Non-60V6 fuel pump problem

[bszopi]

So my wife's Alero (2003 w/ 2.2L Ecotec) has had some starting issues for the last month almost. I haven't had much time to work on it (it broke down a day before we started moving to a new house), but I have changed out the ignition module, fuel filter and fuel pump. After the new fuel pump, I was having issues with it not starting at all. I thought I finally got that figured out last night, and was able to drive it around for a little while and all seemed fine. She went to go take it to work today, and it wouldn't start again. So I went out and looked at it, and I can't hear the pump priming at all when I first turn the key on. The was happening a couple times last night, but went away. I figured last night it might have had air in the lines, causing it to not prime. But since I got it started and running last night, I just don't see more air in the system causing the issues. Is there anything else that could cause the fuel pump to not prime?? I'm starting to think it might be a PCM issue, but that's not something I want to buy unless I know for sure...

1 more thing to note, just in case... When I initially turn the key to RUN (not START), the CEL is not on, but will turn on after ~10 sec. I wouldn't think if a code was set, it would be on right away. When it was running last night, the CEL light was off.

[bszopi]

As an update to this, I decided to try it this morning before work. Turned it to on, and heard the pump prime, so I commenced to try to start it. And what do you know, it started right up. I opted not to drive it just in case it decided to act up this afternoon. But I will try it again tonight and see if it starts up.

With that said, its definately an intermittent issue. And looking over the schematics for the fuel pump, it leads me to think it is most likely a PCM issue, and might have been the entire time...

Thoughts?

[sprucegagt]

Check/replace your fuel pump relay. It's in the underhood fuse box and can cause the same problems your experiencing.

[bszopi]

I've actaully swapped out the fuel pump relay with 3 other relays in the fuse box (same PN) when I was having the original non-priming issue. So unless 4 of the relays are going out, I doubt thats it.

On a similar note, back when we first bought the car, I had to take it in to get fixed due to starting issues. It ended up being a short INSIDE the fuse box, so I replaced the entire fuse box with a new one from the dealership. What's the chances that there is another issue inside the fuse box??

[sprucegagt]

Then it's time to tape a fuel pressure gauge to your windshield.

[RedBird]

it's not a fuel pressure issue, it's the pump not priming. have you checked to see if there's power to the pump when it doesn't want to prime?

[double00bu]

I have had this same problem with an exgf's car,it was a 2002 Alero

Exactly same symptoms,turned out to be the ignition switch
it would start sometimes and sometimes not,same thing with the fuel pump not priming
I would just keep wiggeling the key to on and off till i heard the pump kick on,then it would start
But thats what was wrong with it

[bszopi]

Got home tonight and it wouldn't start again. Tried several times. I was going to try to do some voltage testing, but I have no idea where I put my volt meter when we moved. Anyway, decided to go with double00bu's advice and ordered an ignition switch from Rock Auto. We'll see if this solves the problem (crosses fingers).

[pocket-rocket]

Have you checked any Alero forums to see if this is a common problem? double00bu's idea does make sense, I don't think GM is famous for their ignition switches. I remember when the switch in the 92 went out. It left half of my ignition system on all night long draining my battery, then I went to see if the battery had enough charge on it to let it start back up while driving down the road a ways and my dash gauges, ect. stayed on when the key was off. Freaked me out. Thought I was going to get off of work and find my car a smoldering pile of pooh because I didn't have anything to unhook the battery when I got there.

[bszopi]

I have looked through some forums about issues, but not about the iginition issue yet. I tried it again this morning and nothing happened. When I do turn the key on, it makes some wierd sounds (electrical clicks and such), nothing like what it should sound like. So there is definitely something else going on. And considering it varies each time I turn the key, the ignition switch seems like a good culprit. I opted for the next-day shipping from Rock Auto, so hopefully I'll have some good news on Wed night.

[pocket-rocket]

Are you going to unhook the battery until then? You know, as a better safe then sorry measure.

[bszopi]

No, I didn't unhook the battery. BUT, my ignition switch came today, and I managed to just get it installed. So far, so good. I was able to start the car this evening (wouldn't start at lunch), and got it pulled into the garage to do the work. Can I say it is soooo nice to have a garage again! I was thinking it wasn't going to work, as the car died part way into the garage, and the first time I went to restart it, it wouldn't go. But, it fired up on the second try and I got it into the garage. Replaced it and I've started it a couple time, but haven't done much else. Girls are in bed, and my wife is at the gym, so I can't just go drive it around. When she gets home, I will probably take it for a couple more test runs. And I hope to take it to work tomorrow as well.

If all of this works out, I will have to owe double00bu a beer or something!!

[double00bu]

Well, did the switch fix it?

[bszopi]

Its been fine all day, so it appears that it did. I appreciate the resolution!!

[double00bu]

cool!!!
just glad i could help