Repair manual
Wiring diagrams
Chevrolet Astro I Repair Manual
Step-by-step repair and maintenance instructions for the Chevrolet Astro I (1985–2005): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
67sections
617articles
ENManual language
- APPLICATION
- DESCRIPTION
- OPERATION
- PCM
- SENSORS & SWITCHES
- Shift Solenoids 1-2 & 2-3
- Pressure Control
- TCC Solenoid
- 3-2 Control Solenoid
- TCC PWM Solenoid
- SELF-DIAGNOSTICS
- TROUBLE SHOOTING
- CLUTCH & BAND APPLICATION
- ELECTRONIC SELF-DIAGNOSTICS
- RETRIEVING CODES WITHOUT SCAN TOOL - GASOLINE ENGINES
- RETRIEVING CODES WITH SCAN TOOL - GASOLINE ENGINES
- Preliminary Inspection
- Diagnostic Procedure
- Entering Or Exiting Diagnostic Mode
- TROUBLE CODE DEFINITIONS
- HARD OR INTERMITTENT TROUBLE CODE DETERMINATION (GASOLINE)
- CLEARING TROUBLE CODES
- Diesel
- Gasoline
- Diagnostic Charts
- Diagnostic Aids
- Circuit Description
- Set Condition
- Test Description
- CODE 15, CTS SIGNAL VOLTAGE HIGH (LOW TEMPERATURE INDICATED)
- CODE 22, THROTTLE POSITION SENSOR SIGNAL VOLTAGE LOW
- CODE 38, BRAKE SWITCH ERROR - 4.3L & 5.7L "B/D/F/Y" BODIES
- CODE 58, TRANS. TEMP. SENSOR HIGH - 3.4L "F" BODY, 4.3L & 5.7L "B", "D", "F" & "Y" BODIES
- CODE 59, TRANS. TEMPERATURE SENSOR LOW TEMPERATURE - 3.4L "F" BODY, 4.3L & 5.7L "B", "D", "F" & "Y" BODIES
- CODE 72, VEHICLE SPEED SENSOR LOSS - 5.7L "Y" BODY
- CODE 79, TRANSMISSION FLUID OVERTEMP - 3.4L "F" BODY, 4.3L & 5.7L "B", "D", "F" & "Y" BODIES
- CODE 96, TRANSMISSION VOLTAGE LOW - 3.4L "F" BODY
- CODE 14, COOLANT TEMPERATURE SENSOR SIGNAL VOLTAGE LOW
- CODE 15, COOLANT TEMPERATURE SENSOR SIGNAL VOLTAGE HIGH
- CODE 21, TPS SIGNAL VOLTAGE HIGH
- CODE 22, TPS SIGNAL VOLTAGE LOW
- CODE 59, TRANS. FLUID TEMP. LOW
- CODE 79, TRANS. FLUID TEMPERATURE HIGH
- CHART A-1, NO MIL (SERVICE ENGINE SOON LIGHT)
- CHART A-2, NO SCAN DATA, MIL (SES) ALWAYS ON OR WON'T FLASH
- DTC 15, ECT SENSOR CKT HIGH (LOW TEMPERATURE INDICATED)
- DTC 58, TRANS. FLUID TEMP. SENSOR CK LOW HIGH TEMPERATURE INDICATED)
- DTC 59, TRANS. FLUID TEMP. SENSOR CKT HIGH LOW TEMPERATURE INDICATED)
- DTC 72, VEHICLE SPEED SENSOR CIRCUIT LOSS (TRANS OUTPUT SPEED SIGNAL)
- DTC 75, SYSTEM VOLTAGE LOW
- DTC 79, TRANSMISSION FLUID OVERTEMP
- Poor Connection Or Damaged Harness
- Intermittent Test
- Shifted Sensor
- TP Sensor Scaling
- Circuiot Description
- COMPONENT & WIRING HARNESS RESISTANCE CHECK
- PRESSURE SWITCH ASSEMBLY
- TECHNICAL SERVICE BULLETINS (TSB)
- 1995 "C", "G" & "K" Series Trucks & Vans With 5.7L (VIN K) & 4L60-E (GM TSB No. 67-65-16 2/96)
- 1995 "L" & "M" Series W/ 4.3L RPO 35, VIN Prior To 255435 On Chevrolet & 559796 On GMC (GM TSB No. 57-71-1910/95)
- 1993-95 "C", "G", "K" & "T" 4WD Vehicles (ATRA TSB No. 343)
- Early, Late Or Erratic Shifts (All Models)
- 4WD-Low Diagnostic Check ("K" Series With Manually Or Electronically Shifted Transfer Case In High Position)
- 4WD-Low Diagnostic Check ("T" Series With PCM & Manually Shifted Transfer Case In High Position)
- 4WD-Low Diagnostic Check ("T" Series With VCM & Manually Shifted Transfer Case In High Position)
