2004 Chevrolet Astro Service and Repair Manual

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Factory-Grade Data

2004 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
  • Base Standard Cargo Van 3-Door
  • Base Extended Passenger Van 3-Door
  • LS Extended Passenger Van 3-Door
  • LS Standard Passenger Van 3-Door
  • Base Standard Passenger Van 3-Door
  • LT 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

2004 Chevrolet Astro Recalls & Complaints

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

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11014455

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the

TSB #11009156

This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and

TSB #11007744

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have hi

TSB #11007743

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have hi

TSB #11007208

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed fo

TSB #11006621

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo

TSB #11006421

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the deal

Showing the 8 most recent of 179 technical service bulletins on file with NHTSA.

20081014Component: AIR BAGS:FRONTALCrash reported3 injured

MY WIFE WAS DRIVING A 2004 CHEVY ASTRO VAN APPROX. 35-40 MPH ON A TWO-WAY STREET. ANOTHER DRIVER FROM THE OPPOSITE DIRECTION CUT ACROSS INTO HER LANE AND HAD A HEAD-ON COLLISION. S

20100204Component: ELECTRICAL SYSTEMFire reported

WHEN MY WIFE RETURNED TO OUR 2004 CHEVROLET ASTRO VAN, THE VEHICLE SEEMED TO HAVE A DEAD BATTERY. THE CAR WOULD NOT TURN OVER OR FIRE THE IGNITION. AFTER HAVING THE BATTERY AND STA

20100204Component: SERVICE BRAKES, HYDRAULICFire reported

WHEN MY WIFE RETURNED TO OUR 2004 CHEVROLET ASTRO VAN, THE VEHICLE SEEMED TO HAVE A DEAD BATTERY. THE CAR WOULD NOT TURN OVER OR FIRE THE IGNITION. AFTER HAVING THE BATTERY AND STA

20200421Component: VEHICLE SPEED CONTROL

ONCE OR TWICE PER YEAR WHEN USING CRUISE CONTROL, WHEN I TOUCH BRAKE TO DEACTIVATE CRUISE, IT DOESN'T DISENGAGE. I THEN HAVE TO STAND ON BRAKE WITH ALL MY EFFORT TO STOP VAN AND PU

Showing the 4 most serious of 17 complaints filed with NHTSA.

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