service CHEVROLET ASTRO CARGO VAN 2004 2.G Owners Manual

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-3
Rear Seats
............................................... 1-7
Safety Belts
.............................................1-13
Child Restraints
.......................................1-35
Air Bag System
.......................................1-62
Restraint System Check
............................1-68
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-7
Windows
.................................................2-15
Theft-Deterrent Systems
............................2-17
Starting and Operating Your Vehicle
...........2-18
Mirrors
....................................................2-31
HomeLink
®Transmitter
.............................2-32
Storage Areas
.........................................2-36
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-2
Climate Controls
......................................3-17
Warning Lights, Gages, and Indicators
........3-22
Audio System(s)
.......................................3-35
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-29Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-4
Checking Things Under the Hood
................. 5-9
All-Wheel Drive
........................................5-50
Rear Axle
...............................................5-51
Front Axle
...............................................5-52
Bulb Replacement
....................................5-53
Windshield Wiper Blade Replacement
.........5-59
Tires
......................................................5-60
Appearance Care
.....................................5-91
Vehicle Identication
.................................5-99
Electrical System
....................................5-100
Capacities and Specications
...................5-107
Normal Maintenance Replacement Parts
....5-109
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
2004 Chevrolet Astro Owner ManualM

Air bags are designed to inate only once. After they
inate, 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 ination and driver’s safety belt
usage at deployment. The module also records
speed, engine rpm, brake and throttle data.
Let only qualied 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
inate 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, seeService Publications
Ordering Information on page 7-12.
{CAUTION:
For up to 10 minutes after the ignition key is
turned off and the battery is disconnected, an
air bag can still inate during improper service.
You can be injured if you are close to an air bag
when it inates. 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
qualied to do so.
The air bag system does not need regular maintenance.
1-67

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 modications 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 qualied 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 ve seconds after the key is
turned to RUN.If the engine stalls and the SECURITY light ashes,
wait until the light stops ashing 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.
SeeFuses and Circuit Breakers on page 5-101.
See your dealer for service.
2-17

Notice:Lengthy operation of features such
as the radio in the accessory ignition position
may drain the battery and prevent your vehicle
from starting. Do not operate your vehicle in
the accessory ignition position for a long period
of time.
B (LOCK):This position locks your ignition 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:Using a tool to force the key from the
ignition switch could cause damage or break the
key. Use the correct key and turn the key only
with your hand. Make sure the key is all the way in.
If it is, turn the steering wheel left and right while
you turn the key hard. If none of this works,
then your vehicle needs service.C (OFF):This position lets you turn off the engine.
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.
2-19

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 modications to this system by
other than an authorized service facility could void
authorization to use this equipment.Programming the HomeLink®
Transmitter
Do not use the HomeLink®Transmitter with any garage
door opener that does not have the “stop and reverse”
feature. This includes any garage door opener model
manufactured before April 1, 1982. If you have a newer
garage door opener with rolling codes, please be
sure to follow steps 6 through 8 to complete the
programming of your HomeLink
®Transmitter.
Read the instructions completely before attempting to
program the HomeLink
®Transmitter. Because of the
steps involved, it may be helpful to have another person
available to assist you in programming the transmitter.
Keep the original transmitter for use in other vehicles as
well as for future HomeLink
®programming. It is also
recommended that upon the sale of the vehicle, the
programmed HomeLink
®buttons should be erased for
security purposes. Refer to “Erasing HomeLink®Buttons”
or, for assistance, contact HomeLink®on the internet at:
www.homelink.com or by calling 1-800-355-3515.
2-33