- 4WD-Low Diagnostic Check ("T" Series With Electronically Shifted Transfer Case In High Position)
- MODEL IDENTIFICATION
- TERMINOLOGY
- INTRODUCTION
- CONTROL UNIT
- Ground Circuits
- Power Circuits
- A/C ON SWITCH/SYSTEM TEST
- BRAKE SWITCH
- ENGINE COOLANT TEMPERATURE (ECT) SENSOR
- INTAKE AIR TEMPERATURE (IAT) SENSOR
- KNOCK SENSOR
- MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
- OXYGEN SENSOR (O2S)
- OXYGEN SENSOR HEATING ELEMENT
- THROTTLE POSITION (TP) SENSOR
- TRANSMISSION RANGE SWITCH
- VEHICLE SPEED SENSOR (PM GENERATOR)
- A/C Relays
- Fuel Pump Relay
- SOLENOIDS
- Electronic Air Control (EAC) Solenoid
- EGR Control Solenoid
- Idle Air Control (IAC) Valve
- Torque Converter Clutch (TCC) Solenoid
- FUEL DELIVERY
- Fuel Pressure Regulator (Port Fuel Injection)
- Fuel Pressure Regulator (Central & Throttle Body Injection)
- Fuel Pump Oil Pressure Switch (Back-Up Circuit)
- Fuel Pump Relay By-Pass Procedure
- Fuel Injector(s)
- C-2, Port Fuel Injector Balance Test
- IGNITION SYSTEM
- C-4, Ignition Control Circuit
- C-5, Knock Sensor Circuit (Models Using External Spark Controller Module)
- C-5, Knock Sensor Circuit (Models Using Knock Sensor With Internal Spark Controller Module)
- System Test (Vacuum-Controlled Valve)
- Negative Backpressure EGR Valve
- Linear EGR Valve (Digital Valve)
- Vapor Canister Purge Valve ("P" Series & 4.3L CPI)
- Fuel Tank Pressure Control Valve ("C", "G", "K" & "M" Series -High-Altitude)
- Thermostatic Vacuum Switch
- Required Service
- Checking PCV Valve Function
- Damper Door - Wax Pellet Check
- MISCELLANEOUS ECM/PCM/VCM CONTROLS
- Converter Lock-Up Signal At Transmission
- Converter Lock-Up Signal From ECM/PCM/VCM
- Shift Light (Manual Transmission)
- A/C CLUTCH (C-10) & ELECTRIC COOLING FAN (C-12)
- A/C Clutch Relay
- COOLING FAN (C-12)
- Cooling Fan Relay
- Cooling Fan Motor
- DIAGNOSTIC CHARTS
- CHART C-10, A/C COMPRESSOR CLUTCH CIRCUIT DIAGNOSIS - 4.3L (VIN W & Z) S" & "T" SERIES A/T & 4.3L (VIN W) "T" SERIES M/T
- Diagnostic Aids
- CHART C-10, A/C COMPRESSOR CLUTCH CIRCUIT DIAGNOSIS 4.3L (VIN Z) "S" & "T" SERIES M/T (1 OF 2)
- CHART C-10, A/C COMPRESSOR CLUTCH CIRCUIT DIAGNOSIS 4.3L (VIN Z) "S" & "T" SERIES M/T (2 OF 2)
- A/C REQUEST SIGNAL CIRCUIT DIAGNOSIS - 4.3L VIN W & Z ("C", "G", "K", "L", "M" & "P" SERIES)
- MODEL IDENTIFICATION
- INTRODUCTION
- TERMINOLOGY
- SELF-DIAGNOSTIC SYSTEM
- HARD FAILURES
- INTERMITTENT FAILURES
- DIAGNOSTIC PROCEDURE
- RETRIEVING CODES (NON-SCAN)
- READING TROUBLE CODES
- CLEARING TROUBLE CODES
- ECM LOCATION
- Diagnostic Aids
- Field Service Mode Check
- SPECIAL TOOLS (DIAGNOSTIC)
- SCAN TESTER USAGE
- SCAN TESTER DATA
- TROUBLE CODE CHARTS
- CODE 13, OPEN OXYGEN SENSOR CIRCUIT - ALL MODELS
- CODE 14, COOLANT SENSOR SIGNAL VOLTAGE LOW - ALL MODELS
- CODE 15, COOLANT SENSOR SIGNAL VOLTAGE HIGH - ALL MODELS
- CODE 16, VSS BUFFER FAULT - "S" & "T" SERIES, (VIN W) UTILITY A/T & (VIN Z) PICKUP A/T
- CODE 21, TPS SIGNAL VOLTAGE HIGH - ALL MODELS
