service CHEVROLET ASTRO CARGO VAN 2003 2.G Manual Online

Additional Program Information
Courtesy Transportation is available during the
Bumper-to-Bumper warranty coverage period, but itis
notpart of the New Vehicle Limited Warranty. A
separate booklet entitled ªWarranty and Owner
Assistance Informationº furnished with each new vehicle
provides detailed warranty coverage information.
Courtesy Transportation is available only at participating
dealers and all program options, such as shuttle
service, may not be available at every dealer. Please
contact you dealer for speci®c information about
availability. All Courtesy Transportation arrangements
will be administered by appropriate dealer personnel.
Canadian Vehicles:For warranty repairs during
the Complete Vehicle Coverage period of the General
Motors of Canada New Vehicle Limited Warranty,
alternative transportation may be available under the
Courtesy Transportation Program. Please consult
your dealer for details.
General Motors reserves the right to unilaterally modify,
change or discontinue Courtesy Transportation at
any time and to resolve all questions of claim eligibility
pursuant to the terms and conditions described
herein at its sole discretion.
Reporting Safety Defects
Reporting Safety Defects to the
United States Government
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you
should immediately inform the National Highway Traffic
Safety Administration (NHTSA), in addition to notifying
General Motors.
If NHTSA receives similar complaints, it may open an
investigation, and if it ®nds that a safety defect exists in
a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer or
General Motors.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 366-0123 in
the Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation
Washington, D.C. 20590
You can also obtain other information about motor
vehicle safety from the hotline.
7-10

Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to
General Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you'll notify us.
Please call us at 1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
Transmission, Transaxle, Transfer
Case Unit Repair Manual
This manual provides information on unit repair service
procedures, adjustments, and speci®cations for GM
transmissions, transaxles, and transfer cases.
RETAIL SELL PRICE: $50.00
7-11

Service Bulletins
Service Bulletins give technical service information
needed to knowledgeably service General Motors cars
and trucks. Each bulletin contains instructions to
assist in the diagnosis and service of your vehicle.
In Canada, information pertaining to Product Service
Bulletins can be obtained by contacting your General
Motors dealer or by calling 1-800-GM-DRIVE
(1-800-463-7483).
Owner's Information
Owner publications are written speci®cally for owners
and intended to provide basic operational information
about the vehicle. The owner's manual will include
the Maintenance Schedule for all models.
In-Portfolio: Includes a Portfolio, Owner's Manual, and
Warranty Booklet.
RETAIL SELL PRICE: $35.00
Without Portfolio: Owner's Manual only.
RETAIL SELL PRICE: $25.00
Current and Past Model Order Forms
Service Publications are available for current and
past model GM vehicles. To request an order form,
please specify year and model name of the vehicle.
ORDER TOLL FREE: 1-800-551-4123
Monday-Friday 8:00 AM - 6:00 PM
Eastern Time
For Credit Card Orders Only
(VISA-MasterCard-Discover), visit Helm, Inc. on the
World Wide Web at: www.helminc.com
Or you can write to:
Helm, Incorporated
P. O. Box 07130
Detroit, MI 48207
Prices are subject to change without notice and without
incurring obligation. Allow ample time for delivery.
Note to Canadian Customers: All listed prices are
quoted in U.S. funds. Canadian residents are to make
checks payable in U.S. funds.
7-12

