Metro stalls at startup sometimes and won't re-start without pushing pedal to floor.

[doug2060]

I have a problem with my metro which is becoming progressively worse over time. I want to describe the problem to you guys and get an opinion. I have ordered a new fuel pressure regulator but it won't be here until next week.

1991 Automatic
180K
1.0 3 cyl

After a good long drive up I85 I pulled in to a gas station for drinks and snacks. When I came out and started the car it sputtered and died. I tried to restart it but it wouldn't start. I pushed the gas pedal down all the way and it acted like it wanted to start. After a while it did start and I got home just fine. A few days later it did the same thing again. I took off the filter and housing and watched it. It is getting gas and spark. It acts like it is flooded so I removed the injector fuse and after a couple spins from the starter is hesitantly fired up. Once the fuel burned off it died. I replaced the fuse and it fired up just fine and I got going. The car did the same thing again yesterday at work. I tried the same thing but it would only start after I removed the injector fuse but would act flooded again after replacing it and starting. The injector is not leaking and is spraying a good pattern. I believe it is the fuel pressure regulator. I took the cover off and noticed rust on the round metal part of the diaphram and the spring was also rusted. I didn't relieve the fuel pressure so I had to hurry up and close it back up. When I have it running normally I can quickly tap the gas pedal a few times and the car will sputter and die. This will also cause these hard to start symptoms. I'm somewhat confident I found my problem but I still like to get a second opinion.

There are no trouble codes in the system memory...

[doug2060]

I took a fuel pressure regulator out of one of my parts cars for the time being. The problem is still present. It still floods. The injector is not leaking from what I can tell. All sensors etc check out OK. I have even swapped several from the parts car with no luck. Any thoughts?

[Woodie83]

Has it ever been rebuilt? An automatic with 180K miles is certainly worn out. Low compression will act very much like you say, seems it's flooded because it never gets enough compression to light up. Acts better when warm.

[doug2060]

I rebuilt it toward the end of last year.

[leonbentz]

I would have a fuel pressure test done. Put a fuel pressure guage on the return line and make sure your fuel pressure is reading 16 - 23 psi. I had this issue once and I had a kinked hose in the return line, back by the rear wheel. I was getting 60 psi at the TB.
By the back wheel on the driver's side, there is a small rubber hose that couples the metal lines from the car body to the tank. These have been known to kink or plug up. Check this hose and make sure that it is in good shape. You can remove the return line at the TB and make sure air flows through it freely.

At only 180,000 miles, the compression should still be good enough in that car to run great, unless you have a valve or two going. You could always do a compression test also.