What are the possibilities of cutting a access panel in the trunk?? I ran out of gas and now the car will not start. I can not hear the pump when I turn the key on. I have replaced the fuse and still nothing.

 

To your question about cutting an access panel,,,, it has been covered in several other post and it is NOT possible without removing parts of the frame.

FORGETABOUTIT!

However,,,,,,,,,, You have a LOT of troubleshooting to do before you need to consider replacing the PUMP.

I dont have access to my ESI Schematice for the 2004 fuel pump electrical schematics but, here is the 2002 fuel pump schematic:

 

This is a GM cut away demo C6 aluminum frame. It has the SAME fuel tank as your car. You can see it in the opening. That opening is NOT there on a production frame. Most of the pump assembly is under that cross header:





Here is a picture of a Production C5 Frame. As you can see, there is a plate over the top of the tank and there is very little clearance between the top of the frame and the top of the tank:

 

Its sounds like I have my work cut out for me. It is so bad to blow a pump by running out of gas. Should I try to do it or should I send it out? What would be the going rate to change the pump?

 

Should I replace both pumps? Is there any recall on the gas system that I should look into?

 

Did you check the fuses like mentioned before? How much gas did you put back in it? You need at least 3 or 4 gallons before you have enough to start it if you ran out. Been there done that. There is only one fuel pump. The one on the passenger is a siphoning pump. Not sure if you can see the acesss panel like you can on the 03 and lower cars. You can also jump the fuel pump relay and that for sure will tell you if your pumps working or not. Its relay 35. And when your standing on the side of the passenger side looking straight down at the fuse box with the battery to your left. You wanna jump the upper left and lower right of relay 35 (so diagonal from each other) at the same time with the key in the on position(all the way to the right before actually starting it) you should hear the fuel pump and it will run continusely until you pull that jumper ou or turn the key to the off position. I have run my pump dry for diagnosis purposes and never had a issue ruining it. And this was outside of the tank. Though mine is a 01 I can access it through the panel. As far as removing the tank everyone says its a pain but I found it simple took me about an hour if that to drop it. I had to drop it to clean the inside out. If you are mechanically inclined then do it. I dont know what the dealer charges but I'm sure it won't be cheap. If you not sure on the jumper relay thing pm me and you can call me and ill walk you through it

 

Did you try to see if the pump works while letting air escape and releasing the pressure using the Schraeder valve on the drivers side engine rail ? Be sure to have a big rag or some way to catch the fuel (if) as it comes out.

 

Many people have run out of gas without damage to the pump. It only runs for a few seconds when you turn the key so listening for it is not the best way to check if it's working. You need to check for gas the rail.

 

And, as long as the fuel pressure is out, and you are working on it, you may as well replace the fuel filter while you're at it. Get a Wix from RockAuto for best price. You will need a disconnect tool as well, costs about $8

 

I will recheck everything before I get into the pump. Thanks so much for the info you all have been very helpful. I will let you know the updates as I go along.

 

So how much gas have you put into it after? Its something simple I'm sure do the relay jumper I doubt the pump went

 

Agree with the above statements - check out the circuits before you get to replacing the pump - jumping across the relays will give you a quick idea if the issue is with the relay side of the circuit - check the four terminals of the relay to ensure you have 1 ground and 2-12V. If so it is from relay fwd if the relay is being pulled to ground.
ground strap near the lh wheel-well would be another area to check - not sure if you are getting a fuel disable message or not - would be a security lock preventing fuel relay to be enabled -
again, lot of initial ground work to be done before getting into the pump...

 

I replaced the relay and check for any kind of pressure in that valve on the motor on drivers side but I got nothing no air or gas.

 

Anybody in Mass want to give me a hand or can test and fix the car for a reasonable price?

 

Jump the relay to see if the pump comes on. I posted it above take 2 mins..also how much gas have you put in? Dont throw parts at it blindly process of elimination. Does the pump work when you jump it? How much gas did you put in it? Cmon man help us help you

 

I have jumped the wires and checked everything it must be the pump

 

Just another engineering wonderment from GM to place a fuel filter inside the tank. I guess they just did not feel it would ever need changing. Unbelievable.

 

Yep, and the q

 

Try this again. The issue is the stupid decision by GM designers that built this car. But, we still love it and do what is necessary to repair it to drive it.l

 

Like I stated,,, WAAAAAYYYY BAAACK in the first part of the post; Unless you get a METER out and actually troubleshoot,,,, You better have a BIG WALLET and LOTS of time.


Check continuity between the relay and the tank and continuity/resistance of the PUMP MOTOR.

See if you actually have power and ground at the tank

BC