the other morning i started the van and it ran fine i went to the store and from the time it took to come out of the store to the present it won't run, i changed the spark plugs, wires, distributor cap, rotorand battery, and yes i got the firing order right 1-6-5-4-3-2. i got her home but barely, she hesitates when accellerating, she doesn't idle anymore, i smell burnt rubber but all wires are away from manifold, there is black powder coming out the tailpipe, i had her idling for a few minutes then gave it a rev but it bogged before accellerating its almost like its getting too much gas, then i shut her down and started it back up (without accelerator) it started ran for 5 seconds then stalled, no check engine light, can someone please help:frown:

sounds like the EGR but that should have thrown a trouble code. try cleaning it anyway and use a screened gasget when reinstalling it.

Might be about anything at all,the 02 might have shorted out and has not triggered the code yet.The MAP might be out of whack and dumpping it full of fuel.Could be a few diff things.

Do you have any codes set?

In my experience, too much fuel usually indicates a failure of either a Throttle Position Sensor or a Coolant Temperature Sensor.

Get a volt meter and starting testing these.

ok i have the egr valve off, and i have another question, how freely should the plunger move? because i can JUST push it in and there is a pretty good rattle coming from inside it, by the way thanks for the replys its helping narrow the prob

OK so far so good, i took the egr valve off and cleaned it replaced the pcv valve and the fuel filter, i am only a small engine mechanic, outboard boat engines to be exact, anyway the motor was suffocating which i thought was too much fuel until i took the injector cover off and noticed there was back pressure coming out the intake, so to make sure i wasn't going in the wrong direction AGAIN and destroy a perfectly good cat, i took the O2 sensor off so the exhaust would have a place to go, then it started it, wasn't hesitant but still a little rough, but thats probably because only so much exhaust can escape through a 3/4" hole lol. i was talking to the fork truck mechanic at work saying i haven't heard of a cat going that quickly (because i haven't) and he told me he had one go on him on his way to toronto (which isn't really that far away), so i told myself that would be the last thing i'll check (being the most expensive) other than a stretched timing chain or a fuel pump thank god it wasn't the timing chain so i think the problem is licked, thank for the help everyone, ps if anyone needs help diagnosing a boat motor don't hesitate lol.:p

sounds like a problem a freind has with his 95 and found that the injectors tubes are leaking and they are under the intake you can get a rebuild kit from oriellys you should replace ful pressure regulator at same time aswell the fuel lines that run to it go to blazerforums.com and type in 4.3 W cpi and there are pics and he tells about it good luck

unfortunatly i replaced the cat and it is still having the problem, now, when i replaced the spark plugs my girlfriend bought bosch platinums, and a friend told me they don't run in certain engines, i was hoping this was one of those certain engines? i have the plugs out right now and i think i will go out and buy new ones in the morning

i had a friend over (he is a mechanic) and we were looking over the problems after i changed the fuel pump, fuel filter, cat, pcv valve, etc screwed with the timing and opened the injecter cover then tried to start it then he told me the same darn thing i said in the beginning:banghead: lol, the injectors are spraying too much fuel and i would most likely have to change the fuel pressure reg. luckily i have an extra throttle body sitting at a friends so i hope this will be the cheap fix after some pretty expensive let downs, but i try to look on the bright side, the money i could have paid a mechanic, i purchased new plugs, wires, dist cap, rotor, cat, fuel filter, pcv valve, air filt, fuel pump etc. when i bought the van i only expected it to last me 2 years it better last me 4 now lol, again thanks for the help

I agree with frogman:injectors tubes are leaking and they are under the intake you can get a rebuild kit from oriellys you should replace ful pressure regulator at same time aswell the fuel lines that run to it go to blazerforums.com and type in 4.3 W cpi and there are pics and he tells about it good luck

We tried many if not all of the things you have tried with our '93 astro. These fuel lines were leaking in the manifold. I wanna say they were just over $100. We actually replaced them with fuel line and haven't had any problems yet, and it has been from ohio to florida and back as well as regular driving and towing. However, i would probably recommend getting the replacement if they have updated the part. It's somewhat of a big job as a lot has to be removed to get to it....interior engine cover.

Hope this helps.

I agree with frogman:

We tried many if not all of the things you have tried with our '93 astro. These fuel lines were leaking in the manifold. I wanna say they were just over $100. We actually replaced them with fuel line and haven't had any problems yet, and it has been from ohio to florida and back as well as regular driving and towing. However, i would probably recommend getting the replacement if they have updated the part. It's somewhat of a big job as a lot has to be removed to get to it....interior engine cover.

