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FD Fuel pump problem, potential fire hazard

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Old May 14, 2011 | 04:09 PM
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This is important for all you FD owners with a large after market fuel pump. I found a potentially hazardous weak link in the factory Mazda fuel pump wiring. The blue plug in the first picture is soldered to the wires coming from your fuel pump. The blue plug sits inside your gas tank and is plugged into the white plastic connector on the underside of your fuel pump assembly. I'm assuming the extra amp's drawn by the large fuel pump caused the blue plug to melt internally. When the blue plug was inside the white female connector you couldn't tell anything was wrong. It was only when I removed the blue plug from the connector, did I see that it was all burnt up. The only indication that I had a problem was a slight miss at wide open throttle. My solution to the problem was to cut away some of the white female connector and soldered the fuel pump wires directly to it.

You can see the photos here:
http://www.norotors.com/index.php?topic=6346.new#new
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Old May 14, 2011 | 04:13 PM
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Old May 14, 2011 | 05:16 PM
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Here are the photos. You can not see a problem until physically pull the plug out and inspect it. The white female connector hides the burnt blue plug.
Attached Thumbnails FD Fuel pump problem, potential fire hazard-small-rx7-fuel-pump-004.jpg   FD Fuel pump problem, potential fire hazard-small-rx7-fuel-pump-006.jpg  
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Old May 14, 2011 | 05:26 PM
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the stock connectors are a known issue with upgraded fuel pumps, there's several threads about the subject.

i have yet to hear anyone with it causing a fire issue though as the connection generally just gets hot and then loses continuity without any arcing. it's more of an issue regarding blown engines and no start issues though.
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Old May 14, 2011 | 05:52 PM
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Originally Posted by Aldo
This is important for all you FD owners with a large after market fuel pump. I found a potentially hazardous weak link in the factory Mazda fuel pump wiring. The blue plug in the first picture is soldered to the wires coming from your fuel pump. The blue plug sits inside your gas tank and is plugged into the white plastic connector on the underside of your fuel pump assembly. I'm assuming the extra amp's drawn by the large fuel pump caused the blue plug to melt internally. When the blue plug was inside the white female connector you couldn't tell anything was wrong. It was only when I removed the blue plug from the connector, did I see that it was all burnt up. The only indication that I had a problem was a slight miss at wide open throttle. My solution to the problem was to cut away some of the white female connector and soldered the fuel pump wires directly to it.

You can see the photos here:
http://www.norotors.com/index.php?topic=6346.new#new
Here is a better solution... https://www.rx7club.com/3rd-generation-specific-1993-2002-16/fuel-pump-rewire-right-way-901511/
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