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92 Astro problems


Stonedsurfer
04-23-2007, 12:24 AM
Our 92 4.3L cpi "w" awd ext LT van started having a stall problem. First thing I checked was fuel pressure. It made 60 + psi then seeped off. Tested by pinching the line off to make sure it was not leaking into the intake. I replaced the fuel pump,screen and filter. Thought problems were through. Van would not restart even with good fuel pressure. While testing for injector pulse I found a bad injector wire inside the intake manafold. Wiggled the wire van would start but ran poorly and would stall when driven. Wiggle it again and it would stall. All this with no codes at all. Made my own wires running to the injector clip inside manifold and put it together. Low cost fix and it ran great. Thought the problems were through. 3 weeks later the wife (mad) says vans stalling again. I thought maybe my wires failing,but checked for codes and got 32 egr. Found carbon chips holding it open,cleaned it out and van ran great for 1 more week, then stall again. (wife madder). Checked egr,looked good but somehow broke a flange off it while torquing it down(Husband now real mad). I have a parts van and tried the spare with no luck. Still code 32, still stalling. Went out and bought a new linear egr valve for $200,installed it with a kleen screen gasket and still got code 32 right away. Van would idle great,reve up great,drive easily around under 35mph. If you punched it up to 35mph it stalled. If you took it easy to 40-55 mph it still stalled. I tested egr and clip to make sure it was getting correct voltage and ohms and it passed. Finally I gave up after spending all my money and time, and took it to the dealership. They tested it out for 2.4 hours and diagnosed it a bad injector assembly(spyder) I tore it down again and took out the bad spyder. While removing the one from the parts van, one of the injector retaining clips broke off just below the knub that hold it in. Dealer said its non serviceble and needed to replace the whole unit,$500. I studied the clip and chose to epoxy it back into place. It snapped into place along with all the others,and tested with no leaks. So I put it back together again. It has passed all my driving tests so far but still has code 32. I'll ignore it for now as long as it has no adverse affect on the preformance. Dealership couldn't figure that one out either. Egr had me running around in circles and getting no where,when the spyder was the problem. I couldn't test it as it was dying and thats where they came in. I used them like any other tool I've used to fix this van. Now I'm assuming the problems are through again. I did notice my digital temp. gauge quit working 4 days ago before taking it to the dealership. I'm hoping its only the senser,$20. I'm also hoping it only monitors the engine temperature and does not cause it to over heat. It seemed fine while test driving and wasn't boiling when shut off. When I turn on the key the guage shows full bars then goes down to nothing, so I assume the guage still works. I will replace the senser tomorrow if I can get my paycheck in advance. This all started with a stall out and progressed from there. The fuel pump was weak,but wasn't the main problem. The bad injector wire was a problem,but wasn't the main problem. Linear egr valve was a problem after I broke it,but wasn't the main problem. Spyder was the problem. Even though it functioned great at idle,it failed at upper rpms under load. I believe the spyder was getting weaker all the time and is what caused the initial stalling when the injector wire wasn't being a problem. I never got a code for the spyder,injector,or anything but the egr. Strange. This goes to show that if you fix one thing, it can seem to lead to a whole series of problems. Its been that way in my case but I never gave up (except when I took it to delership after the egr brainfart). Don't give into the downfalls of working the problems through. With some sound advice from the good people at this sight,I've been able to work this all out at minimum cost. All I had to do was ask and not worry about not not knowing or feeling dumb, its how I learned this van from top to bottom. The pressure is off for now and even my eyelid stopped twitching the way it does when I'm stressed out. :) This Astro is the best vehical I've ever owned and is worth the time and effort to keep it on the road instead of giving up and buying a GEO. If you have a long fix-it story, lets hear it. Now the wifes happy and so am I. Peace out..

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