I've been having some strange issues with my FD as of late

first my car randomly died while on the highway..

I thought it was the fuel pump


so I replaced it, with a brand new nippon Denso Supra TT pump

it didn't work..

it turned out to be the wiring..


the wires with the ring clips on the end.. go up to the bottom of the fuel pump "housing" and connect with a small 2 pin blue clip

when i wiggled it.. power would come back..

so I braced it in a position that would hold...

car was ok..

drove it home, then later on drove it to my friends house..

After leaving his place.. car wouldn't start again

i opened the pump again..

to discover the wires had melted and fused in the blue clip


I was considering running heavier gauge wires from the pump directly to the white clip on the opposite side...

but i'm worried it will melt again.. i don't think it's supposed to draw that kind of load..

fuse didn't blow either..

I Fear I have an electrical issue

any idea what is ?

 

Melting the connector, means there is a short or the pump is pulling too much amperage for the gauge wire. This is very dangerous. One spark in the gas tank and it is all over. Honestly you should start with a different fuel pump bracket assembly, or replace the entire bulkhead connector if they are available new.

 

can a Denso pump draw this much amperage?

I had a walbro in it for a long time, then i had a denso supra pump in it after that (green casing 1020 bout 3-4 yrs old)

I went to toyota and bought another one.. with a silver casing.. thinking the old one went bad..


but if it draws too much power, shouldn't the fuse blow? it's the stock 20A unit in there.. and it's working fine..


at the moment, I bypassed the stock wiring.. and used a heavy gauge speaker wire, drilled through the assembly and ran it to the Female side of the clip, splicing it into there directly..

seems to be working now..