Fuel System complaints by model year
Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
What owners report
Front suspension issues, electrical gauges, replacement of fuel tank pump, door latches failing to open on sliding side door making exiting of vehicle impossible, recall of 02V328000 unable to be confirmed as handled by any dealers.
While fueling my vehicle at a gas station, I pumped about $3.00 worth of gas into my 1/8 tank. After it reached $3.00 a loud hissing sound came from the filling neck of my van (not the actual gas station pump) and a large amount of gasoline sprayed me on the stomach and upper legs. There was no sign that this was going to happen. I am still awaiting word on getting repair authorized. It is my understanding that there is a TSB regarding the fuel system on the 2003 Chevrolet Astro van.
Van will not pass smog. The very last time I drove it, I was driving it on a city street and it just died out. I've spent hundreds of dollars to have it fixed and itstill isn't fixed to pass smog. A shop said my fuel injection spider system is bad.
A year and a half ago there as a loss of power and an engine miss. A fuel system cleaning in a shop cleared this up. Then at the end of December the van would no start. We had it towed to our local meineke. It was determined the sequential central port injector had failed. This is a documented problem for a defective part. I wrote a letter to GM to ask for reimbursement. They refused because I did not go to a dealership. And meinke used an after market part.
While traveling at highway speeds the accelerator pedal became stuck. Vehicle continued to accelerate in a run-away mode. Vehicle was eventually stopped through combination of brakes and traveling into mud. Upon stopping it was noticed that the front brakes were flaming - most likely due to excessive heat.
Hi, I was driving this van when all of a sudden it stops. I had a very hard problem of trying to get off the road with no brakes or steering. I had it towed into service. They replaced everything fuel pump, sending unit, fuel filter, plugs, plug wires, distributor and reset the timing. It never did show up a check engine light or showed a code that something was wrong. I drove it two days later and it did the same thing. They checked it out and drove it again for a week and it happen again. I spent $1200 trying to get this safe to drive. It is as if the key was shut off. Finally with some of my knowledge about what can cause this to happen I checked the battery. It was only one year old. It showed up as bad under a load. When I took the van back to the repair shop they said battery showed good. Finally I took the battery back to auto zone they showed it as bad also and replaced it. …
While driving the vehicle would surge and jerk then clunk, the dealer has attempted to repair the vehicle several time but the problem resurfaces, other failures include PCM failed causing the check engine light to illuminate, the gas gauge jumps from full tank to empty causing the vehicle to run out of gas, rear door handle broke twice, drivers side window motor was replaced and the air bag light would flicker on and off.
Dt: there is a problem with the fuel gauge sensor. The problem first started happening on 3-21-05. When the consumer took the vehicle to a mechanic they told her that they had to fix two other vehicles of the same year and make for the same issue. The problem has not been fixed as of yet.
Related recalls (1)
Fuel system, gasoline › Storage › Tank assembly › Mounting
The fuel lines attached to the fuel tank were not properly tightened.
Remedy: Dealers will lower the fuel tank and tighten the fuel tank lines to the proper torque value.
Frequently asked questions
Which Chevrolet Astro years have fuel system problems?
By NHTSA complaints, the 1997 (43), 1995 (28), 1998 (28), 1996 (19) and 2000 (11) model years. Fuel System complaints make up 12% of all complaints for the 1997.
Is there a recall for Chevrolet Astro fuel system problems?
Yes — 1 recall, including 94V-188 (mounting, Oct 4, 1994). Recall repairs are free at authorized dealers; check a specific car with the VIN recall check.
At what mileage do Chevrolet Astro fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 100,000 miles; 10% happened before 50,000 miles.
What part fails most often?
Owners most often name the delivery › fuel pump (41 mentions), followed by the fuel injection system (29).
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.