Repair 7

There are two oxygen or O2 sensors in the exhaust system on the 1995 Chevy Astro van. The process of changing the O2 sensors is the same whether it is the upstream or downstream sensors that you need to change, except that the location is different. These O2 sensors are critical to the proper operation of the fuel system and performance of the engine in your van. If you have a bad sensor, change it right away to correct drivability issues, hard stats and poor fuel mileage.

Instructions

1

Raise the front of your Chevy Astro with a jack and support it under the frame rails with a set of jack stands. Remove the jack once the van is securely on the stands.

2

Locate the O2 sensors from under the van. The upstream sensor threads into the exhaust pipe coming down from the engine manifold. It is on the inside edge of the pipe, closest to the engine block. The downstream O2 sensor is in the exhaust system just forward of the catalytic converter.

3

Determine which sensor you need to change, and position yourself below it. Locate the wiring harness coming out of the back of the top of the sensor and follow it up to the connector where the sensors harness and the vans wiring harness join. Disconnect the two halves of the connector by releasing the locking tab and pulling them apart.

4

Remove the O2 sensor from the exhaust pipe using an O2 sensor socket and ratchet to turn the sensor counterclockwise until it is free from the threads. Discard the old sensor and install the new one into the threaded hole on the exhaust pipe using your hands to get it starter. This will help prevent cross threading.

5

Tighten the O2 sensor with your O2 sensor socket and ratchet. Run the wiring harness connector from the new sensor up to the connector on the vans wiring harness. Push the two halves of the connectors together until the locking tab engages. If you are replacing both sensors, move to the other sensor and repeat the process.

6

Raise the front of your Astro off the jack stands with a jack. Remove the stands from under the van then lower the jack, setting the van back on the ground. Test run the engine to verify the sensors are functioning properly.

If your van runs out of gas, this can create more problems than just not being able to move at the moment. Once you ill the tank, you still may have problems restarting the engine. Any fuel system that runs too low on gas can experience problems with the fuel pump and fuel pressure. You might be able to restart the car if you can re-pressurize the system, but its possible that you will need a new pump altogether.

Instructions

Refilling and Re-pressurizing

1

Fill the fuel tank with unleaded gasoline from an approved gas can. Use the largest amount of fuel you can transport to the van.

2

Turn the ignition key to the start position for about two seconds, then tun it back to the off position for five more seconds. Repeat this five to 10 times to re-pressurize the fuel system.

3

Try starting the car again. If it wont start at this point, you will likely need to replace a burned-out fuel pump.

4

Siphon out the fuel with a never-used vacuum pump and store it in the gas can, if you need to change the pump, then disconnect the negative battery cable.

Fuel Pump

5

Raise the van on its rear end and support it with jack stands, blocking the front wheels with heavy blocks. Raise the floor jack or a transmission jack under the tank.

6

Disconnect the electrical connectors on the fuel tank and then unclip the lower shield on the tanks right side to reveal the fuel line fittings. Loosen and disconnect the fittings with a screwdriver, then disconnect the filler neck from the tank.

7

Unbolt and remove the straps for the tank and lower it down with the jack, disconnecting the fuel pump lead.

8

Tap and loosen the locking ring with a brass punch and hammer until the tangs and cut outs line up. Pull the pump assembly out of the tank.

9

Insert the new pump assembly into the tank, making sure it is lined up in the same position as the old one was, then turn/tap the lock ring into place.

10

Reconnect all the lines and electrical connectors to the fuel pump flange, raise the tank into position and bolt the tank into place.

11

Refill the tank and perform the pressurization steps as described in Section 1.

Towing capability can be an added and often unexpected perk when it comes to vehicles. The 2003 Chevy Astro was a mini van that came in both passenger and cargo versions, and both models came with a factory hitch and respectable towing capacity. The Astro van served well at towing a utility trailer for work tasks or a boat for weekend family adventures. While mini vans were big sellers in the late 1980s and early 1990s, they became less so with the introduction of the SUV.

Cargo Van Towing Capacity

Although the Astro cargo van has only the front two seats, its engine provides more capacity than the passenger van. The cargo van is available in a two-wheel-drive or all-wheel-drive version. The two-wheel-drive cargo van has a towing capacity of 5,800 pounds, and the all-wheel-drive is capable of towing 5,600 pounds.

Passenger Van Towing Capacity

The Astro passenger van has more available seating, but the tow capacity is less than the cargo. The two-wheel-drive passenger van has a towing capacity of 5,400 pounds, while all-wheel-drive passenger version is capable of pulling 5,100 pounds.

Tongue Weight

Both the cargo and passenger versions of the Astro can have a safe tongue weight of 500 pounds. It is possible to gain an additional 10 to 15 percent of capacity and tongue weight by installing an aftermarket hitch assembly known as a weight-distributing hitch.

Safety

Whenever a vehicle is towing something behind it, safety is a priority. Make sure all lights are in working order, and have someone help to check turn signals, brake lights and reverse lights. It is never advisable to go over the speed limit with a trailer. Take care through corners, and avoid sudden directional changes. Braking will require more time and distance than without something in tow, so plan your stops accordingly.