2005 Chevrolet Astro Van Cargo, RWDFACTORY OEM SERVICE PROCEDURE

Fuel System Cleaning

  1. Remove the fuel tank. Refer to Fuel Tank Replacement .
  2. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  3. Inspect the fuel pump strainer. Replace a contaminated strainer and inspect the fuel pump. Refer to Fuel Strainer Replacement .
  4. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet.
    5. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state and federal laws and regulations.
  5. Flush the fuel tank with hot water.
  6. Pour the water out of the fuel sender assembly opening.
  7. Rock the fuel tank to be sure that the removal of water from tank is complete.
  8. Inspect the in-line fuel filter for contamination.
  9. Replace the fuel filter if the filter is plugged. Refer to Fuel Filter Replacement .
    10. IMPORTANT: Only use oil free compressed air to blow out the fuel pipes.
  10. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow.
  11. Install the fuel sender assembly with a new seal into the fuel tank. Refer to Fuel Sender Assembly Replacement .
  12. Install the fuel tank. Refer to Fuel Tank Replacement .
Factory Service Tools

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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.