1996 Chevy Astro Van Rich Running Mystery Solved: Faulty Spider Injector Replacement

Diagnosing the Rich Condition

• 💡 The 1996 Chevy Astro van presented with a severe misfire and a rich running condition, evidenced by fuel dripping from the tailpipe.
• ⚠️ Initial diagnosis pointed to a faulty spider injector assembly, despite a recent replacement.
• 🚀 The process involved partially reassembling the engine to safely test the fuel system and pinpoint the leak.

Identifying the Injector Leak

• 💧 Upon turning the key, fuel was observed leaking directly from the bottom of the injector assembly.
• 🔍 Closer inspection revealed a heavy rub mark on one of the injector straws, suggesting it had worn through.
• 💬 While individual injector repair is possible, the decision was made to replace the entire injector assembly to ensure warranty and reliability.

New Injector Installation and Bracket Differences

• 🛠️ The new injector assembly required a different style of mounting bracket compared to the original.
• 🧐 While the installed height remained the same, the new bracket had a different bolt head profile and was narrower.
• ✅ The new injector assembly was installed, clicking into place with the correct cylinder numbering (1, 3, 5 and 2, 4, 6).

Verification and Final Checks

• 📈 After reassembly, the engine was started, and live data was monitored.
• ✅ The fuel trims were within acceptable limits, indicating the rich condition was resolved.
• 🌟 The customer's complaint of skipping and bucking was fixed, and the check engine light was off.

Additional Precautionary Repair

• ⚙️ The customer also requested the replacement of the crankshaft sensor as a precautionary measure, based on a previous van's issues.
• 🔧 A crankshaft position sensor relearn procedure was performed, which is standard practice on these older GM vehicles after sensor replacement.