1990 Chevrolet Astro Service and Repair Manual

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Factory-Grade Data

1990 Chevrolet Astro service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Extended Cargo Van 3-Door
  • CL Extended Passenger Van 3-Door
  • CS Standard Passenger Van 3-Door
  • Base Standard Cargo Van 3-Door
  • CL Standard Passenger Van 3-Door
  • LT Extended Passenger Van 3-Door
  • CS Extended Passenger Van 3-Door
  • LT Standard Passenger Van 3-Door

Engines covered

  • 4.3L 262Cu. In. V6 GAS OHV Naturally Aspirated
  • 2.5L 2474CC 151Cu. In. l4 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1990 Chevrolet Astro Recalls & Complaints

NHTSA #06E04900024/05/2006Component: EXTERIOR LIGHTING

CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINAT

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING I

Remedy

CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE R

NHTSA #06E02600023/03/2006Component: EXTERIOR LIGHTING

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT E

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING I

Remedy

PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON AP

NHTSA #91V16400020/09/1991Component: SEAT BELTS:FRONT:ANCHORAGE

SEAT BELT ANCHORAGE BAR FOR REAR SOFA FAILED TO SUSTAIN LOADS REQUIRED BY FMVSS 210.

Consequence

VEHICLES WOULD NOT COMPLY WITH FMVSS 210.

Remedy

REPLACE NONCOMPLYING SOFA BAR WITH BAR THAT MEETS REQUIREMENTS.

NHTSA #06E04300019/05/2006Component: FUEL SYSTEM, GASOLINE

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER

Consequence

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FU

Remedy

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGA

NHTSA #93V18700016/11/1993Component: SEATS

THE RECLINER MECHANISM AND THE SEAT FRAME MAY HAVE FOAM AND/OR VINYL BETWEEN THEM, CREATING A "SOFT" JOINT. THIS "SOFT" JOINT RESULTS IN LOWER THAN SPECIFIED BOLT TORQUE WHICH LEAD

Consequence

IF BOLT FAILURE OCCURS TO THE DRIVER'S SEAT, IT WOULDALLOW THE SEAT BACK TO SUDDENLY RECLI

Remedy

DEALERS WILL REMOVE THE FOAM AND/OR VINYL FROM BETWEEN THE RECLINER MECHANISM AND THE SEAT

NHTSA #91V10200014/06/1991Component: SEAT BELTS:FRONT:ANCHORAGE

THE SEAT BELTS FOR THE FRONT AND MID-SHIP SEATS DID NOT REST ON PELVIS AS REQUIRED BY FMVSS 209.

Consequence

SEAT BELTS MAY NOT RESTRAIN SEAT OCCUPANT, AND COULDINJURE THE SEAT OCCUPANT IN THE EVENT

Remedy

RELOCATE SEAT BELT ANCHOR BOLTS TO ADJUST BELTS FOR SEAT LOCATIONS.

NHTSA #90V14600013/08/1990Component: FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

FUEL RETURN HOSES MAY BREAK AT EITHER CRIMPED COUPLING, CAUSING A LEAKAGE OF FUEL.

Consequence

IN THE EVENT OF A FUEL RETURN LINE SEPARATION, A FUELLEAK OCCURRING IN THE PRESENCE OF AN

Remedy

INSTALL A PROPERLY CRIMPED FUEL RETURN HOSE.

TSB #10028790

GENERAL MOTORS: ON ALL 1988-2009 FULL SIZE CHEVROLET/GMC PICKUPS, UTILITIES AND VANS, THE BRAKE PEDAL WILL MOVE DOWN OR SELF APPLY DURING FULL LOCK TURNS OR NEAR FULL LOCK TURNS. CHEVROLET ASTRO AND GMC SAFARI VANS; HUMMER 2 ARE INCLUDED. *

TSB #10007838

DIAGNOSTIC INFORMATION FOR INTERMITTENT TRANSMISSION DOWNSHIFT, SLIP, BUSY/CYCLING TCC OR NOISY COOLING FAN. *TT

TSB #10007244

WINDOW REGULATOR MOTOR DOES NOT FIT. *TT

TSB #634999

DIAGNOSIS OF CRACKED OR BROKEN TRANSMISSION CASE. *TT 2006 AND PRIOR CARS AND LIGHT DUTY TRUCKS. *TT

TSB #39304

COLD ENGINE KNOCK. *TW

TSB #37942

TRANSMISSION EXTENTION SEAL LEAKS. *TW

20000405Component: SEAT BELTS:FRONT:WEBBINGCrash reported1 injured

WHILE DRIVING DOWN THE ROAD, HIT BLACK PIECE OF ICE, SWERVED AND HIT A TREE. DRIVER'S SIDE SHOULDER BELT FAILED. AS A RESULT, DRIVER'S FACE HIT THE STEERING WHEEL. *AK

20000405Component: STEERING:GEAR BOX:SHAFT PITMANCrash reported1 injured

SHOULDER STRAP FAILED AS RESULT HIT FACE ON STEERING WHEEL. TWENTY STITCHES. *AK

19961120Component: SEATSCrash reported1 injured

DRIVER'S SIDE SEAT TRACK/ANCHOR FAILED; ALSO, SEAT BELT FAIE=LED TO RESTRAIN DRIVER, WAS EJECTED FROM VEHICLE. *AK

19961120Component: SEAT BELTS:FRONT:RETRACTORCrash reported1 injured

DRIVER'S SIDE SEAT TRACK/ANCHOR FAILED; ALSO, SEAT BELT FAIE=LED TO RESTRAIN DRIVER, WAS EJECTED FROM VEHICLE. *AK

Showing the 4 most serious of 93 complaints filed with NHTSA.

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