light CHEVROLET ASTRO CARGO VAN 2005 2.G Repair Manual

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.Occupant Distribution:Designated seating positions.
Outward Facing Sidewall:The side of an
asymmetrical tire that has a particular side that faces
outward when mounted on a vehicle. The side of the tire
that contains a whitewall, bears white lettering or
bears manufacturer, brand, and/or model name molding
that is higher or deeper than the same moldings on
the other sidewall of the tire.
Passenger (P-Metric) Tire:A tire used on passenger
cars and some light duty trucks and multipurpose
vehicles.
Recommended Ination Pressure:Vehicle
manufacturer’s recommended tire ination pressure and
shown on the tire placard. SeeInation - Tire Pressure
on page 5-61andLoading Your Vehicle on page 4-28.
Radial Ply Tire:A pneumatic tire in which the ply cords
that extend to the beads are laid at 90 degrees to the
centerline of the tread.
Rim:A metal support for a tire and upon which the tire
beads are seated.
Sidewall:The portion of a tire between the tread and
the bead.
Speed Rating:An alphanumeric code assigned to a
tire indicating the maximum speed at which a tire
can operate.
5-60

Uniform Tire Quality Grading
Quality grades can be found where applicable on the
tire sidewall between tread shoulder and maximum
section width. For example:
Treadwear 200 Traction AA Temperature A
The following information relates to the system
developed by the United States National Highway
Traffic Safety Administration, which grades tires by
treadwear, traction and temperature performance. (This
applies only to vehicles sold in the United States.)
The grades are molded on the sidewalls of most
passenger car tires. The Uniform Tire Quality Grading
system does not apply to deep tread, winter-type
snow tires, space-saver or temporary use spare tires,
tires with nominal rim diameters of 10 to 12 inches
(25 to 30 cm), or to some limited-production tires.
While the tires available on General Motors passenger
cars and light trucks may vary with respect to these
grades, they must also conform to federal safety
requirements and additional General Motors Tire
Performance Criteria (TPC) standards.
Treadwear
The treadwear grade is a comparative rating based on
the wear rate of the tire when tested under controlled
conditions on a specied government test course.
For example, a tire graded 150 would wear one and
a half (1.5) times as well on the government course as
a tire graded 100. The relative performance of tires
depends upon the actual conditions of their use,
however, and may depart signicantly from the norm
due to variations in driving habits, service practices and
differences in road characteristics and climate.
Traction – AA, A, B, C
The traction grades, from highest to lowest, are AA, A,
B, and C. Those grades represent the tire’s ability
to stop on wet pavement as measured under controlled
conditions on specied government test surfaces of
asphalt and concrete. A tire marked C may have poor
traction performance. Warning: The traction grade
assigned to this tire is based on straight-ahead braking
traction tests, and does not include acceleration,
cornering, hydroplaning, or peak traction characteristics.
5-66

They can all be hazardous — some more than
others —and they can all damage the vehicle, too.
Do not use any of these products unless this manual
says you can. In many uses, these will damage
the vehicle:
Alcohol
Laundry Soap
Bleach
Reducing Agents
Cleaning the Inside of Your Vehicle
Your vehicle’s interior will continue to look its best if it is
cleaned often. Although not always visible, dust and dirt
can accumulate on your upholstery. Dirt can damage
carpet, fabric, leather, and plastic surfaces. Regular
vacuuming is recommended to remove particles from
your upholstery. It is important to keep your upholstery
from becoming and remaining heavily soiled. Soils should
be removed as quickly as possible. Your vehicle’s interior
may experience extremes of heat that could cause stains
to set rapidly.
Lighter colored interiors may require more frequent
cleaning. Use care because newspapers and garments
that transfer color to your home furnishings may also
transfer color to your vehicle’s interior.When cleaning your vehicle’s interior, only use cleaners
specically designed for the surfaces being cleaned.
Permanent damage may result from using cleaners on
surfaces for which they were not intended. Use glass
cleaner only on glass. Remove any accidental over-spray
from other surfaces immediately. To prevent over-spray,
apply cleaner directly to the cleaning cloth.
Notice:If you use abrasive cleaners when cleaning
glass surfaces on your vehicle, you could scratch
the glass and/or cause damage to the rear window
defogger. When cleaning the glass on your
vehicle, use only a soft cloth and glass cleaner.
Many cleaners contain solvents that may become
concentrated in your vehicle’s breathing space.
Before using cleaners, read and adhere to all safety
instructions on the label. While cleaning your vehicle’s
interior, maintain adequate ventilation by opening
your vehicle’s doors and windows.
Dust may be removed from small buttons and knobs
using a small brush with soft bristles.
Your GM dealer has a product for cleaning your
vehicle’s glass. Should it become necessary, you can
also obtain a product from your GM dealer to remove
odors from your vehicle’s upholstery.
5-83