- CODE 22, TPS SIGNAL VOLTAGE LOW - ALL MODELS
- CODE 23, INTAKE AIR TEMP. LOW - "L", "M", "S" & "T" SERIES
- CODE 24, VSS TRANSMISSION OUTPUT SIGNAL - A/T - ALL MODELS
- CODE 25, INTAKE AIR TEMPERATURE HIGH - "L", "M", "S" & "T" SERIES
- CODE 28, TRANSMISSION RANGE PRESSURE SWITCH - ALL MODELS
- CODE 32, EGR CIRCUIT ERROR BACKPRESSURE EGR WITH SOLENOID - "C", "K" & "P" SERIES
- CODE 32, EGR CIRCUIT ERROR WITH EVRV SOLENOID - "C", "G", "K" & "P" SERIES
- CODE 32, EGR CIRCUIT ERROR - "L", "M", "S" & "T" SERIES W/ LINEAR EGR
- CODE 32, EGR CIRCUIT ERROR - "C", "G" & "K" SERIES W/ LINEAR EGR
- CODE 33, MAP SENSOR SIGNAL VOLTAGE HIGH - ALL MODELS
- CODE 34, MAP SENSOR SIGNAL VOLTAGE LOW - ALL MODELS
- CODE 35, IDLE SPEED ERROR - ALL MODELS
- IAC Valve Reset Procedure
- System Too Lean
- System Too Rich
- Throttle Body
- IAC Valve Connections
- PCV Valve
- CODE 36, IDLE SPEED ACTUATOR FAULT - "C", "G", "K" & "P" SERIES A/T
- CODES 37/38, TCC BRAKE SWITCH ON/OFF - ALL MODELS A/T
- CODE 39, TCC STUCK OFF - "C", "G", "K" & "P" SERIES WITH 4L80-E TRANSMISSION
- CODE 42, IGNITION CONTROL - ALL MODELS
- CODE 43, KNOCK SENSOR W/O SPARK MODULE (DUAL SENSORS)
- CODE 43, KNOCK SENSOR WITHOUT SPARK MODULE (SINGLE SENSOR)
- CODE 43, KNOCK SENSOR WITH SPARK CONTROL MODULE "C", "K" & "P" SERIES
- CODE 44, LEAN EXHAUST INDICATION - ALL MODELS
- O2 Sensor Wire
- Fuel Contamination
- Fuel Pressure
- Exhaust Leaks
- CODE 45, RICH EXHAUST INDICATION - ALL MODELS
- Fuel Pressure High
- Ignition Ground
- Fuel Canister
- MAP Sensor
- TPS
- O2 Sensor Contamination
- EGR Problem
- CODE 51, PROM ERROR (FAULTY OR INCORRECT PROM)
- CODE 52, FAULTY CALPAK
- CODE 52/53, SYSTEM VOLTAGE HIGH - ALL MODELS
- CODE 54, FUEL PUMP CIRCUIT - ALL MODELS
- CODE 55, ECM/PCM ERROR
- CODE 58, TRANSMISSION FLUID TEMPERATURE HIGH - ALL MODELS
- CODE 59, TRANSMISSION FLUID TEMPERATURE LOW - ALL MODELS
- CODE 66, 3-2 CONTROL SOLENOID CKT FAULT 4L60-E TRANSMISSION
- CODE 67, TCC SOLENOID CIRCUIT CHECK - 4L60-E TRANSMISSION
- CODE 68, OVERDRIVE RATIO ERROR - 4L80-E TRANSMISSION
- CODE 69, TORQUE CONVERTER CLUTCH STUCK ON 4L60-E TRANSMISSION
- CODE 69, TORQUE CONVERTER CLUTCH STUCK ON 4L80-E TRANSMISSION
- CODE 72, VSS CIRCUIT LOSS TRANS OUTPUT SIGNAL - ALL MODELS
- CODE 73, PRESSURE CONTROL SOLENOID (CURRENT ERROR) - ALL MODELS
- CODE 74, TRANSMISSION INPUT SPEED ERROR 4L80-E TRANSMISSION
- CODE 75, SYSTEM VOLTAGE LOW - ALL MODELS
- CODE 79, TRANSMISSION FLUID TEMPERATURE HIGH - ALL MODELS
- CODE 81, TRANSMISSION 2-3 ERROR - ALL MODELS
- CODE 82, TRANSMISSION 1-2 ERROR - ALL MODELS
- CODE 83, TCC SOLENOID CIRCUIT FAULT - ALL MODELS
- CODE 85, UNDEFINED GEAR RATIO - ALL MODELS
- CODE 86, LOW GEAR RATIO ERROR - ALL MODELS
- CODE 87, HIGH GEAR RATIO ERROR - ALL MODELS
- CODE P0106, MAP SENSOR RANGE PROBLEM - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0107, MAP SENSOR CKT - "S" & "T" SERIES 4.3L (VIN W)
- Intermittents
- Sensor Accuracy
- CODE P0108, MAP SENSOR CKT - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0112, IAT SENSOR CIRCUIT LOW INPUT - "S" & "T" SERIES 4.3L (VIN W)
