Service
Fuel
Checking Things Under the Hood
All-Wheel Drive
Rear Axle
Front Axle
Bulb Replacement
Windshield Wiper Blade Replacement
Tires
Appearance Care
Vehicle Identification
Electrical System
Capacities and Specifications
Normal Maintenance Replacement Parts
Maintenance Schedule
Maintenance Schedule
Customer Assistance and Information
Customer Assistance and Information
Reporting Safety Defects
A French language copy of this manual can be obtained
from your dealer or from:
Helm, Incorporated
P.O. Box 07130
Detroit, MI 48207
GENERAL MOTORS, GM, the GM Emblem,
CHEVROLET, the CHEVROLET Emblem, and the
name ASTRO are registered trademarks of General
Motors Corporation.
This manual includes the latest information at the time
it was printed. We reserve the right to make changes
after that time without further notice. For vehicles
first sold in Canada, substitute the name “General
Motors of Canada Limited” for Chevrolet Motor Division
whenever it appears in this manual.
Keep this manual in the vehicle, so it will be there if
it is needed while you are on the road. If the vehicle is
sold, leave this manual in the vehicle.
Litho in U.S.A.
Part No. 05ASTRO A First Edition
ii
How to Use This Manual
Many people read the owner manual from beginning to
end when they first receive their new vehicle. If this
is done, it can help you learn about the features
and controls for the vehicle. Pictures and words work
together in the owner manual to explain things.
Index
A good place to quickly locate information about the
vehicle is the Index in the back of the manual. It is
an alphabetical list of what is in the manual and
the page number where it can be found.
2004 General Motors Corporation. All Rights Reserved.
Safety Warnings and Symbols
There are a number of safety cautions in this book. We
use a box and the word CAUTION to tell about things
that could hurt you if you were to ignore the warning.
{CAUTION:
These mean there is something that could hurt
you or other people.
In the caution area, we tell you what the hazard is.
Then we tell you what to do to help avoid or reduce the
hazard. Please read these cautions. If you do not,
you or others could be hurt.
You will also find a circle
with a slash through it in
this book. This safety
symbol means “Do Not,”
“Do Not do this” or
“Do Not let this happen.”
iii
Vehicle Damage Warnings
Vehicle Symbols
Also, in this manual you will find these notices:
Notice: These mean there is something that could
damage your vehicle.
A notice tells about something that can damage the
vehicle. Many times, this damage would not be covered
by your vehicle’s warranty, and it could be costly. But
the notice will tell what to do to help avoid the damage.
When you read other manuals, you might see CAUTION
and NOTICE warnings in different colors or in different
words.
There are also warning labels on the vehicle. They use
the same words, CAUTION or NOTICE.
iv
The vehicle has components and labels that use
symbols instead of text. Symbols are shown along with
the text describing the operation or information
relating to a specific component, control, message,
gage, or indicator.
If you need help figuring out a specific name of a
component, gage, or indicator, reference the
following topics:
• Seats and Restraint Systems in Section 1
• Features and Controls in Section 2
• Instrument Panel Overview in Section 3
• Climate Controls in Section 3
• Warning Lights, Gages, and Indicators in Section 3
• Audio System(s) in Section 3
• Engine Compartment Overview in Section 5
These are some examples of symbols that may be found on the vehicle:
v
✍ NOTES
vi
Section 1Seats and Restraint Systems
Front Seats ......................................................1-3
Restraint System Check ..................................1-70
Checking Your Restraint Systems ...................1-70
Replacing Restraint System
Parts After a Crash ...................................1-71
Front Seats
Manual Seats
{CAUTION:
1. Move the seat adjustment lever toward the outboard
side of the seat to unlock it.
2. Slide the seat to where you want it.
3. Release the lever and try to move the seat with
your body, to make sure that the seat is locked
into place
You can lose control of the vehicle if you try to
adjust a manual driver’s seat while the vehicle
is moving. The sudden movement could startle
and confuse you, or make you push a pedal
when you do not want to. Adjust the driver’s
seat only when the vehicle is not moving.
If your vehicle has manual
seats, they can be
adjusted forward or
rearward using the lever
located under the front
of the seat(s).
Power Seat
If your vehicle has this feature, there will be controls
located on the inboard side of the driver’s seat.
To raise or lower the front of the seat cushion, raise or
lower the lever located toward the front of the vehicle.
To raise or lower the rear of the seat cushion, raise
or lower the lever located toward the rear of the vehicle.
To move the entire seat backwards, forward, or up or
down, move the center knob.