Hope this helps. I think astrodoomed said he had a TBI and not the CPI as mentioned above. I do not think that could apply here. I am in the exact same prediciment as astrodoomed and a few seconds of dejavue sank I thought I actually wrote it. My 94 TBI ran like a dream until I went to the store and came back and suddenly it just started missing and backfiring while it sat in my driveway. I have replaced plugs and wires as I thought a burn't wire or fouled plug could cause this dramatic change so suddenly. I also had a friend give me a set of TBI injectors which I changed to no avail. Now heres the thing. Even tho I can see fuel coming from the injectors into the TB--EVERYTHING SEEMS TO RUN FINE WHEN i SPRAY A FINE MIST OF STARTER FLUID INTO THE TBI. But as soon as it burns away choke--spit sputter--die--backfire then dead---when u crank ---same sh*t----bad fuel--regulator ---I am at a loss as it decorates my driveway with the doghose sitting in the rear. I changed the fuel pump and filter about three years ago, but when the pump went back then , no fuel at all was coming forward so that diagnosis was easy---this one frusttrates me to no end!!!

ok problem is solved, 92& 94 astro listen up this will hopefully help you, cd smalley was correct it was the coolant temp sensor, it tells the pcm the engine is cold and the pcm gives the engine more gas but if the cts stays at a low reading then it will continue to flood the engine and it will be hesitant spit sputter black smooke and soot, thanks again everyone and especially cd smalley

Thanks for getting back to us. Glad you got if figured out and I'm sure glad to help.

ok problem is solved, 92& 94 astro listen up this will hopefully help you, cd smalley was correct it was the coolant temp sensor, it tells the pcm the engine is cold and the pcm gives the engine more gas but if the cts stays at a low reading then it will continue to flood the engine and it will be hesitant spit sputter black smooke and soot, thanks again everyone and especially cd smalley I don't know--mine spits and sputters from the first second I crank it -- really don't matter if it's cold or hot----BUT I'm going to go buy a cts right now and I'll let ya know.

I don't know--mine spits and sputters from the first second I crank it -- really don't matter if it's cold or hot----BUT I'm going to go buy a cts right now and I'll let ya know.CTS did nothing--I changed plugs--plug wires--injectors--cap-rotor----ran perfect from 9/00-12/06 then in one split second--misses--dies rumbles---backfires... getting fuel to the injectors into the tbi but is it enough--who knows---Maybe pump or regulator because I can bring it to life with a can o starter fluid or even carb cleaner--which tells me maybe not getting enough fuel down the throat?????????:frown:

Have you checked the fuel pressure? Needs to be 9-13psi.

94 & 92 astro, you might have a vaccuum leak take some carb cleaner or start fluid and spray around the base of the TB with engine running if it starts running better you will need a new base gasket and give the hoses a look, could try removing the pcm and clean the connections (thats how i got a code with mine, i had this problem for two months and wasn't getting anywhere, wasn't giving me a codethen one day i took it out and cleaned the terminals and it gave me a code 15) post back

Thanks for the response--I will try to get my hands on a pressure (fuel) gauge --The fuel pumps on these machines leave little to be desired but they traditionally either work or they don't--It is pumping fuel but I have no idea of the pressure without a gauge--I will get back to this thread and let ya know as this machine has been lights out since christmas.... I also have a base gasket from a TBI kit I purchased when I changed the injectors and will keep that in mind after I check fuel PSI...

ok problem is solved, 92& 94 astro listen up this will hopefully help you, cd smalley was correct it was the coolant temp sensor, it tells the pcm the engine is cold and the pcm gives the engine more gas but if the cts stays at a low reading then it will continue to flood the engine and it will be hesitant spit sputter black smooke and soot, thanks again everyone and especially cd smalleyProblem solved--FYI--It turned out to be the small rubber fuel line inside of the fuel pump assembly---it connects the fuel pump to the outgoig line--It had the consistensy of chewed bubble gum and blew a small hole out and the rest is history...

Oh my... Tell me you replaced the pump and the screen while you were in there....

Oh my... Tell me you replaced the pump and the screen while you were in there....

10-4 Mr Smalley--I bought a new carter replacement pump kit--which included the filter screen and tubing--This low pressure pump is very reasonable ($48 new) and although I am not a mechanic by trade, I own 4 Astro/Safari Vans so you can imagine I am a fuel pump exchange expert--They went out on my 94 twice-92 once--97 once and still holding my breath on my 02. I worked on this mystery problem for about three weeks before I by chance noticed bubbles in the fuel line while I was testing pressure... Anyway big relief and I hope my post gives some poor puzzled shadetree at least one new direction to check.