Last post on Apr 30, 2013 at 10:37 AM
You are in the GMC Safari & Chevy Astro
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Chevrolet Astro, Fuel System, Van
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#139 of 210 Re: chevy astro 1993 tbi z motor won't run [Steve_01]
Feb 14, 2009 (3:14 pm)
Thanks Steve. Your problem description matches mine. My Haynes manual has a pretty good trouble shooting section for the fuel system. The fuel pressure regulator is on the 1993 Z-motor TBI assembly. When I get more time to work on it, I will verify that the left line is the fuel supply line, and the right line is the tank return. Another thing to check, if you have a later model (i.e. Vortec) Astro, is whether your fuel gauge is bad. My wife's 1999 (Vortec intake) Suburban died in traffic the other day with the fuel gauge indicating completely full. After we had it towed home, we figured out that the fuel tank was absolutely empty. Now we rely on the trip meter instead of the gauge. My Astro does not seem to be out of fuel, since it primes every time. It will probably be a few weeks before I get to the bottom of this.
#140 of 210 Astro fuel stall problem solved
Feb 21, 2009 (8:27 pm)
For those who have been following my posts, I have tinkered with my 1993 Astro for almost 5 months now, could not get it to run. It would start, run rough for about 5 seconds, then die. I replaced the cap, rotor, plugwires, plugs, and fuel filter. Which was okay, they needed it anyway. Then I made the mistake of cutting off the catalytic converter, big mistake. At this point I got the dealer involved, hoping he could help guide me to a solution. He "installed" a new cat for me. His first foray was to replace the fuel pressure regulator. That did not fix it. Then he convinced me to authorize a fuel pump replacement. But that did not fix it. Then he wanted to replace the injectors, I said no. I could not afford his $90/hour rate. I paid him $500 for nothing, had it towed home. I replaced the injector pod, per the dealer's recommendation, still did not fix it. I noticed he simply clamped the new cat up, did not bother to weld it, big air gaps near the O2 sensor! Over time I also replaced the IAC valve, the fuel oil pressure switch, the coil, and the ECM/PCM; all unnecessary. Then it sat through another hard winter here in Ohio. I finally decided to look at the fuel pump work that was done by the dealer today. When I got the fuel sender assembly out of the tank, I noticed that the dealer had shoved the old torn clogged fuel screen onto the new fuel pump. Pretty shoddy work. Then I noticed that the dealer did not use the short section of fuel hose that comes in the kit, but instead used the original hose, which connects the pump to the main fuel line. When I touched it I noticed it was crumbly, most likely the source of the black specks that I found in the first fuel filter I changed. When I pulled it (the crumbly short foam fuel hose) off the dealer installed fuel pump, I noticed it had a big hole in it!! Actually it looked like a slit. I bought a new pump, a new fuel screen, some fuel hoses, and reinstalled the fuel pump assembly correctly, tank, etc...I added some gas, charged the battery, put the dog house back on, installed the computer and trim panels, dejacked the Astro. She started right up, purred like a kitten. Problem solved! So the original problem was a hole in the short section of fuel hose between the fuel pump and the fuel line. I also replaced the fuel relay connector since it was melted, probably from a fuel pump that was working itself to death. I'll have to have a local welder seal the cat forward of the O2 sensor. I may write a letter to the dealer complaining about the shoddy work of the service department, but in this economy, I don't want to get anyone fired. I hope the Astro returns to its trustworthy self.
#141 of 210 Re: Astro fuel stall problem solved [blackpacific1]
Feb 25, 2009 (9:45 am)
NOT!! I drove this beast to town, it died after about 50 miles! When the tow truck operator picked it up the next day, it started right up. When he dropped it at our house he demonstrated that it would start right up. I changed the fuel filter again this morning, thinking the fuel tank work had stirred up a lot of dirt. The van started and ran fine for a few minutes, then died. Now it won't start. The tow truck guy thought the crank sensor could be losing it, giving good signal when cold, and then going bad when hot. I suppose I could blindly replace another perfectly good part? I can't believe this van.
#142 of 210 Re: Astro fuel stall problem solved [blackpacific1]
Feb 25, 2009 (4:46 pm)
We all feel your pain brother. These vans are fricken unbelievable. I'm tired of throwing good money after bad on mine, not to mention the time involved. If I hadn't lost my job back in January, I think I'd finally give up on mine. About the only thing I haven't replaced are the O2 sensors and catalytic converter. Oh ya, and the fuel injector unit, although I tried one of the new style multiport fuel injector "upgrades" but there's no way it fits. The hoses kink when you try to fit them into the intake manifold. Anyway, I guess we all just keep plugging away. Maybe Obama will provide us all with new Astros! Uhhh...yaaaa....
