when it is safe to do so,
stop the vehicle. Find a safe place to park your vehicle.
Turn the key off, wait at least 10 seconds and restart
the engine. If the light remains on steady, see “If
the Light Is On Steady” following. If the light is still
ashing, follow the previous steps, and see your dealer
for service as soon as possible.
If the Light Is On Steady
You may be able to correct the emission system
malfunction by considering the following:
Did you recently put fuel into your vehicle?
If so, reinstall the fuel cap, making sure to fully install
the cap. SeeFilling Your Tank on page 5-8. The
diagnostic system can determine if the fuel cap has
been left off or improperly installed. A loose or missing
fuel cap will allow fuel to evaporate into the atmosphere.
A few driving trips with the cap properly installed
should turn the light off.
Did you just drive through a deep puddle of water?
If so, your electrical system may be wet. The condition
will usually be corrected when the electrical system
dries out. A few driving trips should turn the light off.
3-31

Certication/Tire Label
A vehicle specic Certication/Tire label is attached to
the rear edge of the driver’s door.
This label shows the size of your original tires and the
ination pressures needed to obtain the gross weight
capacity of your vehicle. This is called the Gross Vehicle
Weight Rating (GVWR). The GVWR includes the
weight of the vehicle, all occupants, fuel, cargo and
tongue weight, if pulling a trailer.The Certication/Tire label also tells you the maximum
weights for the front and rear axles, called Gross
Axle Weight Rating (GAWR). To nd out the actual loads
on your front and rear axles, you need to go to a
weigh station and weigh your vehicle. Your dealer can
help you with this. Be sure to spread out your load
equally on both sides of the centerline.
Never exceed the GVWR for your vehicle, or the GAWR
for either the front or rear axle.
And, if you do have a heavy load, you should spread
it out.
{CAUTION:
Do not load your vehicle any heavier than the
Gross Vehicle Weight Rating (GVWR), or either
the maximum front or rear Gross Axle Weight
Rating (GAWR). If you do, parts on your
vehicle can break, and it can change the way
your vehicle handles. These could cause you
to lose control and crash. Also, overloading
can shorten the life of your vehicle.
Using heavier suspension components to get added
durability might not change your weight ratings. Ask your
dealer to help you load your vehicle the right way.
4-32

To identify the trailering capacity of your vehicle, you
should read the information in “Weight of the Trailer” that
appears later in this section.
If yours was built with trailering options, as many are,
it’s ready for heavier trailers. But trailering is different
than just driving your vehicle by itself. Trailering means
changes in handling, acceleration, braking, durability
and fuel economy. Successful, safe trailering takes
correct equipment, and it has to be used properly.
That’s the reason for this part. In it are many time-tested,
important trailering tips and safety rules. Many of
these are important for your safety and that of your
passengers. So please read this section carefully before
you pull a trailer.
If You Do Decide To Pull A Trailer
If you do, here are some important points:
There are many different laws, including speed limit
restrictions, having to do with trailering. Make sure
your rig will be legal, not only where you live
but also where you’ll be driving. A good source for
this information can be state or provincial police.
Consider using a sway control. See “Hitches” later
in this section.
Don’t tow a trailer at all during the rst 500 miles
(800 km) your new vehicle is driven. Your engine,
axle or other parts could be damaged.
Then, during the rst 500 miles (800 km) that you
tow a trailer, don’t drive over 50 mph (80 km/h)
and don’t make starts at full throttle. This helps your
engine and other parts of your vehicle wear in at
the heavier loads.
See “Driving on Grades” later in this section for
more information.
Three important considerations have to do with weight:
the weight of the trailer
the weight of the trailer tongue
and the weight on your vehicle’s tires
4-35

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...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling Your Tank............................................5-8
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-10
Hood Release..............................................5-11
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.............................................5-26
Radiator Pressure Cap..................................5-28
Engine Overheating.......................................5-28
Cooling System............................................5-30
Engine Fan Noise.........................................5-35
Power Steering Fluid.....................................5-36Windshield Washer Fluid................................5-37
Brakes........................................................5-38
Battery........................................................5-42
Jump Starting...............................................5-42
All-Wheel Drive..............................................5-47
Rear Axle.......................................................5-48
Front Axle......................................................5-49
Bulb Replacement..........................................5-50
Halogen Bulbs..............................................5-50
Headlamps and Sidemarker Lamps.................5-50
Front Turn Signal and Parking Lamps..............5-54
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-55
Replacement Bulbs.......................................5-56
Windshield Wiper Blade Replacement..............5-57
Tires..............................................................5-58
Tire Sidewall Labelling...................................5-59
Tire Terminology and Denitions.....................5-61
Ination - Tire Pressure.................................5-64
Tire Inspection and Rotation...........................5-65
When It Is Time for New Tires.......................5-66
Buying New Tires.........................................5-67
Uniform Tire Quality Grading..........................5-68
Wheel Alignment and Tire Balance..................5-69
Section 5 Service and Appearance Care
5-1

Filling Your Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your
engine when you are refueling. Do not smoke
if you are near fuel or refueling your vehicle.
Keep sparks, ames and smoking materials
away from fuel. Do not leave the fuel pump
unattended when refueling your vehicle — this
is against the law in some places. Keep
children away from the fuel pump; never let
children pump fuel.The tethered fuel cap is located behind a hinged fuel
door on the driver’s side of the vehicle.
To remove the fuel cap, turn it slowly to the left
(counterclockwise). The fuel cap has a spring in it;
if the cap is released too soon, it will spring back to
the right.
While refueling, hang the tethered fuel cap from the
hook on the fuel door.
5-8

