The Chevrolet Astro (1996-2005) is a versatile minivan known for its strong V6 engine, rear-wheel drive, and spacious interior, making it popular for both families and commercial use. It offers features like air conditioning, power windows, and seating for up to eight passengers, all supported by the vehicle’s electrical system.
The fuse box, located under the dashboard and in the engine bay, protects essential electrical components such as headlights, the radio, and power windows from electrical overload. If a fuse blows, it interrupts power to that system, requiring a replacement fuse to restore functionality.
The relays in the Astro control major systems like the fuel pump, cooling fan, and starter motor. These relays act as switches, allowing smaller electrical signals to control larger components. A malfunctioning relay can prevent key systems from operating, such as the engine failing to start or the cooling system overheating.
Proper maintenance of the fuse box and relays ensures that the Astro’s electrical systems, from its engine functions to everyday conveniences, run reliably without electrical failures.
MUST READ: DYI – How to Check Car Fuses?
(1996-2005) Chevrolet Astro fuse box and relay with Diagram
WARNING
- Never replace a fuse with one that has a higher amperage rating.
- A fuse with a too-high amperage could damage the electrical part and cause a fire.
- On no account should fuses be repaired (e.g. patched up with tin foil or wire) as this may cause serious damage elsewhere in the electrical circuit or cause a fire.
- If a fuse blows repeatedly, do not keep replacing it. Instead, have the cause for the repeated short circuit or overload tracked and fixed.
- Terminal and harness assignments for individual connectors will vary depending on vehicle equipment level, model, and market.
Chevrolet Astro 1996-2005 fuse assignment
- Cigar lighter (power outlet) fuses in the Chevrolet Astro are the fuses №7 and 13 in the Instrument panel fuse box.
Year of production: from 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Instrument Panel Fuse Box
Fuse Box Location
It is on the lower portion of the instrument panel on the driver’s side.
Fuse box diagram (1996-1998)
Assignment of the fuses in the instrument panel (1996-1998)
| № | Usage |
|---|---|
| 1 | Stop/Turn/Hazard Lamps, CHMSL, Chime Module |
| 2 | — |
| 3 | Courtesy Lamps, Power Outside Mirrors, Glove Box Lamp, Dome Reading Lamps, Vanity Mirror Lamps |
| 4 | 1996: DRL Relay, DRL Module, Chime Headlamp Switch, Keyless Entry, Cluster, Overhead Console 1997-1998: DRL Relay, DRL Module, Chime Headlamp Switch, Keyless Entry, Cluster, Overhead Console, EVO Module, Interior Lamps Module |
| 5 | — |
| 6 | Cruise Module, Cruise Control Switch |
| 7 | Power Outlets, DLC, Subwoofer Amplifier |
| 8 | Starter Enable Relay |
| 9 | License Plate Lamp, Taillamps, Parking Lamps, Ashtray Lamp, Panel Lights, Trailer Taillamps, Front and Rear Sidemarker Lamps, Door Switch Illumination, Headlamp Switch Illumination, Rear Seat Audio Illumination |
| 10 | Air Bag System |
| 11 | Wiper Motor, Washer Pump, Upfitter Relay Coil |
| 12 | L, MI, M2 Blower Motor, Rear A/C Relay Coil, Front Cont. Temp. Door Motor, Hi Blower Relay, Defogger Timer Coil |
| 13 | Cigar Lighter, Door Lock Switches, Dutch Door Release Module (1998) |
| 14 | Cluster Illum, HVAC Controls, Chime Module, Radio Illumination, Rear Heat Switch Illumination, Rear Wiper/Washer Switch Illumination, Rear Liftgate Switch Illumination, Remote Cassette Illumination, O/H Console |
| 15 | DRL Diode |
| 16 | Front Turn Signals, Rear Turn Signals, Trailer Turn Signals, Back-up Lamps, BTSI Solenoid |
| 17 | Radio: ATC (Standby), 2000 Series (Main Feed), Rear Seat Audio Controls |
| 18 | VCM-Ign 3, VCM- Brake, 4WAL, Cruise Stepper Motor |
| 19 | Radio: ATC (Main Feed), 2000 Series (Standby) |
| 20 | PRNDLI Odometer, TCC Enable and PWM Solenoids, Shift A and Shift B Solenoids, 3-2 Downshift Solenoids |
| 21 | — |
| 22 | Security/Steering Module |
| 23 | Rear Wiper, Rear Washer Pump |
| 24 | — |
| A | (Circuit Breaker) Power Door Lock Relay, 6-way Power Seat, Remote Control Door Lock Receiver, Dutch Door Module, Dutch Door Release |
| B | (Circuit Breaker) Power Windows |
Fuse box diagram (1999-2005)
Assignment of the fuses in the instrument panel (1999-2005)
| № | Usage |
|---|---|
| 1 | Stop/Turn/Hazard Lamps, Center High-Mounted Stop Lamp, Anti-Lock Brakes |
| 2 | 1999: Heated Mirror (Not Used) 2000-2005: Radio Accessory, Rear Seat Audio Controls |
| 3 | Courtesy Lamps, Glove Box Lamp, Dome Reading Lamps, Vanity Mirror Lamps, Courtesy Lamps |
| 4 | 1999: DRL Relay, DRL Module, Chime Headlamp Switch, Keyless Entry, Cluster, Overhead Console, Interior Lamps Module 2000-2005: DRL Relay, Instrument Panel Cluster |
