Fuel Gage Beyond Full - No Start

[astrodaddy]

Hey everyone, I recently replaced the rad support in my 94 Astro EXT and everything is back together and looking good. I now have a new problem, the van wont start and the fuel gage goes beyond full when I turn the key to the "Start" position. Any ideas on what is wrong? The battery is brand new and fully charged, and she cranks over strong but wont kick over. Im heading back out to check the fuses right now.

[Mr_Bowtie]

Were there any ground on the radiator support that you could have forgot to bolt back up?

[astrodaddy]

Im not sure, I have the service manual but I cant seem to find any info on it.

[astrodaddy]

I got power to the headlights, turn signals and brake lights. The cluster lights up and all the gages seem to work but the fuel gage. Hopefully someone can chime in on a ground I missed.

[Mr_Bowtie]

Can you hear the fuel pump priming?

Sounds like it might be time to check for spark and fuel.

Any other info you can give us? How long has the Van been sitting before it was last run? How many miles? Any other repairs done recently?

[astrodaddy]

Can you hear the fuel pump priming?

Sounds like it might be time to check for spark and fuel.

Any other info you can give us? How long has the Van been sitting before it was last run? How many miles? Any other repairs done recently?

Well, I could not hear the fuel pump priming. Last time it was started was about 4 months ago. And no, no other repairs have been done. Im guessing either the fuel pump died or there is a ground I missed. She started up just fine before I took out the old radiator support and welded in a new one.

Can anyone tell me if the fuel pump is grounded to the radiator support?

**EDIT - The fuel gage now goes beyond full to 1/2 tank within a second of turning it to the start position, which I believe is accurate of how much gas is in the tank.

[RECox286]

Sounds to me like the fuel gage is working as advertized, I wouldn't be concerned as long as it indicates the approximate level in the tank.

If you have lost the fuel pump, you can try the "hammer on the old fuel tank trick". You may vibrate it enough to get the motor running, caution though: sometimes it works and sometimes it don't! Other things to try: see if the relay is working (it's in the right corner of the eng compartment, just above the heater and attached to the firewall. There should be a wire tap (connector in the harness nearby. See if you get power to the pump side of the circuit. Next: the ground for the pump is under truck and downstream of the fuel filter , attached to a transverse member. Look for the pump harness coming from the tank. There will be a multiwire connector and the ground wire will be in that vicinity. I can't think of anything that would disable the pump per se from the rad support job. Unless you arc welded during the repair and fried a ground wire.

Tip: Shoot some CRC down the throttle body, and crank the engine to see if you have spark. Caution: don't use starter fluid, O2 sensors don't like the taste it leaves in their mouths.

Good luck, Bob

[astrodaddy]

Thanks Bob!

Its too late at night now for me to be pounding on the gas tank with my neighbors all asleep, but I will give your suggestions a try and update as soon as I can.

Im moving into a new house tomorrow, and wont have internet access until wednesday. Ill probably try to get her together next saturday.

[AmericanMade717]

What year is your van? Check the fuseable links behind the battery. One time mine died and the fuel pump wasn't buzzin, so I thought it was the fuel pump, but it was the fuseable links behind the battery, but mine was a 94', idk were they would be on a newer year. I wiggled the fuseable links and it started up, got it home, and fixed it. Another thing to check is the fuel pump relay.