{CAUTION:
If you spill fuel and then something ignites it,
you could be badly burned. Fuel can spray out
on you if you open the fuel cap too quickly.
This spray can happen if your tank is nearly
full, and is more likely in hot weather. Open
the fuel cap slowly and wait for any hiss noise
to stop. Then unscrew the cap all the way.
Be careful not to spill fuel. Do not top off or overll the
tank and wait a few seconds after you have nished
pumping before removing the nozzle. Clean fuel
from painted surfaces as soon as possible. See
Washing Your Vehicle on page 5-88.
When replacing the fuel cap, turn it to the right
(clockwise) until it clicks. Make sure the cap is fully
installed. The diagnostic system can determine if the
fuel cap has been left off or improperly installed.
This would allow fuel to evaporate into the atmosphere.
SeeMalfunction Indicator Lamp on page 3-30.
{CAUTION:
If a re starts while you are refueling, do not
remove the nozzle. Shut off the ow of fuel by
shutting off the pump or by notifying the
station attendant. Leave the area immediately.
Notice:If you need a new fuel cap, be sure to get
the right type. Your dealer can get one for you.
If you get the wrong type, it may not t properly.
This may cause your malfunction indicator lamp to
light and may damage your fuel tank and emissions
system. SeeMalfunction Indicator Lamp on
page 3-30.
5-9

A. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-37.
B. Engine Coolant Recovery Tank. SeeCooling System
on page 5-30.
C. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-13.
D. Automatic Transmission Fluid Dipstick. See
“Checking the Fluid Level” underAutomatic
Transmission Fluid on page 5-23.
E. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-21.
F. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-13.
G. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-38.
H. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-36.
I. Battery. SeeBattery on page 5-42.
Engine Oil
Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
1. Turn off the engine and give the oil several minutes
to drain back into the oil pan. If you do not do this,
the oil dipstick might not show the actual level.
2. Pull out the dipstick and clean it with a paper towel
or cloth, then push it back in all the way. Remove it
again, keeping the tip down, and check the level.
When to Add Engine Oil
If the oil is at or below the MIN line, then you will need
to add at least one quart of oil. But you must use
the right kind. This section explains what kind of oil to
use. For engine oil crankcase capacity, seeCapacities
and Specications on page 5-101.
Notice:Do not add too much oil. If your engine has
so much oil that the oil level gets above the upper
mark that shows the proper operating range,
your engine could be damaged.
5-13

6. Start the engine and let it run until you can feel the
upper radiator hose getting hot. Watch out for the
engine cooling fan.
7. By this time, the coolant level inside the radiator
ller neck may be lower. If the level is lower, add
more of the proper DEX-COOL
®coolant mixture
through the ller neck until the level reaches
the base of the ller neck.
Then replace the pressure cap. At any time during
this procedure if coolant begins to ow out of
the ller neck, reinstall the pressure cap. Be sure
the arrow on the pressure cap lines up properly.
Engine Fan Noise
This vehicle has a clutched engine cooling fan. When
the clutch is engaged, the fan spins faster to provide
more air to cool the engine. In most everyday driving
conditions, the clutch is not fully engaged. This improves
fuel economy and reduces fan noise. Under heavy
vehicle loading, trailer towing and/or high outside
temperatures, the fan speed increases when the clutch
engages. So you may hear an increase in fan noise.
This is normal and should not be mistaken as the
transmission slipping or making extra shifts. It is merely
the cooling system functioning properly. The fan will
slow down when additional cooling is not required and
the clutch disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch disengages.
5-35

Belt:A rubber coated layer of cords that is located
between the plies and the tread. Cords may be made
from steel or other reinforcing materials.
Bead:The tire bead contains steel wires wrapped by
steel cords that hold the tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the plies are
laid at alternate angles less than 90 degrees to the
centerline of the tread.
Cold Ination Pressure:The amount of air pressure
in a tire, measured in pounds per square inch (psi)
or kilopascals (kPa) before a tire has built up heat from
driving. SeeInation - Tire Pressure on page 5-64.
Curb Weight:This means the weight of a motor vehicle
with standard and optional equipment including the
maximum capacity of fuel, oil and coolant, but without
passengers and cargo.
DOT Markings:A code molded into the sidewall of a
tire signifying that the tire is in compliance with the
U.S. Department of Transportation (DOT) motor vehicle
safety standards. The DOT code includes the Tire
Identication Number (TIN), an alphanumeric designator
which can also identify the tire manufacturer, production
plant, brand and date of production.
GVWR:Gross Vehicle Weight Rating, seeLoading
Your Vehicle on page 4-28.GAWR FRT:Gross Axle Weight Rating for the front
axle, seeLoading Your Vehicle on page 4-28.
GAWR RR:Gross Axle Weight Rating for the rear axle,
seeLoading Your Vehicle on page 4-28.
Intended Outboard Sidewall:The side of an
asymmetrical tire, that must always face outward when
mounted on a vehicle.
KiloPascal (kPa):The metric unit for air pressure.
Light Truck (LT-Metric) Tire:A tire used on light duty
trucks and some multipurpose passenger vehicles.
Load Index:An assigned number ranging from 1 to 279
that corresponds to the load carrying capacity of a tire.
Maximum Ination Pressure:The maximum air
pressure to which a cold tire may be inated. The
maximum air pressure is molded onto the sidewall.
Maximum Load Rating:The load rating for a tire at the
maximum permissible ination pressure for that tire.
Maximum Loaded Vehicle Weight:The sum of curb
weight; accessory weight; vehicle capacity weight;
and production options weight.
Normal Occupant Weight:The number of occupants a
vehicle is designed to seat multiplied by 150 lbs (68 kg).
SeeLoading Your Vehicle on page 4-28.
5-62