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1991 Chevrolet Astro Service and Repair Manual
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Covers all 1991 Astro trims — Base Extended Cargo Van 3-Door, CL Extended Passenger Van 3-Door, CS Standard Passenger Van 3-Door +5 more ·
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$29.99
1991 Chevrolet Astro Service and Repair Manual
Regular price
$29.99 USD
Unit price
This factory service and repair manual for the 1991 Chevrolet Astro documents a single-engine van: the 4.3-liter overhead-valve V6 of 262 cubic inches, naturally aspirated and gasoline-fueled, is the only engine listed for the year. It goes into four bodies — standard and extended three-door vans in passenger and cargo form — offered as Base, CL, CS or LT. Dropping the four-cylinder simplifies the engine chapters, since one set of torque values, clearances and diagnostic charts now applies to every van the manual describes.
Engines covered
- 4.3L V6 (262 cu in) — OHV, naturally aspirated, gasoline
Body styles covered
- 3-door extended cargo van
- 3-door extended passenger van
- 3-door standard passenger van
- 3-door standard cargo van
Trims covered
- Base
- CL
- CS
- LT
Known issues on the 1991 Astro. Six recalls appear on the federal record. Two are restraint problems: front and mid-ship belts that ride above the pelvis, and a rear anchorage bar unable to hold the loads a crash imposes. A third is the seat recliner joint that fatigues its bolts until the backrest collapses rearward. A replacement fuel filter that can leak at the connection and two replacement lamp sets without amber side reflectors round it out. Brakes drive the complaint total of 116, at 50 alone, with electrical at 10 — hydraulic overhaul and circuit diagnosis both sit in this manual.
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
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
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.
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
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
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.
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. *
DIAGNOSTIC INFORMATION FOR INTERMITTENT TRANSMISSION DOWNSHIFT, SLIP, BUSY/CYCLING TCC OR NOISY COOLING FAN. *TT
WINDOW REGULATOR MOTOR DOES NOT FIT. *TT
DIAGNOSIS OF CRACKED OR BROKEN TRANSMISSION CASE. *TT 2006 AND PRIOR CARS AND LIGHT DUTY TRUCKS. *TT
RECALL 91-C-50 - GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1991 CHEVRTOLET C/K TRUCKS, M/L AND G VANS EQUIPPED WITH 4.3L ENGINES [RPO LB4 OR RPO LU2 (M VAN ONLY)] MAY BE EMITTING NON-METHANE HYDROCARBONS (NMHC) IN EXCESS OF CALIFORNIA EMIS
COLD ENGINE KNOCK. *TW
CALIFORNIA RECALL - GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1991 C/K TRUCKS, M/L AND G VANS WITH 4.3L ENGINES MAY BE EMITTING NON-METHANE HYDROCARBONS IN EXCESS OF CALIFORNIA EMISSION STANDARDS. TO CORRECT THIS CONDITION, DEALERS ARE TO
OIL PRESSURE GAUGE READING CONCERNS. *TW
Showing the 8 most recent of 9 technical service bulletins on file with NHTSA.
BOTH FRONT SHOULDER/LAP BELTS DID NOT HOLD UPON IMPACT; HIT HEAD ON BY ANOTHER VEHICLE. TT
DRIVNG VEHICLE AT SPEED 30 MPH, IMPACT 12:00 POSITION, LAP/SHOULDER ON BOTH FRONT DID NOT RETRACT. TT
WHILE IN A LOW SPEED ACCIDENT SHOULDER SEAT BELT DID NOT RETRACT, CAUSING CONSUMER TO HIT STEERING WHEEL. *AK
ABS BRAKES FAILED, VEHICLE LOST CONTROL, RESULTING IN A CRASH/INJURIES. *AK
Showing the 4 most serious of 121 complaints filed with NHTSA.
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