service schedule CHEVROLET ASTRO CARGO VAN 2005 2.G Owners Manual

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-2
Rear Seats
............................................... 1-6
Safety Belts
.............................................1-14
Child Restraints
.......................................1-33
Airbag System
.........................................1-60
Restraint System Check
............................1-67
Features and Controls..................................... 2-1
Keys
........................................................ 2-2
Doors and Locks
....................................... 2-6
Windows
.................................................2-14
Theft-Deterrent Systems
............................2-15
Starting and Operating Your Vehicle
...........2-16
Mirrors
....................................................2-28
HomeLink
®Wireless Control System
...........2-29
Storage Areas
.........................................2-33
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-19
Warning Lights, Gages, and Indicators
........3-24
Driver Information Center (DIC)
..................3-38
Audio System(s)
.......................................3-40Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-34
Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under the Hood
...............5-10
All-Wheel Drive
........................................5-45
Rear Axle
...............................................5-46
Front Axle
...............................................5-47
Bulb Replacement
....................................5-48
Windshield Wiper Blade Replacement
.........5-54
Tires
......................................................5-55
Appearance Care
.....................................5-82
Vehicle Identication
.................................5-91
Electrical System
......................................5-92
Capacities and Specications
.....................5-99
Normal Maintenance Replacement Parts
....5-101
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-10
Index................................................................ 1
2005 Chevrolet Astro Owner ManualM

Oil Pressure Gage
The oil pressure gage
shows the engine oil
pressure in psi (pounds
per square inch) when the
engine is running.
Canadian vehicles indicate pressure in kPa (kilopascals).
Oil pressure may vary with engine speed, outside
temperature and oil viscosity, but readings above the low
pressure zone indicate the normal operating range.A reading in the low pressure zone may be caused by a
dangerously low oil level or other problems causing
low oil pressure.
{CAUTION:
Do not keep driving if the oil pressure is low. If
you do, your engine can become so hot that it
catches re. You or others could be burned.
Check your oil as soon as possible and have
your vehicle serviced.
Notice:Lack of proper engine oil maintenance may
damage the engine. The repairs would not be
covered by your warranty. Always follow the
maintenance schedule in this manual for changing
engine oil.
3-34

Maintenance When Trailer Towing
Your vehicle will need service more often when you’re
pulling a trailer. See the Maintenance Schedule for more
on this. Things that are especially important in trailer
operation are automatic transmission uid (don’t overll),
engine oil, axle lubricant, belt, cooling system and brake
system. Each of these is covered in this manual, and the
Index will help you nd them quickly. If you’re trailering,
it’s a good idea to review these sections before you start
your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
Trailer Wiring Harness
If you have the optional trailering package, your vehicle
will have an eight-wire harness, including the center
high-mounted stoplamp battery feed wire. The harness is
stored on the passenger’s side of the vehicle near the
rear wheel well. This harness has a 30 amp battery feed
wire and no connector, and should be wired by a qualied
electrical technician. After choosing an aftermarket trailer
mating connector pair, have the technician attach one
connector to the eight-wire trailer harness and the other
connector to the wiring harness on the trailer.
Be sure the wiring harness on the trailer is taped or
strapped to the trailer’s frame rail and leave it loose
enough so the wiring doesn’t bend or break, but not so
loose that it drags on the ground. The eight-wire harnessmust be routed out of your vehicle between the rear door
and the oor, with enough of the harness left on both
sides so that the trailer or the body won’t pull it.
If you do not have the optional trailering package, your
vehicle will still have a trailering harness. The harness
is located near the passenger’s side rear wheel
well. It consists of six wires that may be used by
after-market trailer hitch installers.
The technician can use the following color code chart
when connecting the wiring harness to your trailer.
Brown: Rear lamps
Yellow: Left stoplamp and turn signal
Dark Green: Right stoplamp and turn signal
White (Heavy Gage): Ground
Light Green: Back-up lamps
White (Light Gage): Center High-Mounted Stoplamp
Blue: Auxiliary circuit (eight-wire harness only)
Orange: Fused auxiliary (eight-wire harness only)
Store the harness in its original place. Wrap the
harness together and tie it neatly so it won’t
be damaged.
4-44

If you are in an area of extreme cold, where the
temperature falls below−20°F (−29°C), it is
recommended that you use either an SAE 5W-30
synthetic oil or an SAE 0W-30 oil. Both will provide
easier cold starting and better protection for your engine
at extremely low temperatures.
Engine Oil Additives
Do not add anything to your oil. The recommended oils
with the starburst symbol that meet GM Standard
GM6094M are all you will need for good performance
and engine protection.
When to Change Engine Oil
If any one of these are true for you, use the short
trip/city maintenance schedule:
Most trips are less than 5 miles (8 km). This is
particularly important when outside temperatures
are below freezing.
Most trips include extensive idling, such as frequent
driving in stop-and-go traffic.
You frequently tow a trailer or use a carrier on top
of your vehicle.
The vehicle is used for delivery service, police, taxi,
or other commercial application.
Driving under these conditions causes engine oil to
break down sooner. If any one of these is true for your
vehicle, then you need to change your oil and lter
every 3,000 miles (5 000 km) or 3 months — whichever
occurs rst.
If none of them is true, use the long trip/highway
maintenance schedule. Change the oil and lter every
7,500 miles (12 500 km) or 12 months — whichever
occurs rst. Driving a vehicle with a fully warmed engine
under highway conditions will cause engine oil to
break down slower.
5-16

