headlamp CHEVROLET ASTRO CARGO VAN 2004 2.G User Guide

Appearance Care............................................5-91
Cleaning the Inside of Your Vehicle.................5-92
Care of Safety Belts......................................5-94
Weatherstrips...............................................5-94
Cleaning the Outside of Your Vehicle.................5-95
Sheet Metal Damage.....................................5-97
Finish Damage.............................................5-97
Underbody Maintenance................................5-97
Chemical Paint Spotting.................................5-97
Vehicle Care/Appearance Materials..................5-98
Vehicle Identication......................................5-99
Vehicle Identication Number (VIN).................5-99
Service Parts Identication Label.....................5-99Electrical System..........................................5-100
Add-On Electrical Equipment.........................5-100
Headlamp Wiring........................................5-100
Windshield Wiper Fuses...............................5-100
Power Windows and Other Power Options......5-100
Fuses and Circuit Breakers..........................5-101
Capacities and Specications........................5-107
Normal Maintenance Replacement Parts.........5-109
Engine Drive Belt Routing............................5-110
Section 5 Service and Appearance Care
5-2

Bulb Replacement
For any bulb changing procedure not listed in this
section, contact your dealer.
For the type of bulbs, seeReplacement Bulbs
on page 5-59.
Halogen Bulbs
{CAUTION:
Halogen bulbs have pressurized gas inside
and can burst if you drop or scratch the bulb.
You or others could be injured. Be sure to
read and follow the instructions on the
bulb package.
Headlamps
Sealed Beam Headlamp
1. Remove the
four retainer screws
and the retainer.
5-53

2. Pull the connector out
and unplug the lamp.
3. Plug the new lamp into the connector.
4. Reverse Steps 1 and 2 to reinstall the headlamp.Composite Headlamps
1. Open the hood.
2. Remove the two
screws from the
sidemarker/turn
signal lamp.
5-54

Replacement Bulbs
Exterior Lamp Bulb Number
Back-Up Lamps 1156
Halogen Headlamps
Composite9005
(High Beam)
Halogen Headlamps
Composite9006
(Low Beam)
Halogen Headlamps
Sealed BeamH6054
Parking, Turn Signal Lamps 3157NA
Rear, Stoplamps 2057
Sidemarker Lamps 194
For any bulb not listed here, contact your dealer.
Windshield Wiper Blade
Replacement
Windshield wiper blades should be inspected at least
twice a year for wear and cracking. See “Wiper
Blade Check” inAt Least Twice a Year on page 6-22
for more information.
To replace your
windshield wiper
blade inserts, do
the following:
1. Lift the wiper arm away from the windshield.
2. Pinch the two tabs on the wiper arm and slide
the insert out of the blade.
3. Slide the new one in place.
Make sure the tabs are locked into position. SeeNormal
Maintenance Replacement Parts on page 5-109for
the proper type of replacement blade.
5-59

If you need to replace any of your wheels, wheel
bolts or wheel nuts, replace them only with new GM
original equipment parts. This way, you will be sure
to have the right wheel, wheel bolts and wheel nuts for
your vehicle.
{CAUTION:
Using the wrong replacement wheels, wheel
bolts or wheel nuts on your vehicle can be
dangerous. It could affect the braking and
handling of your vehicle, make your tires lose
air and make you lose control. You could have
a collision in which you or others could be
injured. Always use the correct wheel, wheel
bolts and wheel nuts for replacement.
Notice:The wrong wheel can also cause problems
with bearing life, brake cooling, speedometer or
odometer calibration, headlamp aim, bumper height,
vehicle ground clearance and tire or tire chain
clearance to the body and chassis.
SeeChanging a Flat Tire on page 5-78for more
information.
Used Replacement Wheels
{CAUTION:
Putting a used wheel on your vehicle is
dangerous. You can’t know how it’s been used
or how far it’s been driven. It could fail suddenly
and cause a crash. If you have to replace a
wheel, use a new GM original equipment wheel.
Tire Chains
Notice:Use tire chains only where legal and only
when you must. Use only SAE Class″S″type chains
that are the proper size for your tires. Install them
on the rear axle tires and tighten them as tightly
as possible with the ends securely fastened.
Drive slowly and follow the chain manufacturer’s
instructions. If you can hear the chains contacting
your vehicle, stop and retighten them. If the contact
continues, slow down until it stops. Driving too
fast or spinning the wheels with chains on will
damage your vehicle.
5-76

Electrical System
Add-On Electrical Equipment
Notice:Don’t add anything electrical to your
vehicle unless you check with your dealer rst.
Some electrical equipment can damage your
vehicle and the damage wouldn’t be covered by
your warranty. Some add-on electrical equipment
can keep other components from working as
they should.
Your vehicle has an air bag system. Before
attempting to add anything electrical to your vehicle,
seeServicing Your Air Bag-Equipped Vehicle
on page 1-67.
Headlamp Wiring
The headlamp wiring is protected by a circuit breaker in
the lamp switch. An electrical overload will cause the
lamps to icker on and off, or in some cases to remain
off. If this happens, have your headlamp wiring
checked right away.
Windshield Wiper Fuses
The windshield wiper motor is protected by a circuit
breaker and a fuse. If the motor overheats due to heavy
snow, etc., the wiper will stop until the motor cools.
Although the circuit is protected from electrical overload,
overload due to heavy snow, etc., may cause wiper
linkage damage. Always clear ice and heavy snow from
the windshield before using the windshield wipers. If
the overload is caused by some electrical problem and
not snow, etc., be sure to get it xed.
Power Windows and Other
Power Options
Circuit breakers in the fuse panel protect the power
windows and other power accessories. When the current
load is too heavy, the circuit breaker opens and
closes, protecting the circuit until the problem is xed
or goes away.
5-100

