1994 Chevrolet Astro Service and Repair Manual

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Factory-Grade Data

1994 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

1994 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 #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 #06E04100018/05/2006Component: FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

CERTAIN R&B, INC. CENTRAL MULTIPORT FUEL INJECTION (CMFI) FUEL RETURN LINES, MODELS HELP 55163, NAPA BALKAMP 700-3270, AND THE CONNECTION 2560001, SOLD FOR USE AS REPLACEMENT EQUIP

Consequence

A FUEL LEAK CAN OCCUR AT THE VALVE, POSSIBLY RESULTING IN A FIRE.

Remedy

R&B, INC. WILL NOTIFY OWNERS AND AT THE CUSTOMERS REQUEST, EITHER REPLACE THE FUEL LINE OR

NHTSA #94V17700014/09/1994Component: SEATS:FRONT ASSEMBLY:HEAD RESTRAINT

THE FRONT DRIVER AND PASSENGER SEAT BACK HEIGHT DOES NOT CONFORM TO THE REQUIREMENTS OF FMVSS NO. 202, "HEAD RESTRAINTS."

Consequence

CONSEQUENCE OF NON-COMPLIANCE: SEAT OCCUPANTS ARE SUBJECT TO INCREASED RISK OF INJURY IN

Remedy

SHERRY DESIGNS WILL PROVIDE AN ATTACHABLE HEADREST FOR THE DEALER OR CUSTOMER TO ADD TO TH

NHTSA #94V08700009/05/1994Component: EQUIPMENT:OTHER:LABELS

THE MANUFACTURER'S CERTIFICATION LABEL AND/OR THE DRIVER AIR BAG ADVISORY LABEL MAY BE MISSING FROM THE VEHICLES, WHICH DOES NOT CONFORM TO THE REQUIREMENTS OF 49 CFR 567.

Consequence

CONSEQUENCE OF NON-COMPLIANCE: OWNERS OF VEHICLE WOULD BE UNAWARE OF THE LOAD CAPACITY OF

Remedy

THE LABELS WILL BE FURNISHED TO OWNER'S FOR INSTALLATION ON THE VEHICLES.

TSB #10246631

Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules

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 #634576

SOME CUSTOMERS MAY COMMENT THAT THE RIGHT REAR DOOR HANDLE ON THE CARGO DOOR BREAKS. *TT

TSB #608382

SUBJECT REGARDING ABS 3-SENSOR EBC4 - SPECIAL POLICY. *TT

TSB #52571

INTERMITTENT HESTIATIONS, LOW POWER, AND ROUGH RUNNING ENGINE IN COLD TEMPERATURES (REPLACE PCM). *TW

Showing the 8 most recent of 21 technical service bulletins on file with NHTSA.

19961120Component: SEATSCrash reported5 injured

VEHICLE INVOLVED IN HEAD-ON COLLISION, UPON IMPACT, MIDDLE SEAT FOLDED DOWN/COLLAPSED, CAUSING METAL SUPPORTING BAR TO ROLL UP, SIX YEAR OLD BROKE LEFT LEG WHEN HITTING METAL BAR

19970825Component: AIR BAGS:FRONTALCrash reported3 injured

CONSUMER WAS DRIVING APPROX. 45 MPH WHEN AN OTHER VEHCLE CROSSED HIS PATH, CREATING A CRASH. DRIVER'S SIDE AIR BAG DID NOT DEPLOY AT POINT OF IMPACT NOR HAS IT DEPLOYED YET. GARA

19960523Component: SUSPENSION:FRONTCrash reported3 injured

DRIVING VEHICLE, MAKING TURN, BUS HIT & LIFT VEHICLE IN AIR, VEHICLE SLID, DOORS HAD NO INSIDE KNOBS, DRIVER & PASSENGERS TRAPPED, DOORS OPENED FROM OUTSIDE.

19960508Component: LATCHES/LOCKS/LINKAGES:DOORS:LATCHCrash reported3 injured

VEHICLE WAS IMPACTED AT 3:00 POSITION, SPEED 10 MPH, VEHICLE WAS TURNED OVER, NO REAR DOOR LATCH TO GET OPEN. *AK

Showing the 4 most serious of 396 complaints filed with NHTSA.

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