Chevrolet Astro REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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Chevrolet Astro CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW

Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!

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Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Chevrolet Astro car and truck repair procedures including Chevrolet engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Chevrolet Astro automobile. Try the Automotix DIY solution today!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Chevrolet mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your Chevrolet Astro vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR Chevrolet Astro AUTOMOBILES

Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Chevrolet Astro cars and light trucks from 1990+

Component Replacement & Adjustment -> Light Duty Trucks & Vans -> ADJUSTMENTS -> C & K Series -> CONTROL CABLES -> G SERIES -> Less A/C -> MODE/TEMPERATURE/RECIRCULATION ACTUATORS -> S & T Series -> With A/C
Vehicle: 1995 Chevrolet Astro 4.3 V6 GAS

CONTROL CABLES

G SERIES
Less A/C
  • Disconnect battery ground cable.
  • Attach inner cable and sheath to instrument panel control.
  • Move temperature cable to "Cold" then attach loop on inner cable to temperature door on heater case.
  • Attach cable sheath to heater case, then move temperature lever to full "Heat." This will require force to slide inner cable clip to its proper position.
  • Move temperature adjusting lever quickly from "Cold" to "Hot." Door should be heard seating at stops.
With A/C

The temperature door ca...

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BRAKE SERVICE PROCEDURES FOR Chevrolet Astro AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Chevrolet Astro cars and light trucks from 1990+.

Disc Brakes -> Bendix Single Piston Sliding Caliper -> Precautions -> Brake Disc Service -> Brake Lines & Linings -> Brake Roughness -> General
Vehicle: 1996 Chevrolet Astro 4.3 V6 GAS

Brake Lines & Linings

Remove one of the front wheels and inspect the brake disc, caliper and linings.

Do not allow any oil or grease on the linings. It is recommended that all linings be replaced in sets when worn or damaged.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

Brake Roughness

The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If roughness or vibration is encountered during highway operation or if pedal pumping is experienced at low speeds, the disc may have excessive thickne...

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FUEL FILTER REPLACEMENT PROCEDURES FOR Chevrolet Astro AUTOMOBILES

Fuel filter replacement procedures with corresponding images for most domestic and imported Chevrolet Astro cars and light trucks sold in the U.S. for 1980+.

General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Component Locations -> 1985-05 Astro Van & Safari Van w/4.3L Fuel Injected Engine
Vehicle: 1990 Chevrolet Astro 4.3 V6 GAS

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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Chevrolet Astro AUTOMOBILES

Includes CV axle, universal joint, and driveline replacement, for domestic and imported Chevrolet Astro cars and light trucks from 1990+.

DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1997 Chevrolet Astro 4.3 V6 GAS

Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal.

Disassemble

  • Support propeller shaft in a line horizontal with table of a press.
  • Mark propeller shaft in order to show which end connects to transmission and which end goes to rear axle.
  • On models equipped with external snap ring retainers, proceed as follows:
    • Disassemble snap rings by ...

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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Chevrolet Astro AUTOMOBILES

Includes starter and alternator replacement procedures for domestic and imported Chevrolet Astro cars and light trucks from 1990+.

Starter, Replace
Vehicle: 1997 Chevrolet Astro 4.3 V6 GAS

Upon removal of starter, note if any shims are used. If shims are used, they should be installed in their original locations. After installation, if starter is noisy during cranking, remove one .015 inch double shim or add one .015 inch single shim to the outer bolt. If starter makes a high pitched whine after firing, add .015 inch double shims until noise ceases.

  • Disconnect battery ground cable.
  • R...

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MAINTENANCE LAMP RESET PROCEDURES FOR Chevrolet Astro AUTOMOBILES

Maintenance lamp reset procedures with corresponding images for most domestic and imported Chevrolet Astro cars and light trucks sold in the U.S. from 1990+.

General Motors Corp./Saturn Trucks -> Air Cleaner Restriction Indicator ->
Vehicle: 2000 Chevrolet Astro 4.3 V6 GAS

An air cleaner restriction indicator, Fig. , is located in the intake duct between the MAF sensor and the air cleaner assembly.

If the window shows green, no service is required at this time. However, if...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Chevrolet Astro AUTOMOBILES

Includes radiator, cooling and heater hose replacement procedures for domestic and imported Chevrolet Astro cars and light trucks from 1990+

Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2004 Chevrolet Astro 4.3 V6 GAS

Lower

  • Drain cooling system into a suitable container.
  • Remove air cleaner assembly.
  • Reposition hose clamp from water pump housing.
  • Remove radiator outlet hose from water pump housing.
  • Reposition hose clamp from radiator.
  • Remove radiator outlet hose from radiator and from vehicle.
  • Reverse procedu...

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SERPENTINE BELT SERVICE PROCEDURES FOR Chevrolet Astro AUTOMOBILES

Serpentine belt replacement procedures with corresponding images for most domestic and imported Chevrolet Astro cars and light trucks sold in the U.S. from 1990+.

Serpentine Drive Belt, Replace
Vehicle: 1991 Chevrolet Astro 4.3 V6 GAS

  • Insert a 1/2 inch breaker bar into the tensioner pulley.
  • Rotate tensioner counterclockwise, then remove drive belt.
  • Route drive belt over all pulleys except ...