Vehicle Care/Appearance Materials
Description Usage
Polishing Cloth
Wax-TreatedInterior and exterior
polishing cloth.
Tar and Road Oil
RemoverRemoves tar, road oil and
asphalt.
Chrome Cleaner and
PolishUse on chrome or
stainless steel.
White Sidewall Tire
CleanerRemoves soil and black
marks from whitewalls.
Vinyl Cleaner Cleans vinyl.
Glass CleanerRemoves dirt, grime,
smoke and ngerprints.
Chrome and Wire Wheel
CleanerRemoves dirt and grime
from chrome wheels and
wire wheel covers.
Finish EnhancerRemoves dust,
ngerprints, and surface
contaminants. Spray on
wipe off.
Description Usage
Swirl Remover PolishRemoves swirl marks, ne
scratches and other light
surface contamination.
Cleaner WaxRemoves light scratches
and protects nish.
Foaming Tire Shine
Low GlossCleans, shines and
protects in one easy step,
no wiping necessary.
Wash Wax ConcentrateMedium foaming
shampoo. Cleans and
lightly waxes.
Biodegradable and
phosphate free.
Spot LifterQuickly and easily
removes spots and stains
from carpets, vinyl and
cloth upholstery.
Odor EliminatorOdorless spray odor
eliminator used on fabrics,
vinyl, leather and carpet.
5-90

Fuses and Circuit Breakers
The wiring circuits in your vehicle are protected from
short circuits by a combination of fuses, circuit breakers
and fusible thermal links. This greatly reduces the
chance of res caused by electrical problems.
Look at the silver-colored band inside the fuse. If the
band is broken or melted, replace the fuse. Be sure you
replace a bad fuse with a new one of the identical
size and rating.
Spare fuses and a fuse puller are located in the
underhood fuse block. You can remove fuses with the
fuse puller. Remember to replace any of the spare fuses
you use, so you will have some if you ever need them
again.
If you ever have a problem on the road and do not have
a spare fuse, you can borrow one that has the same
amperage. Just pick some feature of your vehicle
that you can get along without – like the radio or
cigarette lighter – and use its fuse, if it is the correct
amperage. Replace it as soon as you can.
There are two fuse blocks in your vehicle: one is inside
the vehicle and one is in the engine compartment.
Instrument Panel Fuse Block
The fuse block is located on the lower portion of the
instrument panel on the driver’s side.
5-93

Fuse/Circuit
BreakerUsage
1Stop/Turn/Hazard Lamps, Center
High-Mounted Stop Lamp, Anti-Lock
Brakes
2Radio Accessory, Rear Seat Audio
Controls
3Courtesy Lamps, Glove Box Lamp,
Dome Reading Lamps, Vanity Mirror
Lamps, Courtesy Lamps
Fuse/Circuit
BreakerUsage
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, Tailamps,
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
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
5-94

Fuse/Circuit
BreakerUsage
UPFITTER-
BATTUptter Battery Power Stud, Trailer
Wiring Harness
UPFITTER-
ACCYUptter Accessory Relay
SPARE Spare
SPARE Spare
SPARE Spare
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
ENG-IOxygen Sensors, Camshaft Position
Sensor, Mass Air Flow Sensor,
Evaporative Emission Canister Vent
SolenoidFuse/Circuit
BreakerUsage
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 Used
BLANK Not Used
LIGHTINGCourtesy Fuse, Power Adjust
Mirrors Fuse, Truck Body Control
Battery Fuse
5-97