- Poor Connection Or Damaged Harness
- Intermittent Test
- CODE P0113, IAT SENSOR CIRCUIT HIGH INPUT - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0117, COOLANT TEMPERATURE SENSOR TEMPERATURE LOW "S" & "T" SERIES 4.3L (VIN W)
- CODE P0118, COOLANT TEMPERATURE SENSOR TEMPERATURE HIGH "S" & "T" SERIES 4.3L (VIN W)
- CODE P0121, TP SENSOR RANGE/PERFORMANCE PROBLEM "S" & "T" SERIES 4.3L (VIN W)
- CODE P0122, THROTTLE POSITION SENSOR SIGNAL LOW "S" & "T" SERIES 4.3L (VIN W)
- CODE P0123, THROTTLE POSITION SENSOR SIGNAL HIGH "S" & "T" SERIES 4.3L (VIN W)
- CODE P0123, THROTTLE POSITION SENSOR SIGNAL HIGH 4.3L "S" & "T" SERIES (VIN Z)
- CODE P0125, COOLANT SENSOR EXCESSIVE TIME TO CLOSED LOOP "S" & "T" SERIES 4.3L (VIN W)
- CODE P0131, HEATED OXYGEN SENSOR LOW SIGNAL VOLTAGE (LEAN) "S" & "T" SERIES 4.3L (VIN W)
- CODE P0132, HEATED O2 SENSOR HIGH SIGNAL VOLTAGE (RICH) "S" & "T" SERIES 4.3L (VIN W) BANK 1, SENSOR 1
- CODE P0133, HEATED OXYGEN SENSOR SLOW RESPONSE
- CODE P0134, HEATED OXYGEN SENSOR OPEN CIRCUIT - "S" & "T" SERIES 4.3L (VIN W) BANK 1, SENSOR 1
- CODE P0135, HEATED OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION "S" & "T" SERIES 4.3L (VIN W) BANK 1, SENSOR 1
- CODE P0137, HEATED OXYGEN SENSOR LOW SIGNAL VOLTAGE (LEAN) "S" & "T" SERIES 4.3L (VIN W) BANK 1, SENSOR 2
- CODE P0138, HEATED OXYGEN SENSOR HIGH SIGNAL VOLTAGE (RICH) "S" & "T" SERIES 4.3L (VIN W) BANK 1, SENSOR 2
- CODE P0139, HEATED OXYGEN SENSOR OPEN CIRCUIT "S" & "T" SERIES 4.3L (VIN Z) BANK 1, SENSOR 2
- CODE P0140, HEATED OXYGEN SENSOR OPEN CIRCUIT "S" & "T" SERIES 4.3L (VIN W) BANK 1, SENSOR 2
- CODE P0141, HEATED OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION "S" & "T" SERIES 4.3L (VIN W) BANK 1, SENSOR 2
- CODE P0171, FUEL TRIM LEAN - "S" & "T" SERIES 4.3L (VIN W) BANK 1, SENSOR 1
- CODE P0171, LEAN EXHAUST - "S" & "T" SERIES 4.3L (VIN Z)
- CODE P0172, FUEL TRIM RICH - "S" & "T" SERIES 4.3L (VIN W) BANK 1, SENSOR 1
- CODE P0172, RICH EXHAUST - "S" & "T" SERIES 4.3L (VIN Z)
- CODE P0300, RANDOM MISFIRE DETECTED - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0301-306, CYLINDERS 1-6 MISFIRING - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0320, IGNITION CONTROL ERROR - "S" & "T" SERIES 4.3L (VIN Z)
- CODE P0325/326, KNOCK SENSOR OPEN OR SHORTED "S" & "T" SERIES 4.3L (VIN W)
- CODE P0327, KNOCK SENSOR GROUNDED - "S" & "T" SERIES 4.3L (VIN Z)
- CODE P0328, KNOCK SENSOR OPEN - "S" & "T" SERIES 4.3L (VIN Z)
- CODE P0337/338, CRANK SENSOR INPUT - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0340, CAM SENSOR MALFUNCTION - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0341, CAM SENSOR RANGE - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0400, EGR ERROR - "S" & "T" SERIES 4.3L (VIN Z)
- CODE P0401, EGR FLOW TEST FAILURE - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0420, CATALYST EFFICIENCY LOW (BANK 1)
- CODE P0441, INCORRECT EVAP PURGE - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0500, VSS CIRCUIT - "S" & "T" SERIES
