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Maintenance Information Chevrolet Astro I

Procedures 13 illustrations ~1933 words

MODEL IDENTIFICATION

Note. For scheduled maintenance intervals and the related fluid capacities, fluid specifications and labor times for major service intervals, see SCHEDULED SERVICES article in this section. Warranty information and specifications for fluid capacities, lubrication specifications, wheel and tire size, and battery type are covered in this article.

VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN Code ID Explanation. Scheme 1

Scheme 1: VIN Code ID Explanation
Scheme 1: VIN Code ID Explanation

SHORT TRIP/CITY & LONG TRIP/HIGHWAY SERVICE DEFINITIONS

Note. Starting in the 1996 model year, General Motors has renamed their maintenance schedules; One is referred to as the Short-Trip/City and the other is the Long Trip/Highway schedule. These schedule requirements are similar to the familiar Severe Service and Normal schedules and can be used in place of one another.

SEVERE & NORMAL SERVICE DEFINITIONS

Note. Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions

Service is recommended at mileage intervals based on vehicle operation, emission classification, and Gross Vehicle Weight Rating (GVWR, VIN Position 4). Emission classification is identified by engine VIN code (except diesel-powered vehicles). Manufacturer's Schedules identify items to be serviced based on type of operation. Service schedules are based on the following primary operating conditions

Severe Service

  1. Short Trips (4 Miles Or Less)
  2. Freezing Temperatures
  3. Towing Or Heavily Loaded
  4. Severe Dust Conditions
  5. Hot Weather, Stop-And-Go Driving
  6. Extensive Idling Conditions (Taxi Or Delivery Type Service)

Normal Service

  1. No Severe Service Operating Conditions

Scheme 2

Scheme 2: SERVICE POINT LOCATIONS
Scheme 2: SERVICE POINT LOCATIONS

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

SERVICE LABOR TIMES

Note. For 1990 and newer vehicles, labor times are provided, where available, within appropriate SERVICE INTERVAL table in SCHEDULED SERVICES article.

TIRE INFLATION

The tire specification decal is located on rear of the driver's door.

WHEEL TIGHTENING

Tighten all wheels to 100 ft. lbs. (135 N.m).

BATTERY SPECIFICATIONS

CAUTIONWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section.

All models use Group 75 batteries.

SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG) - 1994-96 MODELS

Note. See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT Section.

Modifications or improper maintenance, including incorrect removal and installation of the Supplemental Restraint System (SRS), can adversely affect system performance. DO NOT cover, obstruct or change the steering wheel horn pad in any way, as such action could cause improper function of the system. Use only plain water when cleaning the horn pad. Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system.

WARNINGTo avoid injury from accidental air bag deployment, read and carefully follow all warnings and service precautions. See appropriate AIR BAGS article in ACCESSORIES/SAFETY EQUIPMENT.

Modification to the air bag system component or wiring can adversely affect system performance and possibly cause injury.

CAUTIONThe Diagnostic Energy Reserve Module (DERM) can maintain enough voltage to cause a deployment of the inflator module for up to 10 minutes after the ignition switch is turned off and the battery is disconnected. Many of the service procedures require disconnection of the inflator module to avoid an accidental deployment.
CAUTIONDisconnect negative battery cable before servicing any air bag system, steering column or passenger side dash component. After any repair, turn ignition key to the ON position from passenger's side of vehicle in case of accidental air bag inflation

AIR CONDITIONING SERVICING (1994-96)

CAUTIONAvoid breathing R-134a refrigerant and PAG lubricant vapors, exposure may irritate eyes, nose and throat. To remove R-134a from system use R-134a recycling equipment that meets SAE J2210 specifications. If accidental system discharge occurs, ventilate work area before resuming service.
WARNINGR-134a service equipment or vehicle A/C systems SHOULD NOT be pressure tested or leak tested with compressed air. Some mixtures of air/R134a have shown to be combustible at elevated pressures. These mixtures are dangerous and may cause fire and/or explosions. See AIR CONDITIONING SERVICE article in GENERAL INFORMATION section.

ANTI-LOCK BRAKE SYSTEM (If Equipped)

The anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions

  1. DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES Section.
  2. DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
  3. Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

REPLACING BLOWN FUSES

Before replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BATTERY WARNING

WARNINGWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION section.

BRAKE PAD WEAR INDICATOR

Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

To prevent catalytic converter overheating, DO NOT allow engine to idle for more than 20 minutes.