Automatic Transmission Fluid
When to Check and Change
A good time to check your automatic transmission uid
level is when the engine oil is changed.
Change both the uid and lter every 15,000 miles
(25,000 km) if the vehicle is mainly driven under one or
more of these conditions:
In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
In hilly or mountainous terrain.
When doing frequent trailer towing.
Uses such as found in taxi, police or delivery
service.
If you do not use your vehicle under any of these
conditions, change the uid and lter every
50,000 miles (83 000 km).
SeePart A: Scheduled Maintenance Services on
page 6-4.
How to Check
Because this operation can be a little difficult, you may
choose to have this done at the dealership service
department.
If you do it yourself, be sure to follow all the instructions
here, or you could get a false reading on the dipstick.
Notice:Too much or too little uid can damage
your transmission. Too much can mean that some
of the uid could come out and fall on hot engine
part or exhaust system parts, starting a re.
Too little uid could cause the transmission to
overheat. Be sure to get an accurate reading if you
check your transmission uid.
Wait at least 30 minutes before checking the
transmission uid level if you have been driving:
When outside temperatures are above 90°F (32°C).
At high speed for quite a while.
In heavy traffic — especially in hot weather.
While pulling a trailer.
To get the right reading, the uid should be at normal
operating temperature, which is 180°F to 200°F (82°C
to 93°C).
5-23

Rear Axle
When to Check Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant. SeePart A: Scheduled
Maintenance Services on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.If the level is below the bottom of the ller plug hole,
you’ll need to add some lubricant. Add enough lubricant
to raise the level to the bottom of the ller plug hole.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeePart D: Recommended
Fluids and Lubricants on page 6-29.
5-46

Front Axle
When to Check and Change Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant and when to change it. See
Part A: Scheduled Maintenance Services on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.
If the level is below the
bottom of the ller plug
hole, you may need to add
some lubricant.When the differential is cold, add enough lubricant
to raise the level to 1/2 inch (12 mm) below the ller
plug hole.
When the differential is at operating temperature
(warm), add enough lubricant to raise the level to the
bottom of the ller plug hole.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeePart D: Recommended
Fluids and Lubricants on page 6-29.
5-47

Tire Inspection and Rotation
Tires should be rotated every 5,000 to 8,000 miles
(8 000 to 13 000 km).
Any time you notice unusual wear, rotate your tires as
soon as possible and check wheel alignment. Also
check for damaged tires or wheels. SeeWhen It Is Time
for New Tires on page 5-64andWheel Replacement
on page 5-67for more information.
Make sure the spare tire is stored securely. Push, pull,
and then try to rotate or turn the tire. If it moves,
use the ratchet/wheel wrench to tighten the cable.
SeeChanging a Flat Tire on page 5-70.
The purpose of regular rotation is to achieve more
uniform wear for all tires on the vehicle. The rst rotation
is the most important. SeePart A: Scheduled
Maintenance Services on page 6-4.When rotating your tires, always use the correct rotation
patterns shown here.
Do not include the compact spare tire in your tire rotation.
5-63

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
How This Section is Organized.........................6-3
Part A: Scheduled Maintenance Services...........6-4
Using the Maintenance Schedule......................6-4
Selecting the Right Schedule...........................6-5
Short Trip/City Scheduled Maintenance..............6-6
Long Trip/Highway Scheduled Maintenance......6-16
Part B: Owner Checks and Services................6-24
At Each Fuel Fill..........................................6-24
At Least Once a Month.................................6-24
At Least Twice a Year...................................6-24At Least Once a Year...................................6-25
Part C: Periodic Maintenance Inspections.........6-28
Steering, Suspension and Front Drive Axle
Boot and Seal Inspection............................6-28
Exhaust System Inspection............................6-28
Fuel System Inspection..................................6-28
Engine Cooling System Inspection...................6-28
Throttle System Inspection.............................6-29
Transfer Case and Front Axle (All-Wheel
Drive) Inspection.......................................6-29
Brake System Inspection................................6-29
Part D: Recommended Fluids and Lubricants. . . .6-29
Part E: Maintenance Record...........................6-31
Section 6 Maintenance Schedule
6-1

How This Section is Organized
This maintenance schedule is divided into ve parts:
“Part A: Scheduled Maintenance Services”explains
what to have done and how often. Some of these
services can be complex, so unless you are technically
qualied and have the necessary equipment, you should
let your GM dealer’s service department do these jobs.
Your GM dealer has GM-trained and supported
service people that will perform the work using genuine
GM parts.
{CAUTION:
Performing maintenance work on a vehicle can
be dangerous. In trying to do some jobs, you
can be seriously injured. Do your own
maintenance work only if you have the
required know-how and the proper tools and
equipment for the job. If you have any doubt,
have a qualied technician do the work.
If you want to purchase service information, seeService
Publications Ordering Information on page 7-11.“Part B: Owner Checks and Services”tells you what
should be checked and when. It also explains what
you can easily do to help keep your vehicle in good
condition.
“Part C: Periodic Maintenance Inspections”explains
important inspections that your dealer’s service
department can perform for you.
“Part D: Recommended Fluids and Lubricants”lists
some recommended products necessary to help
keep your vehicle properly maintained. These products,
or their equivalents, should be used whether you do
the work yourself or have it done.
“Part E: Maintenance Record”is a place for you to
record and keep track of the maintenance performed on
your vehicle. Keep your maintenance receipts. They
may be needed to qualify your vehicle for warranty
repairs.
6-3