A
Accessory Power Outlets.................................3-16
Activating the Theft-Deterrent Feature................3-48
Adding Equipment to Your Air Bag-Equipped
Vehicle.......................................................1-70
Adding Washer Fluid.......................................5-41
Additional Program Information.........................7-10
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment............................5-92
Add-On Equipment..........................................4-31
Adjusting the Speakers (Balance/Fade)......3-40, 3-43
Air Bag System..............................................1-62
Adding Equipment to Your Air
Bag-Equipped Vehicle...............................1-70
How Does an Air Bag Restrain?....................1-67
Servicing Your Air Bag-Equipped Vehicle.........1-69
What Makes an Air Bag In¯ate?....................1-67
What Will You See After an Air Bag In¯ates?......1-68
When Should an Air Bag In¯ate?...................1-66
Where Are the Air Bags?..............................1-64
Air Bag .........................................................3-26
Readiness Light..........................................3-26
Air Cleaner/Filter, Engine.................................5-24
All-Wheel Drive (AWD) System.........................2-26
All-Wheel Drive...............................................5-52
All-Wheel-Drive Service Light............................3-35
AM-FM Radio.................................................3-39AM ...............................................................3-50
Antenna, Fixed Mast.......................................3-50
Anti-Lock Brake, System Warning Light..............3-29
Anti-lock Brake System..................................... 4-7
Appearance Care............................................5-83
Care of Safety Belts....................................5-86
Chemical Paint Spotting...............................5-89
Cleaning the Inside of Your Vehicle................5-83
Cleaning the Outside of Your Vehicle..............5-86
Finish Damage............................................5-88
Sheet Metal Damage...................................5-88
Underbody Maintenance...............................5-89
Vehicle Care/Appearance Materials................5-89
Weatherstrips..............................................5-86
Ashtrays........................................................3-17
Audio System(s).............................................3-38
AM-FM Radio.............................................3-39
Care of Your CD Player...............................3-50
Care of Your CDs........................................3-50
Fixed Mast Antenna.....................................3-50
Radio with CD............................................3-41
Rear Seat Audio (RSA)................................3-46
Setting the Time for Radios with
HR and MN Buttons.................................3-38
Setting the Time for Radios
with the Set Button...................................3-38
Theft-Deterrent Feature................................3-47
Understanding Radio Reception.....................3-50
1

Audio System(s) (cont.)
Automatic Headlamp System............................3-13
Automatic Transmission Check..........................6-27
Automatic Transmission Shift Lock Control
System Check.............................................6-28
Automatic Transmission...................................5-25
Fluid..........................................................5-25
Operation...................................................2-23
B
Backing Up....................................................4-38
Battery Replacement......................................... 2-6
Battery Run-Down Protection............................3-16
Battery..........................................................5-46
Before Leaving on a Long Trip.........................4-21
Bench Seat............................................1-11, 1-57
Body Lubrication Service..................................6-27
Brake Adjustment............................................5-45
Brake Fluid....................................................5-42
Brake Pedal Travel.........................................5-45
Brake Wear...................................................5-45
Brake............................................................2-26
Parking......................................................2-26
System Inspection.......................................6-31
System Warning Light..................................3-28
Brakes..........................................................5-42
Braking in Emergencies..................................... 4-9Braking........................................................... 4-6
Break-In, New Vehicle.....................................2-19
Bucket Seats, Rear.........................................1-12
Bulb Replacement...........................................5-55
Front Turn Signal Lamps..............................5-59
Halogen Bulbs............................................5-55
Headlamps.................................................5-55
Replacement Bulbs......................................5-61
Taillamps....................................................5-60
Buying New Tires...........................................5-66C
California Fuel.................................................. 5-6
Canada ± Customer Assistance.......................... 7-5
Canadian Owners................................................ ii
Canadian Roadside Assistance........................... 7-7
Canceling the Sliding Door Security Lock...........2-12
Capacities and Speci®cations............................5-99
Carbon Monoxide...........................4-24, 4-31, 2-30
Care of.........................................................5-86
Safety Belts................................................5-86
Your CD Player...........................................3-50
Your CDs ...................................................3-50
Cargo Vans...........................................1-41, 1-48
Center Passenger Position, Safety Belts.............1-27
Chains, Tires..................................................5-70
Charging System Light....................................3-27
2

Customer Assistance Information........................ 7-8
Courtesy Transportation.................................. 7-8
Customer Assistance for Text Telephone
(TTY) Users.............................................. 7-4
Customer Assistance Offices........................... 7-4
Customer Satisfaction Procedure..................... 7-2
GM Mobility Program for Persons with
Disabilities................................................ 7-5
Reporting Safety Defects to General Motors....7-11
Reporting Safety Defects to the Canadian
Government............................................7-11
Reporting Safety Defects to the United States
Government............................................7-10
Roadside Assistance Program......................... 7-6
Service Publications Ordering Information........7-11
D
Daytime Running Lamps (DRL).........................3-14
Defensive Driving............................................. 4-2
Defogging and Defrosting.................................3-19
Directing the Air¯ow........................................3-20
Disabling the Theft-Deterrent Feature.................3-49
Doing Your Own Service Work........................... 5-3
Dome Lamps.................................................3-16
Door............................................................... 2-8
Front Doors.................................................. 2-8
Locks.......................................................... 2-7
Power Door Locks......................................... 2-8Door (cont.)
Programmable Automatic Door Locks............... 2-9
Rear Doors.................................................2-13
Sliding Side Door........................................2-10
Driver Information System................................2-42
Driver............................................................1-18
Position, Safety Belt.....................................1-18
Driving On Grades..........................................4-39
Driving on Snow or Ice....................................4-24
Driving Through Deep Standing Water...............4-18
Driving Through Flowing Water.........................4-18
Driving with a Trailer.......................................4-37
Driving..........................................................4-14
At Night.....................................................4-14
City...........................................................4-19
Defensive..................................................... 4-2
Drunken....................................................... 4-3
Freeway.....................................................4-20
Hill and Mountain Roads..............................4-22
In Rain and on Wet Roads...........................4-16
Winter........................................................4-24
E
Electrical System............................................5-92
Add-On Equipment......................................5-92
Fuses and Circuit Breakers...........................5-93
Headlamp Wiring.........................................5-92
4