- CODES P0502/P0503, VSS CIRCUIT LOW/HIGH - "S" & "T" SERIES 4.3L (VIN W)
- CODE, P0506/507 IAC COUNTS LOW/HIGH - "S" & "T" SERIES 4.3L (VIN W)
- CODE 560, SYSTEM VOLTAGE MALFUNCTION - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0703 - TCC BRAKE INPUT CIRCUIT "S" & "T" SERIES 4.3L (VIN W)
- CODE P0712, TRANSAXLE TEMPERATURE SENSOR SIGNAL VOLTAGE LOW "S" & "T" SERIES 4.3L (VIN W)
- CODE P0713, TRANSAXLE TEMPERATURE SENSOR SIGNAL VOLTAGE HIGH "S" & "T" SERIES 4.3L (VIN W)
- CODE P0742, TCC STUCK ON - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0748, PRESSURE CONTROL SOLENOID - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0753, 1-2 SHIFT SOLENOID - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0756, 2-3 SHIFT SOLENOID PERFORMANCE - "S" & "T" SERIES 4.3L (VIN W)
- CODE P0758, 2-3 SHIFT SOLENOID ELECTRICAL "S" & "T" SERIES 4.3L (VIN W)
- CODE P1106, MAP INTERMITTENT HIGH - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1107, MAP INTERMITTENT LOW - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1111, IAT INTERMITTENT HIGH - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1112, IAT INTERMITTENT LOW - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1114, ECT INTERMITTENT LOW - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1115, ECT INTERMITTENT HIGH - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1121, TP SENSOR INTERMITTENT HIGH - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1122, TP SENSOR INTERMITTENT LOW - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1133, OXYGEN SENSOR INSUFFICIENT ACTIVITY "S" & "T" SERIES 4.3L (VIN W) BANK 1, SENSOR 1
- CODE P1221, FUEL PUMP SECONDARY SYSTEM CIRCUIT LOW "S" & "T" SERIES 4.3L (VIN W)
- CODE P1222, FUEL PUMP VOLTAGE LOW - "S" & "T" SERIES 4.3L (VIN Z)
- CODE P1345, CRANKSHAFT/CAMSHAFT SENSOR CORRELATION ERROR "S" & "T" SERIES 4.3L (VIN W)
- CODE P1351, EST OUTPUT HIGH - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1361, EST NOT TOGGLING - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1406, EGR VALVE PINTLE POSITION - "S" & "T" SERIES 4.3L (VIN W) (1 OF 2)
- CODE P1406, EGR VALVE PINTLE POSITION - "S" & "T" SERIES 4.3L (VIN W) (2 OF 2)
- CODE P1441, EVAPORATIVE SYSTEM CONTINUOUS PURGE "S" & "T" SERIES 4.3L (VIN W)
- CODE P1442, EVAPORATIVE SYSTEM VACUUM SWITCH STATIC TEST MALFUNCTION - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1508/1509, IDLE SPEED LOW/HIGH - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1632, SYSTEM VOLTAGE HIGH - "S" & "T" SERIES 4.3L (VIN Z)
- CODE P1810, TRANSMISSION RANGE SWITCH ASSEMBLY CIRCUIT "S" & "T" SERIES 4.3L (VIN W)
- CODE P1812, TRANS FLUID OVERTEMP - "S" & "T" SERIES 4.3L (VIN W)
- CODE P1860, TCC PWM SOLENOID ELECTRICAL CIRCUIT "S" & "T" SERIES 4.3L (VIN W)
- CODE P1864, TCC SOLENOID ELECTRICAL CIRCUIT "S" & "T" SERIES 4.3L (VIN W)
- CODE P1870, TRANSMISSION COMPONENT SLIPPING "S" & "T" SERIES 4.3L (VIN W)
- CODE P1886, 3-2 SOLENOID ELECTRICAL CIRCUIT "S" & "T" SERIES 4.3L (VIN W)
- SUMMARY