Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Chevrolet Astro Van Cargo, AWDFACTORY OEM SERVICE PROCEDURE
Installation Procedure
- Properly position each spark plug washer.
- Inspect each spark plug gap. Adjust each plug as needed.
Specification: Spark plug gap: 1.524 mm (0.060 in).
NOTE: Refer to FASTENER NOTICE in Cautions and Notices. - Hand start the spark plugs in the corresponding cylinders.
- Tighten the spark plugs.
Tighten:
- For used heads tighten the spark plugs to 15 N.m (11 lb ft).
- For new aluminum heads tighten the spark plugs to 20 N.m (15 lb ft).
- For new iron heads tighten the spark plugs to 30 N.m (22 lb ft).
- Install the spark plug wires. Refer to Spark Plug Wire Replacement .
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.