Fuse/Circuit
BreakerUsage
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
RAP Radio Accessory, Power Windows
HTD MIR/RR
DEFOGRear Window Defogger,Climate
Control HeadRelays Usage
A/C RELAY Rear/Heat and Air Conditioning
UPFITTER-
ACCY RELAYUptter Accessory
STARTER
ENABLE
RELAYStarter
A/C ENABLE
RELAYAir Conditioning
HEAD LAMPS
RELAYHeadlamps
FUEL PUMP
RELAYFuel Pump
Feed Usage
AUX B Uptter Battery Feed
AUX A Uptter Accessory Feed
5-98

Part B: Owner Checks and Services
Listed in this part are owner checks and services
which should be performed at the intervals specied to
help ensure the safety, dependability and emission
control performance of your vehicle.
Be sure any necessary repairs are completed at once.
Whenever any uids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
in Part D.
At Each Fuel Fill
It is important for you or a service station attendant to
perform these underhood checks at each fuel ll.
Engine Oil Level Check
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil on page 5-13for further
details.
Engine Coolant Level Check
Check the engine coolant level and add DEX-COOL®
coolant mixture if necessary. SeeEngine Coolant
on page 5-25for further details.
Windshield Washer Fluid Level Check
Check the windshield washer uid level in the windshield
washer tank and add the proper uid if necessary.
SeeWindshield Washer Fluid on page 5-36for further
details.
At Least Once a Month
Tire Ination Check
Visually inspect your tires and make sure tires are
inated to the correct pressures. Do not forget to check
your spare tire. SeeTires on page 5-55for further
details.
At Least Twice a Year
Restraint System Check
Make sure the safety belt reminder light and all your
belts, buckles, latch plates, retractors and anchorages
are working properly. Look for any other loose or
damaged safety belt system parts. If you see anything
that might keep a safety belt system from doing its
job, have it repaired. Have any torn or frayed safety belts
replaced.
6-24

A
Accessory Power Outlets.................................3-18
Adding Equipment to Your Airbag-Equipped
Vehicle.......................................................1-67
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment............................5-92
Air Cleaner/Filter, Engine.................................5-21
Air Conditioning..............................................3-19
Airbag
Readiness Light..........................................3-27
Airbag Sensing and Diagnostic Module (SDM)...... 7-9
Airbag System................................................1-60
Adding Equipment to Your Airbag-Equipped
Vehicle...................................................1-67
How Does an Airbag Restrain?......................1-64
Servicing Your Airbag-Equipped Vehicle..........1-66
What Makes an Airbag Inate?......................1-64
What Will You See After an Airbag Inates?....1-65
When Should an Airbag Inate?....................1-63
Where Are the Airbags?...............................1-62
All-Wheel Drive...............................................5-45
All-Wheel Drive (AWD) System.........................2-23
All-Wheel-Drive Service Light............................3-35
AM-FM Radio.................................................3-41
Antenna, Fixed Mast.......................................3-51
Anti-Lock Brake System (ABS)........................... 4-6Anti-Lock Brake, System Warning Light..............3-30
Appearance Care............................................5-82
Aluminum Wheels........................................5-88
Care of Safety Belts....................................5-86
Chemical Paint Spotting...............................5-89
Cleaning Exterior Lamps/Lenses....................5-86
Cleaning the Inside of Your Vehicle................5-83
Fabric/Carpet..............................................5-84
Finish Care.................................................5-87
Finish Damage............................................5-89
Instrument Panel, Vinyl, and Other Plastic
Surfaces.................................................5-85
Leather......................................................5-85
Sheet Metal Damage...................................5-89
Tires..........................................................5-88
Underbody Maintenance...............................5-89
Vehicle Care/Appearance Materials................5-90
Washing Your Vehicle...................................5-86
Weatherstrips..............................................5-86
Windshield and Wiper Blades........................5-87
Ashtrays........................................................3-18
Audio System(s).............................................3-40
AM-FM Radio.............................................3-41
Care of Your CD Player...............................3-51
Care of Your CDs........................................3-51
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