COOLANT (DEX-COOL 1995 MODELS)

CAUTIONSome 1995 build-out models may have DEX-COOL engine coolant installed at the factory. DEX-COOL coolant is orange in color and should not be mixed with regular ethylene-glycol coolant. To avoid possible damage to vehicle cooling system, visually check engine coolant color before adding and/or changing engine coolant. Vehicle should have an identification label placed under the hood stating what type coolant is installed.

COOLANT (PROPYLENE-GLYCOL FORMULATIONS)

To avoid possible damage to vehicle use only ethylene-glycol based coolants with a mixture ratio from 44-68% anti-freeze. DO NOT use 100% anti-freeze as it will cause the formation of cooling system deposits. This results in coolant temperatures of over 300° F (149°C) which can melt plastics. 100% anti-freeze has a freeze point of only -8° F (-22°C).

CAUTIONPropylene-Glycol Mixtures has a smaller temperature range than Ethylene-Glycol. The temperature range (freeze-boil) of a 50/50 Anti-Freeze/Water Mix is as follows: Propylene-Glycol -26° F (-32°C) - 257° F (125°C) Ethylene-Glycol -35° F (-37°C) - 263° F (128°C)
CAUTIONPropylene-Glycol/Ethylene-Glycol Mixtures can cause the destabilization of various corrosion inhibitors. Also Propylene-Glycol/Ethylene-Glycol has a different specific gravity than Ethylene-Glycol coolant, which will result in inaccurate freeze point calculations.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

CAUTIONMany solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not. Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.

FUEL SYSTEM SERVICE

WARNINGRelieve fuel system pressure prior to servicing any fuel system component (fuel injection models).

HALOGEN BULBS

WARNINGHalogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

RADIATOR FAN

WARNINGKeep hands away from radiator fan.

WARRANTY INFORMATION

CAUTIONDue to the different warranties offered in various regions and the variety of after-market extended warranties available, please refer to the warranty package that came with the vehicle.

Scheme 7

Scheme 7: FUSE PANEL IDENTIFICATION (1985)
Scheme 7: FUSE PANEL IDENTIFICATION (1985)

Fuse & Circuit Breaker Identification

  1. 1 - 10 Amp - Instrument Panel Lights
  2. 2 - 30 Amp Circuit Breaker - Power Accessories
  3. 3 - 30 Amp - Horn/Dome Light
  4. 4 - 20 Amp - Ignition/Gauges
  5. 5 - 25 Amp - Auxiliary Heater
  6. 6 - 20 Amp - Stoplight/Hazard
  7. 7 - 20 Amp - Taillights
  8. 8 - 20 Amp - Turn/Back-Up Lights
  9. 9 - 20 Amp - Heater/A/C
  10. 10 - 10 Amp - Radio
  11. 11 - 10 Amp - ECM B
  12. 12 - 10 Amp - ECM I
  13. 13 - 30 Amp Circuit Breaker - Power Windows
  14. 14 - 25 Amp - Wiper
  15. 15 - 10 Amp - Choke (V6 Only), Brake

Scheme 8

Scheme 8: FUSE PANEL IDENTIFICATION (1986-89)
Scheme 8: FUSE PANEL IDENTIFICATION (1986-89)

Scheme 9

Scheme 9
Scheme 9
  1. 1 - 10 Amp - Instrument Panel Lights
  2. 2 - 30 Amp Circuit Breaker - Power Door Locks
  3. 3 - 30 Amp - Horn Relay, Digital Clock, Cigarette Lighter, Dome Light
  4. 4 - 20 Amp - Instrument Panel Gauges, Brake Switch, Audio Alarm, Headlight Switch and Ashtray Illumination
  5. 5 - 25 Amp - Auxiliary (Rear) Heater (If Equipped)
  6. 6 - 20 Amp - Stoplight/Hazard
  7. 7 - 20 Amp - Headlight Switch, Tail and Parking Lamps
  8. 8 - 20 Amp - Turn/Back-Up Lights
  9. 9 - 20 Amp - Front Heater and A/C
  10. 10 - 10 Amp - Radio
  11. 11 - 10 Amp - ECM B
  12. 12 - 10 Amp - ECM I
  13. 13 - 30 Amp Circuit Breaker - Power Windows
  14. 14 - 25 Amp - Wiper
  15. 15 - 7.5 Amp - Fuel Injector Nozzles (V6 Only)
  16. 16 - 10 Amp - Crank Signal to ECM (V6 Only)
  17. 17 - 10 Amp - Fuel Pump (V6 Only)