1-3
Manual Lumbar
If your vehicle has this feature, there will be a knob
located on the inboard side of the driver’s and
passenger’s bucket seats.
Turn the knob toward the front of the vehicle to increase
lumbar support. Turn the knob toward the rear of the
vehicle to decrease lumbar support.
Reclining Seatbacks
There is a lever located
on the inboard side of
the seat to adjust
the seatback.
1. Lift the lever and lean back until the seatback
is at the desired position.
2. Release the lever to lock the seatback where you
want it.
To return the seatback to an upright position, pull up on
the lever and lean forward.
1-4
But do not have a seatback reclined if your vehicle
is moving.
{CAUTION:
Sitting in a reclined position when your vehicle
is in motion can be dangerous. Even if you
buckle up, your safety belts can not do their
job when you are reclined like this.
The shoulder belt can not do its job because it
will not be against your body. Instead, it will be
in front of you. In a crash you could go into it,
receiving neck or other injuries.
The lap belt can not do its job either. In a
crash the belt could go up over your abdomen.
The belt forces would be there, not at your
pelvic bones. This could cause serious internal
injuries.
For proper protection when the vehicle is in
motion, have the seatback upright. Then sit
well back in the seat and wear your safety
belt properly.
1-5
Head Restraints
Adjust your head restraint so that the top of the
restraint is closest to the top of your head. This position
reduces the chance of a neck injury in a crash.
Seatback Latches
The seatback lever is
located on the right rear of
your seat. If your vehicle
has the non-touring
bench seatback, pull up on
the latch release lever
while pulling the seatback
toward the rear of the
vehicle.
After the latch has been released, push the seatback
toward the front of the vehicle until it locks into place.
To raise the seatback, unlock the seatback latch
by pushing up on the lever while pushing down on the
upper edge of the seatback. Move the seatback into the
upright position. Make sure the seatback is locked
when it is back in the upright position.
1-6
{CAUTION:
If the seatback is not locked, it could move
forward in a sudden stop or crash. That could
cause injury to the person sitting there. Always
press rearward on the seatback to be sure it is
locked.
Rear Seats
Rear Seat Operation
Removing the Rear Seats
To remove the rear seats, do the following:
1. If you are removing
the center seat,
remove the right
lap-shoulder belt.
To do this, press
the tip of a key into
the release hole of the
safety belt attachment
while pulling up on
the safety belt.
1-7
2. If you have a safety
belt guide on your
seat, pull the safety
belt all the way
out through the guide.
3. To store the safety belt while the second row bench
seat is removed, pull the belt out and put both
buckles in the passenger’s side rear storage bin.
Route the belt out of the forward edge of the storage
bin. Close the cover to retain the belt.
4. Pull up on the seatback latch on the right rear of
the seat. Push the seatback down until it locks
into place.
5. Lift up on the left and the right seat release levers
at the same time. The latches are near the floor on
the rear legs of the seat.
1-8
6. Lift up on the rear of the seat to remove the seat
assembly from the rear latch pins. Then, pull the
whole seat back to remove the seat from the
front retainers and then lift the seat out of the
vehicle.
Replacing the Rear Seats
1. Lower the seat into position. Make sure the front
retainers are hooked onto the anchor pins.
1-9
2. Pull the seat down to latch the rear retainers.
Make sure the seat is locked in by pulling up
and down on the seat.
{CAUTION:
A seat that is not locked into place properly
can move around in a collision or sudden stop.
People in the vehicle could be injured. Be sure
to lock the seat into place properly when
installing it.
3. To raise the seatback, do the following:
3.1. Unlock the seatback latch by pulling up on
the latch release lever at the right rear of the
seat, while pushing down on the upper
edge of the seatback.
3.2. Move the seatback into the upright position.
Make sure the seatback is locked when it is
back in the upright position.
If you are replacing the center seat, connect the right
lap-shoulder belt to the attachment on the seat cushion.
If you have a safety belt guide on your seat, pull the
belt through the guide before reattaching the
lap-shoulder belt to the side of the seat. The release
hole should be facing outward.
1-10
If you installed the safety belt with the release hole facing
inward (toward the seat), slide the plastic cover up so you
can see the buckle. Disconnect the seat belt. Slide the
cover back down and reinstall the belt correctly.
{CAUTION:
A safety belt that is improperly routed, not
properly attached, or twisted will not provide
the protection needed in a crash. The person
wearing the belt could be seriously injured.
After raising the rear seatback, always check
to be sure that the safety belts are properly
routed and attached, and are not twisted.