Electrical System (cont.)
Power Windows and Other Power Options......5-92
Windshield Wiper Fuses...............................5-92
Emissions Inspection and Maintenance
Programs...................................................3-33
Engine Coolant Level Check.............................6-26
Engine Oil Additives........................................5-18
Engine Oil Level Check...................................6-26
Engine..........................................................5-24
Air Cleaner/Filter.........................................5-24
Battery.......................................................5-46
Check and Service Engine Soon Light............3-30
Compartment Overview................................5-14
Coolant Heater............................................2-22
Coolant Temperature Gage...........................3-30
Coolant......................................................5-28
Cooling System Inspection............................6-30
Cover........................................................5-20
Exhaust.....................................................2-30
Fan Noise..................................................5-39
Oil .............................................................5-15
Overheating................................................5-31
Starting......................................................2-21
Entry Lighting.................................................3-15
Erasing HomeLink
žButtons..............................2-37
Except Cargo Vans.................................1-38, 1-47
Exit Lighting...................................................3-15Express-Down Window....................................2-17
Extender, Safety Belt.......................................1-34
Exterior Lamps...............................................3-12
F
Filter.............................................................5-24
Engine Air Cleaner......................................5-24
Finding a Station....................................3-39, 3-41
Finish Care....................................................5-87
Finish Damage...............................................5-88
Fixed Mast Antenna........................................3-50
Flash-to-Pass................................................... 3-7
Flat Tire, Changing.........................................5-71
Flat Tire........................................................5-70
Fluid.............................................................5-25
Automatic Transmission................................5-25
Power Steering...........................................5-40
Windshield Washer......................................5-41
FM ...............................................................3-50
Following Distance..........................................4-38
Front Axle......................................................5-54
Front Doors..................................................... 2-8
Fuel Regulator................................................2-21
Fuel............................................................... 5-5
Additives...................................................... 5-6
California Fuel.............................................. 5-6
5

How to Add Coolant to the Coolant
Recovery Tank............................................5-34
How to Add Coolant to the Radiator..................5-37
How to Add Fluid............................................5-27
How to Check Lubricant...................................5-53
How to Check Power Steering Fluid..................5-40
How to Check........................................5-25, 5-64
How to Inspect the Engine Air Cleaner/Filter.......5-24
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-18
Hydroplaning..................................................4-18
I
If No Steam Is Coming From Your Engine..........5-32
If Steam Is Coming From Your Engine...............5-31
If the Light Is Flashing.....................................3-32
If the Light Is On Steady.................................3-32
If You Are Stuck in Sand, Mud, Ice or Snow.......4-28
If You Do Decide To Pull A Trailer.....................4-32
If You're Caught in a Blizzard...........................4-26
Ignition Positions.............................................2-19
Ignition Transmission Lock Check......................6-29
Infants and Young Children, Restraints...............1-38
In¯ation Ð Tire Pressure.................................5-64
Inspection......................................................6-31
Brake System.............................................6-31
Engine Cooling System................................6-30Inspection (cont.)
Exhaust System..........................................6-30
Fuel System...............................................6-30
Part C - Periodic Maintenance.......................6-30
Steering, Suspension and Front Drive Axle
Boot and Seal.........................................6-30
Throttle System...........................................6-31
Transfer Case and Front Axle
(All-Wheel Drive)......................................6-31
Installing a Garage Door Opener.......................2-40
Instrument Panel Brightness Control..................3-15
Instrument Panel Fuse Block............................5-93
Instrument Panel.............................................3-24
Cluster.......................................................3-24
Overview..................................................... 3-2
Interior Lamps................................................3-15
J
Jump Starting.................................................5-47
K
Key Lock Cylinders Service..............................6-27
Keyless Entry System....................................... 2-4
Keys............................................................... 2-2
7