Fuse/Circuit
BreakerUsage
1Stop/Turn/Hazard Lamps,
Center High Mounted Stop Lamp,
Anti-Lock Brakes
2Radio Accessory, Rear Seat
Audio Controls
Fuse/Circuit
BreakerUsage
3Courtesy Lamps, Glove Box Lamp,
Dome Reading Lamps, Vanity
Mirror Lamps, Courtesy Lamps
4Daytime Running Lamps Relay,
Instrument Panel Cluster
5 Rear Defogger
6Cruise Module, Truck Body
Control Module, Instrument Panel
Cluster, Cruise Control Switch,
Electrochromic Mirror
7 Power Outlets, Subwoofer Amplier
8Crank Circuit Fuse, Park/Neutral
Switch, Starter Enabler Relay
9License Plate Lamp, Taillamps,
Parking Lamps, Ashtray Lamp,
Panel Lights, Trailer Taillamps,
Front and Rear Sidemarker
Lamps, Door Switch Illumination,
Headlamp Switch Illumination,
Rear Seat Audio Illumination,
Truck Body Control Module
10 Air Bag System
5-102

Fuse/Circuit
BreakerUsage
11 Not Used
12Blower Motor, Rear Air Conditioning
Relay Coil, Front Cont. Temp.
Door Motor, HI Blower Relay,
Defogger Timer Coil
13Cigarette Lighter, Door Lock
Switches, Dutch Door
Release Module
14Cluster Illumination, Climate
Controls, Chime Module, Radio
Illumination, Rear Heat Switch
Illumination, Rear Wiper/Washer
Switch Illumination, Rear Liftgate
Switch Illumination, Remote
Cassette Illumination,
Overhead Console, Truck Body
Control Illumination
15Truck Body Module,
Headlamp Relay
16Front Turn Signals, Rear
Turn Signals, Trailer Turn
Signals, Back-Up Lamps,
Brake Transmission Shift
Interlock SolenoidFuse/Circuit
BreakerUsage
17 Front Wipers, Front Washer Pump
18VCM-Ign 3, VCM-Brake,
Cruise Stepper Motor Signal,
ATC Module
19Instrument Panel Radio: ATC
(Main Feed), 2000 Series (Standby)
20PRNDL/Odometer, Shift A and
Shift B Solenoids, 3–2 Downshift
Solenoid, Instrument Panel Cluster,
VCM Module
21 Powr Adjust Mirrors
22 Not Used
23 Rear Wiper, Rear Washer Pump
24 Not Used
A(Circuit Breaker) Power Door
Lock Relay, 6–Way Power Seats
B (Circuit Breaker) Power Windows
5-103

Relays Usage
A/C Relay
(Rear Heat
and A/C)Rear/Heat and Air Conditioning
Uptter-ACCY
RelayUptter Accessory
Starter Enable
RelayStarter
A/C Enable
RelayAir Conditioning
Headlamps
RelayHeadlamps
Fuel Pump
RelayFuel PumpFuse/Circuit
BreakerUsage
UPFITTER-
BATTUptter Battery Power Stud,
Trailer Wiring Harness
UPFITTER-
ACCYUptter Accessory Relay
Spare Not used
Spare Not used
Spare Not used
ECM-1BFuel Pump Relay and Motor,
VCM, Oil Pressure Switch/Sender
HORN Horn Relay and Horn
A/C COMPAir Conditioning Enable Relay
and Compressor
RR HTR/AC Rear Heater and Air Conditioning
ATC Active Transfer Case-L Van
FRT HVAC Front Heater and Air Conditioning
5-105

Fuse/Circuit
BreakerUsage
ENG-IOxygen Sensors, Camshaft Position
Sensor, Mass Air Flow Sensor,
Evaporative Emission Canister
Vent Solenoid
IGN-E Air Conditioning Enable Relay Coil
ECM-IFuel Injectors 1–6, Crankshaft
Position Sensot, VCM, Coil Driver
Module (EST), Ignition Coil
Blank Not Used
RH HDLMP Right Headlamp
LH Headlamp Left Headlamp
Blank Not Used
Blank Not Used
DIODE-1 Air Conditioning
Blank Not Used
Blank Not UsedFuse/Circuit
BreakerUsage
Blank Not Used
LIGHTINGCourtesy Fuse, Power Adjust
Mirrors Fuse, Truck Body Control
Battery Fuse
BATTPower Accessory Circuit Breaker,
Stop/Hazard Fuse, Auxiliary Power
Fuse, Cigarette Lighter Fuse,
Radio Battery Fuse
IGN A Starter Relay, Ignition Switch
IGN B Ignition Switch
ABSElectronic Brake
Control Module
Blank Not Used
RAPRadio Accessory,
Power Windows
HTD MIR/RR
DEFOGRear Window Defogger,
Climate Control Head
5-106