| 5 | Rear Defogger |
| 6 | Cruise Module, Truck Body Control Module, Instrument Panel Cluster, Cruise Control Switch, Electrochromic Mirror |
| 7 | Power Outlets, DLC, Subwoofer Amplifier |
| 8 | Crank Circuit Fuse, Park/Neutral Switch, Starter Enabler Relay |
| 9 | License 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 | 1999: Wiper Motor, Washer Pump, Upfitter Relay Coil 2000-2005: Not used |
| 12 | Blower Motor, Rear Air Conditioning Relay Coil, Front Cont. Temp. Door Motor, HI Blower Relay, Defogger Timer Coil |
| 13 | Cigarette Lighter, Door Lock Switches, Dutch Door Release Module |
| 14 | Cluster Illumination, Climate Controls, Chime Module, Radio Illumination, Rear Heat Switch Illumination, Rear Wiper/Washer Switch Illumination, Rear Liftgate Switch Illumination, Remote Cassette Illumination, Overhead Console, Truck Body Control Illumination |
| 15 | 1999: DRL Lamps 2000-2005: TBC Module, Headlamp Relay |
| 16 | Front Turn Signals, Rear Turn Signals, Trailer Turn Signals, Back-Up Lamps, Brake Transmission Shift Interlock Solenoid |
| 17 | 1999: 2000 Series (Main Feed), Rear Seat Audio Controls 2000-2005: Front Wipers, Front Washer Pump |
| 18 | VCM-Ign 3, VCM-Brake, Cruise Stepper Motor Signal, ATC Module |
| 19 | 1999: Radio: ATC (Main Feed), 2000 Series (Standby) 2000-2005: Instrument Panel Radio: ATC (Main Feed), 2000 Series (Standby) |
| 20 | 1999: PRNDL/ Odometer, TCC Enable and PWM Solenoid, Shift A and Shift B Solenoids, 3-2 Downshift Solenoid 2000-2003: PRNDL/ Odometer, TCC Enable and PWM Solenoid, Shift A and Shift B Solenoids, 3-2 Downshift Solenoid, Instrument Panel Cluster, VCM Module 2004-2005: PRNDL/Odometer, Shift A and Shift B Solenoids, 3–2 Downshift Solenoid, Instrument Panel Cluster, VCM Module |
| 21 | 1999: Security 2000-2005: Power Adjust Mirrors |
| 22 | — |
| 23 | Rear Wiper, Rear Washer Pump |
| 24 | — |
| A | 1999: (Circuit Breaker) Power Door Lock Relay, 6-way Power Seat, Remote Control Door Lock Receiver, Dutch Door Module, Dutch Door Release 2000-2005: (Circuit Breaker) Power Door Lock Relay, 6-Way Power Seats |
| B | (Circuit Breaker) Power Windows |
Engine Compartment Fuse Box
Fuse Box Location
It is located in the engine compartment.
Fuse box diagram
Assignment of the fuses and relay in the engine compartment
| Name | Usage |
|---|---|
| UPFITTER-BATT | Upfitter Battery Power Stud. Trailer Wiring Harness |
| UPFITTER-ACCY | Upfitter Accessory Relay |
| Spare | — |
| Spare | — |
| Spare | — |
| ECM-1B | Fuel Pump Relay and Motor, VCM, Oil Pressure Switch/Sender |
| HORN | Horn Relay and Horn |
| A/C COMP | Air Conditioning Enable Relay and Compressor |
| RR HTR/AC | 1996-1999: Auxiliary Heater, A/C Relay 2000-2005: Rear Heater and Air Conditioning |
| ATC | Active Transfer Case-L Van |
| FRT HVAC | Front Heater and Air Conditioning |
| ENG-I | 1996-1999: Oxygen Sensors, Camshaft Position Sensor, Mass Air Flow Sensor, Evaporative Emission Canister Purge Solenoid, Linear EGR Valve Solenoid, VCM EGR HI 2000-2005: Oxygen Sensors, Camshaft Position Sensor, Mass Air Flow Sensor, Evaporative Emission Canister Vent Solenoid |
| IGN-E | Air Conditioning Enable Relay Coil |
| ECM-I | Fuel Injectors 1–6, Crankshaft Position Sensot, VCM, Coil Driver Module (EST), Ignition Coil |
| BLANK | — |
| RH HDLMP | Right Headlamp |
| LH HEADLAMP | Left Headlamp |
| Blank | — |
| Blank | — |
| DIODE-1 | Air Conditioning |
| Blank | — |
| Blank | — |
| Blank | — |
| LIGHTING | 1996-1999: Park Lamps Fuse, DRL Fuse, Headlamp and Panel Dimmer Switch 2000-2005: Courtesy Fuse, Power Adjust Mirrors Fuse, Truck Body Control Battery Fuse |
| BATT | Power 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 |
| ABS | Electronic Brake Control Module |
| A/C | Blower Motor Resistor, Blower Relay |
| Blank | — |
| RAP | Radio Accessory, Power Windows |
| HTD MIR/RR DEFOG | Rear Window Defogger, Climate Control Head |
| Relays | |
| A/C Relay (Rear Heat and A/C) | Rear Heat and Air Conditioning |
| Upfitter ACCY Relay | Upfitter Accessory |
| Starter Enable Relay | Starter |
| A/C Enable Relay | Air Conditioning |
| Headlamps Relay | Headlamps (2000-2005) |
| Fuel Pump Relay | Fuel Pump |
| Feed | |
| AUX B | Upfitter Battery Feed |
| AUX A | Upfitter Accessory Feed |
Conclusion
For owners and enthusiasts of classic Chevrolet Astro 1996-2005, understanding the fuse box and relay systems is essential for vehicle maintenance. Regular inspection and maintenance of these components helped ensure the vehicle’s longevity and reliability, preserving its status as a symbol of Chevrolet’s craftsmanship and innovation in the automotive industry during that era.