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Chevrolet Astro CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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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!
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+
General Service Domestic Vehicles -> 1994-95 -> Oil Charge -> 1994 Villager -> 1995 Aerostar, Explorer, Ranger & Windstar -> 1995 F-Series, Bronco & Villager -> Acclaim, LeBaron, Spirit, Shadow & Sundance -> Achieva, Grand Am & Skylark -> Aspire & Probe -> Aurora & Riviera -> Avenger & Sebring DOHC & 1995 Talon Less Turbo -> Avenger & Sebring SOHC & 1995 Talon w/Turbo -> Beretta & Corsica -> Bonneville, Eighty-Eight, LeSabre, Ninety-Eight & Park Avenue -> Camaro & Firebird -> Capri -> Caprice, Impala SS & Roadmaster -> Cavalier, Sunbird & Sunfire -> Century & Cutlass Ciera/Cutlass Cruiser -> Cherokee, Dakota, Full Size Pickup, Grand Cherokee & Wrangler -> Chrysler Corp. -> Cirrus & Stratus -> Colt & Summit -> Colt Vista & Summit Wagon -> Concorde, Intrepid, LHS, New Yorker & Vision -> Corvette -> Cutlass Supreme, Grand Prix, Lumina, Monte Carlo & Regal -> DeVille, Eldorado & Seville -> Econoline & 1994 F-Series, Bronco, Aerostar, Explorer & Ranger -> Escort & Tracer w/1.8L/4-112 Engine -> Except Aspire, Capri & Probe & Escort & Tracer w/1.8L/4-112 Engine -> Except Geo Tracker -> Fleetwood (RWD) -> Ford Motor Company -> Full Size Van -> General Motors Corp. -> Geo Metro & Prizm -> GEO Tracker -> Laser & 1994 Talon -> Light Trucks & Vans -> Mini Van -> Neon -> Passenger Cars -> Saturn -> Stealth
Vehicle: 1994 Chevrolet Astro 4.3 V6 GAS
Chrysler Corp.
Passenger Cars
Before installing replacement compressor, drain oil from replacement and failed compressors (drain oil from suction port). Add same amount of oil to replacement compressor as drained from failed compressor.
Remove defective components. Add the proper amount of oil to each replacement component as follows:
Concorde, Intrepid, LHS, New Yorker & Vision
When other air conditioning system components are replaced add the following quantities of refrigerant oil: evaporator, 2.0 ozs.; condenser, 1.0 oz; receiver/drier, 1.0 oz.; l...
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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+.
Anti-lock Brakes -> Rear Wheel Anti-Lock Brake System -> Diagnosis & Testing -> 1992 -> 1993 S & T SERIES -> 1993-94 C & K SERIES & 1994 S & T SERIES -> 1993-95 -> 1995 S & T SERIES -> Accessing Diagnostic Trouble Codes -> C & K Series -> Clearing Diagnostic Trouble Codes -> Diagnostic Trouble Code Interpretation -> RWAL System -> S & T Series -> ZPRWAL System
Vehicle: 1995 Chevrolet Astro 4.3 V6 GAS
Accessing Diagnostic Trouble Codes
1992
Diagnostic trouble codes can be accessed by connecting a TECH 1 or equivalent scan tool or by manually grounding the Assembly Line Diagnostic Link (ALDL) connector. To manually ground the ALDL connector, connect a jumper wire between terminals A and H, Fig. , and observe the flashes of the brake warning lamp. Note the following when performing the Diagnostic Circuit Check to access diagnostic trouble codes:
- When terminals are jumped, count number of short flashes starting from initial long flash, include long flash in count.
- The count se...
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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 -> Fuel Pressure Relief -> Except Montana SV6, Relay, Rendezvous w/3.6L Engine, Terraza, Tracker & Uplander -> Engine Fuel Pressure Service Port -> Engines Less Fuel Pressure Service Port
Vehicle: 2001 Chevrolet Astro 4.3 V6 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strategy.
Engines Less Fuel Pressure ...
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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: 1992 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: 1990 Chevrolet Astro 2.5 L4 GAS
- Disconnect battery ground cable.
- Remove starter braces or shields, if equipped.
- Remove wires from starter solenoid.
- Raise and support vehicle.
- Remove starter motor to engine attaching bolts an...
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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 -> Reduce Engine Power Indicator Lamp ->
Vehicle: 2001 Chevrolet Astro 4.3 V6 GAS
The Reduce Engine Power indicator lamp should light for a approximately 3 seconds when the ignition is turned On as a bulb check. If the warning lamp turns On during vehicle operation, a vehicl...
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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+
Radiator, Replace
Vehicle: 1990 Chevrolet Astro 2.5 L4 GAS
- Drain cooling system into a suitable container.
- Remove upper fan shroud.
- Remove radiator hose inlet.
- Remove radiator hose outlet.
- Remove transmission oil cooler lines.
- Remove engine oil cooler pipes.
- Remove overflow hose.
- Remove two radiator mounting bolts.
- Remov...
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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: 1997 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+.
 Body Diagram for 2000 Chevrolet Astro 4.3 V6 GASComponents on diagram: |
 Front End Center Wiring Diagram for 2005 Chevrolet Astro 4.3 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Chevrolet Astro AUTOMOBILES
OEM drawn wiring diagrams for most Chevrolet Astro cars and light trucks sold in the U.S.
 1998 Chevrolet Astro 4.3 V6 GAS Wiring DiagramComponents on diagram: |
 1998 Chevrolet Astro 4.3 V6 GAS Wiring DiagramComponents on diagram: |
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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+.
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Document: AUXILIARY SEAT BELT FOR SECURING CHILD RESTRAINT Vehicle: 1989 Chevrolet Astro 4.3 V6 GAS Auto Systems: |
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Document: INFORMATION ON ALUMINUM HEATER CORE AND/OR RADIATOR REPLACEMENT - REVISED Vehicle: 1990 Chevrolet Astro 4.3 V6 GAS Auto Systems: |
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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
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