Bench Seat
Each bench seat can carry up to three passengers.
They can also be removed to increase storage space.
See “Removing the Rear Seats” following.
Only the third row bench seat can be adjusted forward
or rearward.
Move the seat adjustment
lever located at the front
of the seat toward the
passenger’s side to unlock
it. Slide the seat to
where you want it and
release the lever. Try to
move the seat with
your body, to make sure
the seat is locked into
place.
The center bench seat has a pivoting right armrest.
The optional bench seats come with moveable armrests,
individual reclining seatbacks, adjustable headrests
and a fold-down center armrest console.
1-11
To adjust your seatback, pull up on the lever located on
the outboard sides of the seat cushion.
Entering the Third Row Seat
The second row seat has
a seatback lever that
makes it easier to enter
the third row seat, if
equipped. The lever is
located on the right rear
of the second row seat.
1. Pull up on the seatback release lever while pulling
the seatback toward the rear of the vehicle.
2. After the lever has been released, push the seatback
toward the front of the vehicle until it locks into place.
1-12
To raise the seatback, do the following
1. Unlock the seatback lever by pulling up on the lever
while pushing down on the upper edge of the
seatback.
2. Move the seatback into the upright position.
3. Make sure the seatback is locked when it is back
in the upright position.
{CAUTION:
If the seatback is not locked, it could move
forward in a sudden stop or crash. That could
cause injury to the person sitting there. Always
press rearward on the seatback to be sure it
is locked.
Removing the Rear Seats
To remove the rear bench seats, do the following:
1. If you are removing
the center seat,
remove the right
lap-shoulder belt.
To do this, press
the tip of a key into
the release hole of the
safety belt attachment
while pulling up on
the safety belt.
1-13
2. If you have a safety
belt guide on your
seat, pull the safety belt
all the way out
through the guide.
3. To store the safety belt while the second row bench
seat is removed, pull the belt out and put both
buckles in the passenger’s side rear storage bin.
Route the belt out of the forward edge of the storage
bin. Close the cover to retain the belt.
4. Pull up on the seatback latch on the right rear of
the seat. Push the seatback down until it locks
into place.
5. Lift up on the left and the right seat release levers
at the same time. The latches are near the floor on
the rear legs of the seat.
1-14
6. Lift up on the rear of the seat to remove the seat
assembly from the rear latch pins. Then, pull the
whole seat back to remove the seat from the
front retainers and then lift the seat out of the
vehicle.
Reinstalling the Rear Seats
1. Lower the seat into position. Make sure the front
retainers are hooked onto the anchor pins.
1-15
2. Pull the seat down to latch the rear retainers.
Make sure the seat is locked in by pulling up
and down on the seat.
{CAUTION:
A seat that is not locked into place properly
can move around in a collision or sudden stop.
People in the vehicle could be injured. Be sure
to lock the seat into place properly when
installing it.
3. To raise the seatback, do the following:
3.1. Unlock the seatback latch by pulling up on
the latch release lever at the right rear of the
seat, while pushing down on the upper
edge of the seatback.
3.2. Move the seatback into the upright position.
Make sure the seatback is locked when it is
back in the upright position.
4. If you are replacing the center seat, connect the
right lap-shoulder belt to the attachment on the
seat cushion. If you have a safety belt guide on
your seat, pull the belt through the guide before
reattaching the lap-shoulder belt to the side of the
seat. The release hole should be facing outward.
1-16
5. If you installed the safety belt with the release hole
facing inward (toward the seat), slide the plastic
cover up so you can see the buckle. Disconnect the
seat belt. Slide the cover back down and reinstall
the belt correctly.
{CAUTION:
A safety belt that is improperly routed, not
properly attached, or twisted will not provide
the protection needed in a crash. The person
wearing the belt could be seriously injured.
After raising the rear seatback, always check
to be sure that the safety belts are properly
routed and attached, and are not twisted.
Bucket Seats
Your vehicle may have rear bucket seats with an
adjustment release bar located under the front of the
seats. These seats can be adjusted forward or rearward
with the release bar. Pull the release bar up to release
the seat bottom. Slide the seat where you want it
and then let go of the release bar. Then try to move the
seat with your body to make sure the seat is locked
into place.
1-17
Safety Belts
Safety Belts: They Are for Everyone
This part of the manual tells you how to use safety
belts properly. It also tells you some things you should
not do with safety belts.
{CAUTION:
Do not let anyone ride where he or she can not
wear a safety belt properly. If you are in a
crash and you are not wearing a safety belt,
your injuries can be much worse. You can hit
things inside the vehicle or be ejected from it.