L
Lamps On Reminder.......................................3-14
Lamps...........................................................3-12
Exterior......................................................3-12
Interior.......................................................3-15
Lap Belt........................................................1-27
Lap-Shoulder Belt...................................1-18, 1-29
LATCH System...............................................1-52
Child Restraints...........................................1-52
Securing a Child Restraint Designed for the
LATCH System........................................1-54
Latches, Seatback............................................ 1-6
Leaving Your Vehicle With the
Engine Running..........................................2-28
Leaving Your Vehicle.......................................2-10
Light.............................................................3-26
Air Bag Readiness.......................................3-26
Anti-Lock Brake System Warning...................3-29
Brake System Warning.................................3-28
Charging System.........................................3-27
Check Gages Warning.................................3-36
Low Fuel Warning.......................................3-37
Malfunction Indicator....................................3-30
Safety Belt Reminder...................................3-26
Security.....................................................3-35
Service All-Wheel-Drive................................3-35
Tow/Haul Mode...........................................3-36Loading Your Vehicle.......................................4-29
Locking Rear Axle............................................ 4-9
Locks............................................................. 2-7
Door........................................................... 2-7
Front Doors.................................................. 2-8
Leaving Your Vehicle....................................2-10
Power Door.................................................. 2-8
Programmable Automatic Door Locks............... 2-9
Long Trip/Highway De®nition.............................. 6-6
Long Trip/Highway Intervals............................... 6-6
Long Trip/Highway Scheduled Maintenance........6-18
Loss of Control...............................................4-13
Low Fuel Warning Light...................................3-37
Luggage Carrier..............................................2-44
Lumbar........................................................... 1-3
Manual Controls............................................ 1-3
M
Maintenance, Normal Replacement Parts..........5-101
Maintenance Schedule.....................................6-26
At Each Fuel Fill.........................................6-26
At Least Once a Month................................6-26
At Least Once a Year..................................6-27
At Least Twice a Year..................................6-26
Brake System Inspection..............................6-31
Engine Cooling System Inspection.................6-30
Exhaust System Inspection...........................6-30
8

Maintenance Schedule (cont.)
Fuel System Inspection................................6-30
How This Section is Organized....................... 6-3
Introduction.................................................. 6-2
Long Trip/Highway Scheduled Maintenance.....6-18
Maintenance Requirements............................. 6-2
Part A - Scheduled Maintenance Services......... 6-4
Part B - Owner Checks and Services.............6-26
Part C - Periodic MaintenanceInspections......6-30
Part D - Recommended Fluids and Lubricants....6-32
Part E - Maintenance Record........................6-34
Selecting the Right Schedule.......................... 6-5
Short Trip/City Scheduled Maintenance............. 6-7
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection..........................6-30
Throttle System Inspection............................6-31
Transfer Case and Front Axle
(All-Wheel Drive) Inspection.......................6-31
Using Your................................................... 6-4
Your Vehicle and the Environment................... 6-2
Maintenance When Trailer Towing.....................4-40
Making Turns.................................................4-38
Malfunction Indicator Light................................3-30
Manual Lumbar Controls.................................... 1-3
Manual Seats................................................... 1-2
Manual Windows............................................2-16
Matching Transmitter(s) to Your Vehicle............... 2-5Mexico, Central America and Caribbean
Islands/Countries (Except Puerto Rico and
U.S. Virgin Islands) ± Customer Assistance....... 7-5
Mirrors..........................................................2-32
Manual Rearview Mirror................................2-32
Outside Convex Mirror.................................2-33
Outside Manual Mirror..................................2-32
Outside Power Mirrors..................................2-32
Model Reference................................................ vi
MyGMLink.com................................................ 7-4
N
New Vehicle Break-In......................................2-19
Normal Maintenance Replacement Parts...........5-101
O
Odometer......................................................3-25
Off-Road Recovery..........................................4-11
Oil ................................................................5-15
Engine.......................................................5-15
Pressure Gage............................................3-34
Older Children, Restraints................................1-35
Online Owner Center........................................ 7-4
9