1991 Chevrolet Astro Service and Repair Manual

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Factory-Grade Data

1991 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

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

1991 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.

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 #41063

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

TSB #39304

COLD ENGINE KNOCK. *TW

TSB #38076

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

TSB #37947

OIL PRESSURE GAUGE READING CONCERNS. *TW

Showing the 8 most recent of 9 technical service bulletins on file with NHTSA.

19950610Component: SEAT BELTS:FRONT:WEBBINGCrash reported4 injured

BOTH FRONT SHOULDER/LAP BELTS DID NOT HOLD UPON IMPACT; HIT HEAD ON BY ANOTHER VEHICLE. TT

19950605Component: SEAT BELTS:FRONT:RETRACTORCrash reported2 injured

DRIVNG VEHICLE AT SPEED 30 MPH, IMPACT 12:00 POSITION, LAP/SHOULDER ON BOTH FRONT DID NOT RETRACT. TT

20001019Component: SEAT BELTS:FRONT:RETRACTORCrash reported1 injured

WHILE IN A LOW SPEED ACCIDENT SHOULDER SEAT BELT DID NOT RETRACT, CAUSING CONSUMER TO HIT STEERING WHEEL. *AK

19970918Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITEDCrash reported1 injured

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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