You can be seriously injured or killed. In the
same crash, you might not be, if you are
buckled up. Always fasten your safety belt,
and check that your passengers’ belts are
fastened properly too.
{CAUTION:
It is extremely dangerous to ride in a cargo
area, inside or outside of a vehicle. In a
collision, people riding in these areas are more
likely to be seriously injured or killed. Do not
allow people to ride in any area of your vehicle
that is not equipped with seats and safety
belts. Be sure everyone in your vehicle is in a
seat and using a safety belt properly.
Your vehicle has a light
that comes on as a
reminder to buckle up.
See Safety Belt ReminderLight on page 3-25.
In most states and in all Canadian provinces, the law
says to wear safety belts. Here is why: They work.
You never know if you will be in a crash. If you do have
a crash, you do not know if it will be a bad one.
1-18
A few crashes are mild, and some crashes can be so
serious that even buckled up, a person would not
survive. But most crashes are in between. In many of
them, people who buckle up can survive and sometimes
walk away. Without belts they could have been badly
hurt or killed.
After more than 30 years of safety belts in vehicles,
the facts are clear. In most crashes buckling up
does matter...a lot!
Why Safety Belts Work
When you ride in or on anything, you go as fast as
it goes.
Take the simplest vehicle. Suppose it is just a seat
on wheels.
1-19
Put someone on it.Get it up to speed. Then stop the vehicle. The rider
1-20
does not stop.
The person keeps going until stopped by something.
In a real vehicle, it could be the windshield...
or the instrument panel...
1-21
Questions and Answers About
Safety Belts
Q: Will I be trapped in the vehicle after an accident
if I am wearing a safety belt?
A: You could be — whether you are wearing a safety
belt or not. But you can unbuckle a safety belt,
even if you are upside down. And your chance of
being conscious during and after an accident,
so you can unbuckle and get out, is much greater
if you are belted.
Q: If my vehicle has airbags, why should I have to
wear safety belts?
or the safety belts!
With safety belts, you slow down as the vehicle does.
You get more time to stop. You stop over more distance,
and your strongest bones take the forces. That is why
safety belts make such good sense.
1-22
A: Airbags are in many vehicles today and will be in
most of them in the future. But they are
supplemental systems only; so they work with
safety belts — not instead of them. Every airbag
system ever offered for sale has required the use of
safety belts. Even if you are in a vehicle that has
airbags, you still have to buckle up to get the most
protection. That is true not only in frontal collisions,
but especially in side and other collisions.
Q: If I am a good driver, and I never drive far from
home, why should I wear safety belts?
A: You may be an excellent driver, but if you are in an
accident — even one that is not your fault — you
and your passengers can be hurt. Being a good
driver does not protect you from things beyond your
control, such as bad drivers.
Most accidents occur within 25 miles (40 km)
of home. And the greatest number of serious
injuries and deaths occur at speeds of less than
40 mph (65 km/h).
Safety belts are for everyone.
How to Wear Safety Belts Properly
This part is only for people of adult size.
Be aware that there are special things to know about
safety belts and children. And there are different
rules for smaller children and babies. If a child will be
riding in your vehicle, see Older Children on page 1-38
or Infants and Young Children on page 1-40. Follow
those rules for everyone’s protection.
First, you will want to know which restraint systems your
vehicle has.
We will start with the driver position.
Driver Position
Lap-Shoulder Belt
The driver has a lap-shoulder belt. Here is how to
wear it properly.
1. Close and lock the door.
2. Adjust the seat so you can sit up straight.
To see how, see “Seats” in the Index.
1-23
3. Pick up the latch plate and pull the belt across you.
Do not let it get twisted.
4. Push the latch plate into the buckle until it clicks.
Pull up on the latch plate to make sure it is secure.
If the belt is not long enough, see Safety BeltExtender on page 1-37.
Make sure the release button on the buckle is
positioned so you would be able to unbuckle the
safety belt quickly if you ever had to.
1-24
The lap part of the belt should be worn low and snug on
the hips, just touching the thighs. In a crash, this
applies force to the strong pelvic bones. And you would
be less likely to slide under the lap belt. If you slid
under it, the belt would apply force at your abdomen.
This could cause serious or even fatal injuries. The
shoulder belt should go over the shoulder and across
the chest. These parts of the body are best able to take
belt restraining forces.
The safety belt locks if there is a sudden stop or crash,
or if you pull the belt very quickly out of the retractor.
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