2004 Chevrolet Astro Service and Repair Manual

This factory service and repair manual for the 2004 Chevrolet Astro covers the van in its four familiar bodies — three-door cargo and passenger, standard and extended — with the 262-cubic-inch 4.3-liter overhead-valve V6, naturally aspirated and gasoline-fueled, as the only engine. Base, LS and LT remain the trims. The material is the shop kind: removal and installation sequences, torque values, clearances, fluid and system specifications, wiring diagrams and diagnostic charts for the engine, driveline, chassis and body of that specific van.

Engines covered

• 4.3L V6 (262 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 3-door extended cargo van
• 3-door standard cargo van
• 3-door extended passenger van
• 3-door standard passenger van

Trims covered

• Base
• LS
• LT

Known issues on the 2004 Astro. Two recalls only, both traced to replacement parts rather than to the van as built: lamp assemblies supplied without amber side reflectors, which leave the vehicle poorly marked to traffic approaching from the side, and a fuel filter that can seal inadequately at its connection and let fuel escape where it could ignite. Complaints are few as well — 14 in total, with six on service brakes and two on vehicle speed control. The brake hydraulic procedures and the speed control diagnostics in this manual answer both categories.