I have a 95 Astro van with 285,000+ miles on it. About a year ago, I had the cylinder heads reconditioned and the engine ran great up until about two weeks ago. It started cutting out on my way to work. I thought I might have gotten some bad fuel, so I added a bottle of gas dryer. It didn't help, and finally quit running and wouldn't start up again. After checking through this forum and other web sites, it appeared that the problem could be the fuel pressure regulator that is attached to the cpi injector. I replaced it and the engine started right up and ran great for about 3 miles. At which point it simply died without a sputter. Had it towed home and pulled the plenum again. Removed the fuel pressure regulator and re-installed it. Again, the engined fired right up. This time it ran ok for two days, then started cutting out again and finally quit and wouldn't start up again.
I installed a new distributor cap and rotor and and ignition coil but no change. I hooked up a fuel pressure gauge and with the key on, I got a reading of between 60 and 65 psi. However, as soon as the pump stopped running, the pressure immediately dropped to about 8 psi. From what I've read, it should stay up for at least a couple of minutes.

Ok, here is the confusing part. The van started right up this morning after sitting for several days. I didn't move it for fear of it stalling on me again, but I let it idle. A half hour later, it was still running. I shut it off, and tried starting it and it wouldn't even fire. When it was sitting there idling, the fuel pressure stayed at 55 psi.

Will replacing the cpi spider assembly fix the problem or do I look for something else?

Did you replace just the fuel pressure regulator part or the whole spider part?

Also, did you check the lines leading to/from the spider for leaks?

When you had the intake off did you see puddling of fuel there?

Did you replace just the fuel pressure regulator part or the whole spider part?

Also, did you check the lines leading to/from the spider for leaks?

When you had the intake off did you see puddling of fuel there?


I only replaced the fuel pressure regulator. No, I didn't specifically check the lines leading to and from the spider. There was a little gas in the manifold when I removed the plenum. I turned the key on with the plenum off, but didn't notice any leaks at the time. It will have to come off again, so I will look more closely this time.

Thanks

Excessive leakdown could also be due to a leaking check valve in the fuel pump. To determine where the problem is, (in the plenum or the fuel pump) a shut off valve must be installed between the pump and the service port to isolate the pump after it pressureizes the system.