Scheme 10

Scheme 10: FUSE PANEL IDENTIFICATION (1990-93)
Scheme 10: FUSE PANEL IDENTIFICATION (1990-93)
  1. 1 - 10 Amp - Instrument Panel Lights
  2. 2 - 30 Amp Circuit Breaker - Power Accessories
  3. 3 - 30 Amp - Horn/Dome Lights, Digital Clock, Cigarette Lighter, Radio Memory, Glove Box Light
  4. 4 - 20 Amp - Ignition/Gauges, Cruise Control, Headlight Switch, Ashtray Light, Brake Switch, Audio Alarm (1993)
  5. 5 - 25 Amp - Auxiliary Heater (If Equipped)
  6. 6 - 20 Amp - Stoplights, Hazard Flasher, Digital Instrument Cluster
  7. 7 - 20 Amp - Tail & Parking Lights, Headlight Switch
  8. 8 - 20 Amp - Turn/Back-Up Lights
  9. 9 - 20 Amp - Heater/A/C
  10. 10 - 10 Amp - Radio
  11. 11 - 10 Amp - ECM B
  12. 12 - 10 Amp - ECM I
  13. 13 - 30 Amp Circuit Breaker - Power Windows
  14. 14 - 25 Amp - Windshield Wiper
  15. 15 - 10 Amp - Daytime Running Lights (Canada Only)
  16. 16 - 15 Amp - ABS Brake, Speedometer (1993)
  17. 17 - 15 Amp - Foglights

Scheme 11

Scheme 11: FUSE PANEL IDENTIFICATION (1994-95)
Scheme 11: FUSE PANEL IDENTIFICATION (1994-95)
  1. 1 - INST LPS 10 Amp (Red) - Instrument Panel Lamps, Radio Dial Lamps, Heater Lamps
  2. 2 - PWR ACC 30 Amp Circuit Breaker - Power Accessories, Power Door Locks, Power Seats
  3. 3 - CIG LTR/DM 20 Amp (Yellow) - Dome Lights, Digital Clock, Cigarette Lighter, Radio Memory, Glove Box Lamp
  4. 4 - GAGES 20 Amp (Yellow) - Instrument Cluster Gauges, Brake Switch, Audio Alarm, Headlight Switch Illumination, Ashtray Illumination, Cruise Control
  5. 5 - AUX HTR A/C 25 Amp (Clear) - Auxiliary Heater-Rear A/C (If Equipped)
  6. 6 - STOP/HAZ 20 Amp (Yellow) - Stop Lamps, Hazard Flasher, Digital Instrument Cluster
  7. 7 - HRN/TL LPS 20 Amp (Yellow) - Tail & Parking Lamps, Headlamp Switch, Horn Relay
  8. 8 - TURN - B/U 20 Amp (Yellow) - Direction Signal Flash, Back-Up Lamps
  9. 9 - HTR A/C 20 Amp (Yellow) - Front Heater & A/C
  10. 10 - RADIO 10 Amp (Red) - Radio
  11. 11 - ECM B 15 Amp (Blue) - ECM B
  12. 12 - ECM 1 10 Amp (Red) - ECM I
  13. 13 - PWR WDO 30 Amp Circuit Breaker - Power Windows
  14. 14 - WIPER 25 Amp (Clear) - Windshield Wiper
  15. 15 - AIR BAG 10 Amp (Red) - Air Bag
  16. 16 - BRAKE 15 Amp (Blue) - ABS Brake, Speedometer
  17. 17 - DRL 10 Amp (Red) - Daytime Running Lights FOG 15 Amp (Blue) - Foglights (If Equipped)

IN-LINE FUSE IDENTIFICATION

  1. Foglight 15 Amp - Foglights (If Equipped W/Foglights & DRL)
  2. Power Mirrors 3 Amp - Power Mirrors (If Equipped)
  3. Trailer 30 Amp - Trailer Package (If Equipped)

