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2009 Chevy HHR 2.2 ecotec-
Replaced fuel pump about a month ago. Spent $110 on RA for a US Motor Works fuel pump. Had problems from day one after installing it. First off, the fuel tank pressure sensor that came with the pump did not play nice with the computer as the voltage readings it was putting out was not the same as a GM sensor. So rather than sending the whole pump back I just bought a GM sensor and put it in and problem was solved.
Car ran great for the last week or two. Started noticing that sometimes the car would die while in the middle of accelerating but it quickly came back. Didn't think anything of it. Three days ago car wouldn't start at all after stopping for a quick bite. Checked pump relay, even swapped it. Fuse good too. Put my OBD2 scanner on it and tried to actuate the fuel pump and nothing! Crawled under car and smacked on the fuel tank real good and pump started working again. Car was good until the next day when same thing happened again. I didn't get so lucky this time with banging on the tank. Fuel pump is dead. Checked relay again and it's good. Checked fuse block on the relay circuit for power and ground and all good as well. Can not actuate the pump with scanner either. Seems to definitely be pointing to the pump. Just can't believe after not even a month it's bad. I knew it was a cheaper pump but DAMN a month and that's it!!
I have ordered a Delphi pump this time as I had the extra money to do it this time. I want to check at the fuel pump harness for power before I put new one in. I have not done that yet as I've got to drop the tank. It's a 4 wire harness. Anyone know what specs and what wires? Access to a diagram?? Testing procedure??? I"m sure i can find something on google but sometimes it's just quicker to ask around.
There is nothing unusual about the car that would make the pump burn up. I've changed it once before about 7 years ago and had no problems. Wires and harness were all in good shape when i disconnected. Not sure why this thing went bad besides brand/price range.
Car was hesitating to start after sitting overnight. Also heard grinding/metallic like noise when fuel pump would prime. Fuel pressure would not hold steady and would bleed off more than 5psi in 5 mins.
So not these same symptoms you have now? Put a more reputable brand pump in it and make sure you change your inline filter (if you haven't already) and recheck fuel psi when the new pump is installed to make sure psi isn't too high.
No, not the same symptoms. I have a Delphi on the way. Any ideas on how to drain the gas out of my tank? It's got a full tank and this is a driveway job! Could I unhook the pressure line at the fuel rail and put a mechanical pump on to siphon it out or is there valving in the pump that would prevent this? Most people use the old pump but mine doesn't work. I just know you can't go through the filler neck.
Just to answer a few of your questions, of the 4 wires, the thickest gauge 2 are for the pump circuit. GM usually uses grey for the power and black for the ground.
With multiple failed pumps, I would recommend making sure there is no debris in the tank.
As far as draining the tank in the car, that can be tricky when the pump doesn't work. If you are able to siphon off the pressure line at the rail as you suggested, let us know. I think it sounds plausible.
