I bought a Walbro 255 High Pressure and installed it in my car about a year ago. I have recently starting hearing my pump make funny noises when it primed but it would go away once the car got to operating voltage. I have been monitoring my AFR's recently and they have been somewhat inconsistent (.1-.5 variance) but since I installed a new intercooler I figured it was the tune and I would just re-tune it.

I go outside and find my car will not start. I can crank it over and over and nothing. I look at the AFR's and see it's not even registering fuel in the exhaust. I then turn the key and don't hear my pump prime up. I start thinking about how so many people hate Walbro's and I think maybe I burnt it up. My G/F starts searching for me as I'm cleaning up my mess of things and finds out that the electrical connections can go bad and I should check it out. So today I pull the fuel pump assembly and here's what I found:



Has anyone else experienced this or heard of this happening? I am going to run two bulkhead connectors through the tank and run 12ga wire rated for fuel immersion to hopefully solve this from happening again.

If you installed your pump the way I did (following supplied directions) you should check your electrical connections ASAP! I have a fuel pump rewire also so the increased voltage may have expedited what has happened.

 

how does the connector side on the pump look? Burnt?

-AzEKnightz

 

both S5 and S6 have this issue with replacement high volume pumps(since both series have the tiny plastic connector on the top of the tank, S4's didn't have this issue), it's a good idea to rewire it to bypass the connector completely ie. drill through the housing and use an isolator stud to pass through the top pump cover. there's also another connector by the LR strut tower that can have the same issue so rewiring the pump completely is highly advised when modifying the car much over stock.

granted i haven't seen the terminal on the pump itself burn out like that but low voltage issues can cause any of the connections to burn up at the weakest point. it looks like the negative crimp is at fault in your situation, f you tug on it i bet it pulls right out..

 

Damn, I just installed one yesterday.
I'll have keep a close eye on it.
Thanks for the heads up!

 

Anyone know of a place that sells a good electrical bulkhead? I went to a number of stores last night and still can't find anything like I want.

I was searching last night and found this one:
http://www.deutsch.net/deutsch-produ...e=3&prodId=485

Any suggestions would be greatly appreciated!

 

https://www.rx7club.com/showthread.p...light=bulkhead
https://www.rx7club.com/showthread.p...light=bulkhead

 

Hey I got a pair of bulkhead connectors I never used. PM me $40 shipped and their yours