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Have you ever replaced the fuel pump? If so, what brand is it?

The fuel filter is internal to the fuel pump. Whole thing has to come out and be replaced. Not like the pumps of yester year where you replaced a little sock on them and the filter inline somewhere
 

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Do you smell fuel or see a leak on the ground? That's common with the fuel pumps. Assuming a 3.5 V6? Unfortunately I can't give you any good news. Got a 06 G6 3.5 here on it's third fuel pump. Eats them like potato chips and i'm tired of it. Nothing makes sense on why it keeps doing that
 

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Did you replace those pumps with ACDelco Pumps or some other brand? I suggest you use ACDelco. They cost more but they use better parts! Also keeping your Gas level at least 1/2 full most of the time helps cool the pump and keeps them from over heating.

First was a Airtex. Barely lasted. Second was a Carter (recommended by someone who fixes GM's) the first had a broken fuel level float, so it got warranty swapped. Second one worked fine until it started whining and idling like crap,rpm's surged and then dropped and you had to floor it to get over a hill and points beyond.CEL also flashed indicating a horrendous misfire.

Truly at wit ends with this garbage. I've had folks say delphi is garbage (pump got replaced when bought as it stank like raw fuel and was pissing it on the ground, classic failure of cracked tubes and naturally GM did a recall for every other model but a G6 with the same issue) Airtex is garbage, Carter is good but now trash, Now AC-Delco is good (rebadged delphi???)

Rear fuse block might be causing issues is other information i've read, but since it's a $200+ part i'm not going to blow money on a vehicle that is amounting to a money pit with a poor resale value. Taking it apart and analyzing it showed nothing internally least I drill out the Rivets which destroys it... Ugh

(Rock Auto shows Ac Delco pumps which have "AFCO" stickers on them, (Bosch/Denso joint venture) a internet search turns up that the company shuttered it's doors in 2018. So now there are pumps on the market with no recourse except keep swapping the junkers until something works or the stock runs out?

And I thought pt cruisers are unsufferable with their issues. Hah
 

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Well, you are the first person I have heard of that has had this many problems with a Fuel pump! If I were you, I would be looking for electrical connection problems causing a large Voltage drop somewhere! From the Fuse panel to the connector at the Tank! I would bet you are not getting enough Voltage and current to those pumps! A low Voltage condition will cause them to run hot! Measure Voltage, and Voltage Drops at every point. Clean every connector socket and pin with WD-40 Electrical Contact Cleaner and then apply dielectric grease!
That's the confusing part, those have been accounted for. Even got new wiring because of the fuel pump harness changes. No burned/bubbling/etc wiring in the distribution block located in the trunk.

As this forum has mentions of 05-06 G6's having electrical issues, i'm off to a junkyard wednesday armed with part numbers for a "newer" fuse block hoping that solves the issues. So far they seem to have newer part numbers out there, which I am not sure if that means just a supplier change or they fixed some screw up silently and didn't bother telling the customers/owners.

I come from the ford corral where part number changes could usually easily be decoded down to "the supplier just changed" or "oops, we screwed up and did a major revision on the part" No idea in the GM corral.

While the butt end is in the air,going to go through the wiring yet again.

In the mess that is this project also around the time we purchased the vehicle and got the fuel pump replaced due to a cracked line, I could swear there was a code set for the evap system not working. One of the PXXX codes. Now no matter what is done, the Evap system will not set the codes in the OBD-II system readiness monitors.

As the state here allows one failure code due to the age of the vehicle, (straight from the dmv smog tech test book) I ignore it. Is there some possibility this could be killing the fuel pumps also?
 

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I suppose anything is possible but I have never heard of an Evap system damaging a fuel pump. You might need a better scan tool to give you more information? Did you go to a shop and get a print out of the code information or did you use a tool at an auto parts store or your own? If you have replaced the cable to the pump and the connectors checked out okay on both ends then I guess the fuse block is the next step. Do you have a schematic of the Fuel system? Did you make sure the Fuel Pump Relay is allowing full voltage with no drop across those contacts? You can measure Resistance if you can pull it out of the circuit and apply Voltage to the coil. You should be seeing Zero Resistance across those contacts. I do not know how you tested things and what kind of test equipment you have. Did you check for Voltage out of the PCM? If all the components check out okay then you might have a problem with your PCM! It is all a process of testing and elimination.
It was just basic testing with a multimeter. Have a grey market GM Tech II here actually, but aside from differences like the fuel trim and all that it spit out the same error codes as a plug and play code reader.

This is what the plug and play reader spit out when it was revving high and barely getting out of it's own way:

(Have no way of using the tech II on it currently, I pulled the battery and analyzed the fuse panel in the back trunk for any visible signs of melted wires/other issues. Blew dust out of it)

Thanks for your help. Currently i'm compiling part numbers on fuse panels and hitting two junkyards to harvest them and hope that eliminates some/all of the issue. I did replace the MAF sensor, that code keeps flaring up which makes no sense. Brand new AC Delco part and it's still throwing codes? ugh

P0174
P0171
P1111
P0113

Fuel Sys 1: CL
Fuel Sys 2: CL
Calc Load (%) 37.3
ECT (F) 190
STFT B1(%) 0.0
LTFT B1(%) 21.9
STFT B2(%) 3.1
LTFT B2 (%) 21.9
MAP(inHg) 13.3
Eng RPM 835
Veh Speed (mph) 0
Spark ADV (Degrees) 26.5
IAt(F) 154
MAF(lb/min) 0.9
TPS(%) 15.3
Command EGR(%) 0.0
EGR Error (%) 0.0
Command EVAP(%) 0.0
Fuel Level(%) 76.1
Warm-up DTC Clr 128
Clr Dist (Miles) 1937
Evap VP(InH20) -2.053
BARO(InHg) 13.3
Cat Te 11(F) 1201
CAT Te 21 (F) 1201
ECU Volts (V) 13.195
LOAD Value (%) 28.2
EQ Ratio 1.004
Rel TPS(%) 5.1)
Ambient (F) -33
TPS B(%) 15.3
ACC Pedal D(%) 0.0
ACC Pedal E(%) 0.0
Command Tac(%) 15.3
 
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