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COMPONENT LOCATION DIAGRAMS FOR Chevrolet Astro AUTOMOBILES

Component location diagrams for most Chevrolet Astro cars and light trucks sold in the U.S. from 1990+.

Rear Window Coolant Recovery Reservoir Location Diagram for 2003 Chevrolet Astro  4.3 V6 GASRear Window Coolant Recovery Reservoir Location Diagram for 2003 Chevrolet Astro 4.3 V6 GAS

Components on diagram:
  • Rear Window Washer Fluid Pump
  • Rear Window Washer Fluid Pump Connector
  • RH Side of Engine Diagram for 1993 Chevrolet Astro  4.3 V6 GASRH Side of Engine Diagram for 1993 Chevrolet Astro 4.3 V6 GAS

    Components on diagram:
  • TP Sensor
  • Starter Solenoid
  • Ignition Coil
  • Starter Motor
  • Generator
  • CLICK HERE TO GET FULL ACCESS TO Chevrolet Astro PARTS/COMPONENTS LOCATION DIAGRAMS!

    WIRING DIAGRAMS FOR Chevrolet Astro AUTOMOBILES

    OEM drawn wiring diagrams for most Chevrolet Astro cars and light trucks sold in the U.S.

    2004 Chevrolet Astro  4.3 V6 GAS Wiring Diagram2004 Chevrolet Astro 4.3 V6 GAS Wiring Diagram

    Components on diagram:
  • Ignition Switch
  • Rap Relay
  • Body Control Module
  • 2005 Chevrolet Astro  4.3 V6 GAS Wiring Diagram2005 Chevrolet Astro 4.3 V6 GAS Wiring Diagram

    Components on diagram:
  • License Lamp
  • Center High Mounted Stop Lamp
  • Tail/ Stop and Turn Signal Lamp- Right
  • Tail/ Stop and Turn Signal Lamp- Left
  • Marker Lamp- Left Rear
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    TECHNICAL SERVICE BULLETINS FOR Chevrolet Astro AUTOMOBILES

    OEM TSB listings for most Chevrolet Astro cars and light trucks sold in the U.S. from 1985+.

    Document: ACCESSORY RECEPTACLE/CIGAR LIGHTER INOP
    Vehicle: 1995 Chevrolet Astro 4.3 V6 GAS

    Symptoms:
  • Inoperative, No Response
  • Auto Systems:
  • Chassis Electrical, Wiring, Fuses & Breakers, Wipers, Motors
  • Document: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStarA® Systems
    Vehicle: 2005 Chevrolet Astro 4.3 V6 GAS

    Symptoms:
  • Insufficient Performance
  • Auto Systems:
  • Entertainment: Stereo, Radio, Cassettes
  • CLICK HERE TO GET FULL ACCESS TO Chevrolet Astro TECHNICAL SERVICE BULLETINS!

    COMPONENT/PARTS SPECIFICATIONS FOR Chevrolet Astro AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Chevrolet Astro cars and light trucks sold in the U.S. and Canada from 1970+.

    • Brake caliper mounting bolt torque
    • Brake drum runout, machining, & discard specs
    • Minimum brake lining thickness.
    • Brake rotor runout, parallelism, machining, discard, & finish specs

    A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Chevrolet Astro cars and light trucks sold in the U.S. and Canada from 1980+.

    • Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap

    COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.

    PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules

    QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Chevrolet Astro cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.

    • Automatic transmission/transaxles capacities, lubricant recommendations
    • Differential/final drive capacities, lube recommendations, grades, & viscosities
    • Final drive fill & drain plug torques
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
    • Severe service maintenance & interval recommendations
    • Tire sizes, wheel nut/bolt torque, pressures & rim sizes
    • Transfer case capacities, lube recommendations, grades, & viscosities

    TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Chevrolet Astro cars and light trucks sold in the U.S. and Canada from 1980+

    • Airflow sensor electrical specifications
    • Tensioning specifications for systems with automatic tensioners
    • Barometric pressure sensor specs
    • Battery group number and cranking performance
    • Crankshaft & camshaft position sensor resistance
    • Engine compression pressures
    • Coolant temperature sensor specs
    • Computer advance.
    • Diesel fuel temperature sensor resistance.
    • Distributor advance specifications
    • Ignition pickup coil resistance
    • Exhaust gas recirculation temperature sensor resistance
    • Engine fastener torque values
    • Firing order diagrams
    • Fuel system pressures
    • Generator (alternator) specs
    • Intake air temperature sensor specs
    • Ignition coil specifications
    • Fuel injector resistance
    • Engine idle speeds
    • Knock sensor resistance
    • Manifold absolute pressure sensor specs
    • Mixture control solenoid resistance
    • Voltage regulator specs
    • Spark plug applications & gaps
    • Starter motor electrical specs.
    • Tensioning specifications for systems without automatic tensioners
    • Throttle body temperature sensor resistance
    • Ignition timing in degrees at rpm
    • Transmission oil temperature sensor resistance
    • Throttle position sensor specs
    • Vacuum sensor valve specs

    CLICK HERE TO GET FULL ACCESS TO Chevrolet Astro SPECIFICATIONS DATA!

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