Scheme 12

Scheme 12: FUSE PANEL IDENTIFICATION (1996)
Scheme 12: FUSE PANEL IDENTIFICATION (1996)
  1. 1 - Stop, Turn, Hazard Lamps, CHMSL, Chime Module
  2. 2 - No Fuse - Resistor
  3. 3 - Courtesy Lamps, Power Outside Mirrors, Glove Box Lamp, Dome- Reading Lamps, Vanity Mirror Lamps
  4. 4 - DRL Relay, DRL Module, Chime Headlamp Switch, Keyless Entry,- Cluster, Overhead Console
  5. 5 - Not Used
  6. 6 - Cruise Control
  7. 7 - Power Outlets, ALDL, Subwoofer Amplifier
  8. 8 - Not Used
  9. 9 - License Plate Lamp, Taillamps, Parking Lamps, Ashtray Lamp,- Panel Lights, Trailer Taillamps, Front & Rear Sidemarker Lamps, Door Switch Illumination, Headlamp Switch Illumination, RSA Illumination
  10. 10 - Air Bag System
  11. 11 - Wiper Motor, Washer Pump
  12. 12 - L, M1, M2 Blower Motor, Rear A/C Relay Coil, Front Cont. Temp. Door Motor, Hi Blower Relay, Defogger Timer Coil, Upfitter Relay Coil
  13. 13 - Cigarette Lighter, Door Lock Relay
  14. 14 - Cluster HVAC Controls, Chime Module, Radio Illumination, Rear Heat Switch Illumination, Rear Wiper/Washer Switch Illumination, Rear Liftgate Switch Illumination, OH Cassette
  15. 15 - DRL Lamps
  16. 16 - Front Turn Signals, Rear Turn Signals, Trailer Turn Signals, Back Up Lamps, BTSI Solenoid
  17. 17 - Radio: ATC (Standby), 2000 Series (Main Feed), Rear Seat Audio Controls
  18. 18 - VCM-Ign 3, VCM Brake, 4WAL, Stepper, Cruise
  19. 19 - Radio: ATC (Main Feed), 2000 Series (Standby)
  20. 20 - PRNDL/Odometer, TCC Enable & PCM Solenoids, Shift A & Shift B Solenoids
  21. 21 - Not Used
  22. 22 - Not Used
  23. 23 - Rear Wiper, Rear Washer Pump
  24. 24 - Not Used
  25. A - Circuit Breaker: Power Door Lock, 6-Way Power Seat, Keyless Entry Module, Dutch Door Module, Dutch Door Release
  26. B - Circuit Breaker: Power Windows

Scheme 13

Scheme 13: UNDERHOOD ELECTRICAL CENTER IDENTIFICATION (1996)
Scheme 13: UNDERHOOD ELECTRICAL CENTER IDENTIFICATION (1996)

Circuit Identification

  1. AUX B - Upfitter Battery Feed
  2. AUX A - Upfitter Battery Feed
  3. Relay - A/C Relay
  4. Relay - IGN Relay
  5. Relay - Starter Enable Relay
  6. Relay - A/C Enable Relay
  7. Relay - Empty Relay
  8. Relay - Fuel Pump Relay Relay
  9. UPFIT-BATT - Upfitter Battery
  10. UPFIT-IGN - Upfitter Ignition Relay
  11. SPARE - Not Used
  12. SPARE - Not Used
  13. ECM-B - Fuel Pump Relay
  14. HORN - Horn Relay
  15. A/C COMP - A/C Enabel Relay
  16. RR DEFOG - Heater-A/C Control Selector Switch
  17. ENG-1 - Oxygen Sensors 1-4, Camshaft Position Sensor, Mass Air Flow Sensor, evaporative Emission Canister Purge Solenoid Valve, Linear EGR Valve Solenoid, VCM
  18. IGN-E - A/C Enabel Relay
  19. ECM-1 - Fuel Injectors 1-6, Crankshaft Position Sensor, VCM, Distributor Ignition Control Module
  20. LIGHTING - Park Lamps Fuse, DRL Fuse, Headlamp & Panel Dimmer Switch
  21. BATT I/P - Fuse Block Fuses, Power Accessory CB, Stop/Hazard Fuse, Auxiliary Power Fuse, Cigarette Lighter Fuse, Radio, Battery Fuse
  22. IGN A - Starter Relay, Ignition Switch
  23. IGN B - Ignition Switch
  24. ABS - Brake Pressure Module Valve
  25. A/C - Blower Motor Resistor, Blower Relay
  26. RR HTR/AC - Auxiliary Heater A/C Relay
  27. SPARE - Not Used