04 cavalier intermittent fuel pump

GMC guy

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#1
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MAKE: Chev
MODEL: Cavalier
YEAR:2004
MILES:160
ENGINE:2.2
DESCRIBE ISSUE....Car runs for a week, then get in to start...no start, just crank. Tow truck time. One day i wiggled the fuel relay and had pressure gauge connected to the fuel port. The pressure would go to 60 psi and car would run. I wiggle it again and pressure starts to drop and car stalls. I pulled the relay box apart and got the wires out and put them on the relay. I still didnt get pressure. now i thought that was the problem. It is not. I keep reading that there is a connector by the kick panel. I looked, and there is not a connector there. I guess i'll be testing the relay wires..Thanks in advance!
 
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#2
I am a little confused -
Lets start with the wiggling - you are in the underhood fuse box and shaking the fuel pump relay ?
You pulled the relay box apart - did you remove the fuse box and inspect wiring?

Sounds like an issue with underhood fuse box - corrosion maybe? Ign sw, not energizing circuit, bad relay A test light and a jumper should help isolate missing circuit,

keep in mind
The system will only energize the fuel pump relay @2seconds if eng is not running - so if vehicle does not start by the time you get to check realy the relay is commanded off.
 

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GMC guy

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#3
I am a little confused -
Lets start with the wiggling - you are in the underhood fuse box and shaking the fuel pump relay ?
You pulled the relay box apart - did you remove the fuse box and inspect wiring?

Sounds like an issue with underhood fuse box - corrosion maybe? Ign sw, not energizing circuit, bad relay A test light and a jumper should help isolate missing circuit,

keep in mind
The system will only energize the fuel pump relay @2seconds if eng is not running - so if vehicle does not start by the time you get to check realy the relay is commanded off.
 

GMC guy

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#4
Yes, i was under the hood at the relay. Ill have to check behind the fuse box too. When the car is moved the fuel pump will work. Same thing for when it sits. The car will not start at some point. I never had it stall while driving. It seems like a connector is loose somewhere. I also found a mind boggling amount of wires under the driver side dash. A remote starter was installed at some point. But thanks for the info. Ill post back, once i have time to get at it again.
 

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#5
Yes, i was under the hood at the relay. Ill have to check behind the fuse box too. When the car is moved the fuel pump will work. Same thing for when it sits. The car will not start at some point. I never had it stall while driving. It seems like a connector is loose somewhere. I also found a mind boggling amount of wires under the driver side dash. A remote starter was installed at some point. But thanks for the info. Ill post back, once i have time to get at it again.
Okay, I checked the under dash fuse box and its all good. No loose connections. Doesnt appear to be any build-up on contacts. I was cruising down the street and it stalled on me. I moved the bundle of wires under the street and no start. I banged on the rear floor, under the seat, and it started up right away.
 

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#7
Okay, I checked the under dash fuse box and its all good. No loose connections. Doesnt appear to be any build-up on contacts. I was cruising down the street and it stalled on me. I moved the bundle of wires under the street and no start. I banged on the rear floor, under the seat, and it started up right away.
yeah, im kinda wondering. It had a new pump, twice. The last one in November 2016. Not even a year old. I got a code po440
 

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#10
It was one metal tang in connector that was not making sufficient contact with male side connector. I disconnected the connector near tank and looked closely. Someone may have used something too large to probe the contact. I pulled the female side out of the housing and bent it back to where it should be. Reinstalled it in the harness connector and plugged it in. I havent had one problem with the fuel system! It is fixed! :fixed:
 

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It was one metal tang in connector that was not making sufficient contact with male side connector. I disconnected the connector near tank and looked closely. Someone may have used something too large to probe the contact. I pulled the female side out of the housing and bent it back to where it should be. Reinstalled it in the harness connector and plugged it in. I havent had one problem with the fuel system! It is fixed! :fixed:
Update! Car failed to start again. Banged on rear floor and it started. I later dropped the tank and someone had swapped connectors to fuel pump. There were repairs to wires, cut and crimped. They used heat shrink over the connectors. The wires at connectors were not completely attached. I soldered them and used heat shrink. Car has not failed to start since
 

nickb2

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#12
Well chalk this one up to another poor connection. I just want to know how phat fingures got in there before you.;)

I guess banging of the rear floor was the trick to finding this. Wiggle tests would have done that faster, but hey, it's done/fixed.