#143 of 210 Re: Astro fuel stall not solved [Steve_01]
Feb 28, 2009 (10:21 am)
I went another round with the Astro today, and lost. I could not get it to start, no spark. I re-investigated a relay next to the fuel relay that looked like it might have cooked in the past, replaced it with a new one I had sitting around, and the damn van started. While it was running I wiggled the wire harness to this unnamed relay, it might be for the ac/heater blower, and the van stumbled a little. Then I closed the passenger door and it died. It would not start after that. It's too cold to work on it any more today, but I suspect the computer is not properly grounded? It is right there next to the passenger door hinge. I checked the resistance(s) of the coil, all 3 tests were nominal. I suppose I'll need to pull the computer out and see if there is some ground strap that I did not reinstall the last time I pulled it out. This van does not want to serve. The good news is that I think I have fixed all the fuel issues I was having. Now I just need to find this electrical bug.
#144 of 210 Astro fuel and electrical stall fixed
Mar 03, 2009 (6:58 am)
I finally vanquished the Astro's problems. After fixing the fuel issues, which you can see from my previous posts, I went after the sudden loss of spark. I took the ignition module to the auto parts store, had it tested. It failed. I replaced it yesterday, and the van is running just fine.
In summary, I had the following failures in order of appearance. The first thing that happened in September (5 months ago) was I jump started the van, and melted the 4 prong connector behind the battery. I fixed it, then went on a long road trip. When I got back the van died. Basically no fuel pressure. I replaced the fuel filter, which was jammed with black flecks, and but that was not the problem. I had the dealer replace the fuel pump, but he did it incorrectly. I discovered later that the short (2" long) section of hose between the pump and the steel line had a hole in it. The dealer had reused the original hose on the new pump, and thus the new pump delivered fuel right back into the tank! It was also the source of the black flecks which jammed my fuel filter. I found that the electrical connector to the fuel relay was badly melted, and replaced it. It may have overheated from a fuel pump that was overworked. The last problem was an intermittent ignition control module which finally failed hard. None of these problems were detected by the computer, which is probably why so many shade tree mechanics like myself have such difficulty finding them. I do hope the Astro will ride for many more miles.
#145 of 210 Problem is solved
Mar 18, 2009 (3:56 pm)
Ok so after many months of using carb cleaner to start the car, It finally gave out in the McDonalds Drive Thru.
It just stalled and wouldn't start.
After towing it home, I couldn't hear the fuel pump engage at all.
So I dropped the tank, and rebuilt the pump. Low and behold she fired right up
As far as the the fuel filter, I cut the lines and used a fuel line repair kit, so i could install the the new filter.
I will say this much. This was no easy job. The bolts that the secure the fuel tank straps were rusted and would not bulge. Two of them would not budge. So I had to cut the straps.
Anyway I ordered new straps and am in the process now of cutting into the floor to install some new bolts.
Removing the fuel lines that run from the tank (Which are suppose to be quick connect) was very time consuming. There was a lot of rust buildup.
I am just happy there were no fuel leaks.
Anyway by tomorrow i will finally be finished and back on the road
#146 of 210 Re: Problem is solved [keico]
by steve_ HOST
Apr 02, 2009 (11:04 am)
I haven't been following this thread, but sometimes you can get a balky fuel pump working temporarily by banging on the fuel tank with a rubber mallet or chunk of wood. It helps to know the "right spot" to bang on.
But that trick saved my neighbor a tow with his Aerostar last summer.
Steve, visiting host
#147 of 210 Crank angle sensor = Some definite progress...
May 05, 2009 (8:00 pm)
I replaced the crankshaft position sensor and now the engine seems to run better, but still not good. Now instead of all the misfiring, choking, and puking, it just seems to be a bit underpowered. Before replacing the crank angle sensor, if I would give the engine a little throttle, it would sound like it was about to self destruct. Now it runs much better but it has a stumble and/or hesitation and runs smooth at a constant RPM. I believe the crank angle sensor was definitely part of the overall problem. I just ordered 6 new separate injectors and am going to rebuild the injector unit myself. About $150 for a set of brand new, not rebuilt, injectors. I'll let you know how it goes...
May 16, 2009 (6:33 pm)
Did you find the answer to why your astro dous not have lights or fuel pump? Please reply, thanks.