Complete digital official shop manual in English & Spanish contains service, maintenance, and troubleshooting information for the 1985-2005 Chevrolet Astro. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Chevrolet Astro 1985-2005 is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

EXCERPT:
2005 ENGINE Engine Mechanical - 4.3L - Astro & Safari
Oil Filter Bypass Valve Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Position a suitable container to catch the engine oil.
3. Remove the oil filter.
4. Remove the oil filter adapter. Refer to Oil Filter Adapter Replacement.
Fig. 133: Removing Oil Filter Bypass Valve
5. Using a suitable prying tool remove the oil filter bypass valve.
6. Clean and inspect valve bore for damage.
Installation Procedure
Fig. 134: Installing Oil Filter Bypass Valve
CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
1. Install a NEW oil filter bypass valve using the following procedure:
1. Use a brass drift that is the same diameter as the outside diameter of the oil filter bypass valve.
2. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block.
3. Using a pointed punch, stake the engine block area around the oil filter bypass valve.
Stake in 3 locations 120 degrees apart.
2. Install the oil filter adapter. Refer to Oil Filter Adapter Replacement.
3. Install the oil filter. Refer to Engine Oil and Oil Filter Replacement.
4. Lower the vehicle.
Oil Pan Replacement
Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
2. Remove the oil level indicator.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the oil pan drain plug and drain the engine oil into a suitable container.
5. Remove the oil filter.
Fig. 135: Locating Oil Cooler Pipes Bracket Retaining Bolt
6. Remove the bolt holding the oil cooler pipes bracket to the oil pan.
7. Remove the oil filter adapter. Refer to Oil Filter Adapter Replacement.
Fig. 136: Identifying Starter Wiring Harness & Transmission Cooler Pipes Bracket Retaining Bolt
8. Remove the bolt holding the bracket for the starter wiring harness and the transmission cooler pipes.
9. Remove the crankcase position (CKP) sensor wiring harness from the retainer.
10. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.

1. Los tubos de freno, apretando las conexiones manualmente en el cilindro principal y en la unidad hidráulica (2/3).
– Las conexiones de los tubos de freno: 11,5 N.m (8,5 lbf.pie).
– Alinee los tubos de freno, asegurándose de que los mismos estén paralelos para que no haya interferencia entre ellos y ni tampoco con los otros componentes.
2. Las abrazaderas de fijación (1) en los tubos rígidos de freno.
3. La caja de relevadores en el soporte.
4. El mazo de conductores en el soporte de la caja de relevadores.
5. Los conectores múltiples en el soporte de la caja de relevadores.
6. La batería en el vehículo.

Tubo de Freno de la Unidad Hidráulica del ABS a la Manguera (Flexible) de la Rueda Delantera Izquierda (Freno de Servicio) – Quitar e Instalar
Grupo H - 5 de 6 10/2002 Astra
1. El tubo de freno de la rueda delantera izquierda, fijándolo en los soportes y hebillas alrededor de la carrocería del vehículo.
2. La conexión del tubo de freno de la rueda delantera izquierda en la manguera flexible del freno delantero. – La conexión del tubo de freno a la manguera de la rueda: 11,5 N.m (8,5 lbf.pie).
3. El tubo de freno (2) de la rueda delantera izquierda en la unidad hidráulica, apretando la conexión manualmente. – Alinee el tubo de freno, asegurándose de que estén perfectamente alineados y paralelos para evitar fricción con el otro tubo y los demás componentes.
– La conexión del tubo de freno a la unidad hidráulica: 11,5 N.m (8,5 lbf.pie).
4. La abrazadera de fijación (1) en los tubos de freno.
5. La caja de relevadores en el soporte.
6. El mazo de conductores en el soporte de la caja de relevadores.
7. Los conectores múltiples en los soportes de la caja de relevadores.

Tubo de Freno de la Unidad Hidráulica del ABS a la Manguera (Flexible) de la Rueda Delantera Derecha (Freno de Servicio) – Quitar e Instalar Grupo H - 3 de 6 10/2002 Astra
3. La caja de relevadores (3) del soporte de la caja de relevadores y desplácela hacia el lado.
4. El mazo de conductores del soporte de la caja de relevadores.
5. La tapa del depósito de fluido de freno y quite el fluido de freno.
6. La abrazadera de fijación (1) de los tubos de freno.
7. El tubo de freno de la rueda delantera derecha (2) de la unidad hidráulica.
– Proteja las conexiones abiertas de la unidad hidráulica para evitar contaminación; utilice tapones selladores.
– Levante el vehículo.
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