Car won't start after changing fuel tank, sending unit and filter - please help.

Tiny
MALIBU-98
  • MEMBER
  • 1998 CHEVROLET MALIBU
  • 155,000 MILES
My gas tank on a 1998 chevy Malibu LS rusted and was leaking. I ordered replacement OEM tank and fuel sending unit. I was able to drop the tank and replace with new tank and new sending unit. The new sending unit required a new harness connection which I replaced with supplied crimp terminal connectors and heat shrink cover. I installed everything, reconnected the battery and then cycled the key several times and tried starting. It cranked but did not start. I cycled the key several more times, like 20+ times and still no luck. I thought maybe I miss connected one of the fuel lines or new harness wires so I dropped the tank again and double checked everything. It seemed all correct so I but it back together and had the same result. I started thinking the fuel filter maybe clogged. While reading about this I also learned about the schrader valve on the fuel injector manifold. Before changing thenfilter I cycled the key to on and depressed the valve stem on the schrader valve to check for fuel. There was just a dribble of fuel. I forgot to mention that the fuel pump can be heard cycling on with the key for about two seconds. Assuming now that the filter really is the culprit. I changed that and tried again. Same result although a little gas seemed to make it because after several cycles with the key the engine fired ever so slightly. I checked fuel at the schrader valve and only a liitle fuel trickled out.

The car was running fine before I replaced everything, what could be wrong. I am about to give up and have it towed to shop to be fixed but am hoping I am missing something simple. I appreciate your help.
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Tuesday, December 20th, 2011 AT 5:33 PM

5 Replies

Tiny
2CEXPT
  • MEMBER
Sounds like a fuel pump problem-check the fuel pressure if its within specs with a gauge -you sure you hook the hoses correctly inside the tank
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Tuesday, December 20th, 2011 AT 5:48 PM
Tiny
MALIBU-98
  • MEMBER
I did not pay attention to hoses in tank on new sending unit. I only placed in and attached the lines outside of the tank. Did I need to attach lines within tank? Thx
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Tuesday, December 20th, 2011 AT 5:53 PM
Tiny
2CEXPT
  • MEMBER
Check the fuel pressure with a gauge and then comeback with the readings
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Tuesday, December 20th, 2011 AT 5:55 PM
Tiny
MALIBU-98
  • MEMBER
Unfortunately I do not currently have a fuel pressure gauge. I can only tell you that a spoonful of gas comes out under very low pressure and stops. Anyway to proceed without pressure reading?
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Tuesday, December 20th, 2011 AT 5:59 PM
Tiny
2CEXPT
  • MEMBER
Sounds like the fuel pump is a goner
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Tuesday, December 20th, 2011 AT 11:12 PM

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