Instrument Panel Overview...............................3-2
Hazard Warning Flashers................................3-4
Other Warning Devices...................................3-5
Horn.............................................................3-5
Tilt Wheel.....................................................3-5
Turn Signal/Multifunction Lever.........................3-6
Exterior Lamps.............................................3-12
Interior Lamps..............................................3-14
Accessory Power Outlets...............................3-15
Ashtrays and Cigarette Lighter........................3-16
Climate Controls............................................3-17
Climate Control System.................................3-17
Outlet Adjustment.........................................3-19
Rear Heating System....................................3-20
Rear Air Conditioning System.........................3-20
Warning Lights, Gages, and Indicators............3-22
Instrument Panel Cluster................................3-23
Speedometer and Odometer...........................3-24
Safety Belt Reminder Light.............................3-24
Air Bag Readiness Light................................3-25
Charging System Light..................................3-26
Voltmeter Gage............................................3-26
Brake System Warning Light..........................3-27Anti-Lock Brake System Warning Light.............3-28
Engine Coolant Temperature Gage..................3-28
Malfunction Indicator Lamp.............................3-29
Oil Pressure Gage........................................3-32
Security Light...............................................3-33
Service All-Wheel Drive Light.........................3-33
Tow/Haul Mode Light....................................3-34
Check Gages Warning Light...........................3-34
Fuel Gage...................................................3-34
Low Fuel Warning Light.................................3-35
Audio System(s).............................................3-35
Setting the Time for Radios with
the Set Button..........................................3-36
Setting the Time for Radios with
HR and MN Buttons..................................3-36
AM-FM Radio...............................................3-36
Radio with CD..............................................3-38
Rear Seat Audio (RSA).................................3-43
Theft-Deterrent Feature..................................3-44
Radio Reception...........................................3-47
Care of Your CDs.........................................3-47
Care of Your CD Player................................3-47
Fixed Mast Antenna......................................3-47
Section 3 Instrument Panel
3-1

Air Bag Readiness Light
There is an air bag readiness light on the instrument
panel, which shows AIR BAG or the air bag symbol.
The system checks the air bag’s electrical system
for malfunctions. The light tells you if there is an
electrical problem. The system check includes the air
bag sensor, the air bag modules, the wiring and
the crash sensing and diagnostic module. For more
information on the air bag system, seeAir Bag System
on page 1-62.
This light will come on when you start your vehicle,
and it will ash for a few seconds. Then the light should
go out. This means the system is ready.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
serviced right away.
{CAUTION:
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 inate in a crash, or they
could even inate 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 ash for a few
seconds when you turn the ignition key to RUN. If the
light doesn’t come on then, have it xed so it will
be ready to warn you if there is a problem. United States
Canada
3-25

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.This light should come on
briey when you turn the
ignition key to RUN. If
it doesn’t come on then,
have it xed so it will
be ready to warn you if
there’s a problem.
If the light comes on while you are driving, pull off the
road and stop carefully. You may notice that the pedal
is harder to push. Or, the pedal may go closer to
the oor. It may take longer to stop. If the light is still
on, have the vehicle towed for service. SeeTowing Your
Vehicle on page 4-29.
{CAUTION:
Your brake system may not be working properly
if the brake system warning light is on. Driving
with the brake system warning light on can lead
to an accident. If the light is still on after you
have pulled off the road and stopped carefully,
have the vehicle towed for service.
3-27

Anti-Lock Brake System
Warning Light
With the anti-lock brake system, this light will come
on when you start your engine and may stay on
for several seconds. That’s normal.
If the light stays on, or comes on when you’re driving,
your vehicle needs service. If the regular brake system
warning light isn’t on, you still have brakes, but you don’t
have anti-lock brakes. If the regular brake system
warning light is also on, you don’t have anti-lock brakes
and there’s a problem with your regular brakes. See
“Brake System Warning Light” earlier in this section.
The anti-lock brake system warning light should
come on briey when you turn the ignition key to RUN.
If the light doesn’t come on then, have it xed so it
will be ready to warn you if there is a problem.
Engine Coolant Temperature Gage
This gage shows
the engine coolant
temperature. If the
gage pointer moves
to the red area, your
engine is too hot!
It means that your engine coolant has overheated.
If you have been operating your vehicle under normal
driving conditions, you should pull off the road, stop your
vehicle and turn off the engine as soon as possible.
SeeEngine Overheating on page 5-29. United States
Canada
3-28