Fuel sender connector burnt ?

[HUENEMEGN]

I’ve been having some fuel sender connector issues in when the bulk head connector power pin will burn out (1st picture). This one just happen last week .

I fix this issue 4 years ago but what burned out last time was the in-tank fuel pump to the bulk head connector (2nd picture) .

Ive replace the Racetronix bulk head connector twice now (3rd Picture). I just ordered a new one. But these have a weather proof connector and I’m wondering if the pin-outs are correct in my set up? I do drive the car about 600miles a year . But I hadn’t drove the car in about 3 months now. I’ve just been turning it on in my garage but last week it wouldnt fire up . I realized I had no fuel pressure . Tried priming the pump via connector behind the alternator and still no pressure . Took the pump out to bench test it , it works . Then I saw the burnt out connector .
Do I have a short somewhere. Any help would be appreciated.

My fuel pump is a DW400 .
I do have a newer Hotwire kit

 

[BEATAV8]

All the positive current going through 1 pin?

Racetronix makes a “HD” bulkhead kit that sends the positive power through 2 pins that’s what you want.
2 pins for power
1 for ground
1 for fuel level
Then a nut & bolt bulkhead ground drilled through the header.

Use the HD version hot wire kit to the alternator
And use a 10ga copper strand ground wire from rear of car to the battery

This is an HD kit. Red & blue feed power. Grounds are black, note the nut & bolt ground. Purple is fuel level. They sell HD kit pieces for a few different pump connectors including tyco style.

 

[N2BUICK]

I don't have an answer for your electrical problems. Can you tell my the purpose of the four steel lines.

 

[BEATAV8]

. Can you tell my the purpose of the four steel lines.

Supply / return / tank vent / filler neck vent
It’s a Chevy astrovan fuel pump hanger in a g body station wagon tank.

 

[N2BUICK]

Okay thanks for the info.

 

[scgnx2]

That connector melted due to high resistance through the male pin/female contact. Corrosion on the plating of the contacts or “loose” female contacts which affects the spring force on the pin.
Those are common failure modes.
Additionally, when using 2 pins to apply power (splitting) sounds like a good idea.
However, in reality it doesn’t work that way. If the resistance (ohms) is higher in one circuit. The other circuit will see higher amperage from the flow of power seeking the path of least resistance. This can also lead to overload and failure as pictured.

 

[HUENEMEGN]

All the positive current going through 1 pin?

Racetronix makes a “HD” bulkhead kit that sends the positive power through 2 pins that’s what you want.
2 pins for power
1 for ground
1 for fuel level
Then a nut & bolt bulkhead ground drilled through the header.

Use the HD version hot wire kit to the alternator
And use a 10ga copper strand ground wire from rear of car to the battery

This is an HD kit. Red & blue feed power. Grounds are black, note the nut & bolt ground. Purple is fuel level. They sell HD kit pieces for a few different pump connectors including tyco style.

View attachment 403889View attachment 403890

I do believe I have the HD bulk head kit . Except the ground has a hose clamp type to tie around a metal fuel line .I purchased it last time after it melted my connected as seen on picture #2 .

I only have one red positive wire coming out the actual fuel pump to the blue wire pin in the bulk head connector . I didn’t know I had to use the red in addition to the blue power feed . Do I just add a certain wire of the same gauge ? I did find that weird that red wasn’t connected to anything . This is the HD bulk head connector I have .

 

[HUENEMEGN]

That connector melted due to high resistance through the male pin/female contact. Corrosion on the plating of the contacts or “loose” female contacts which affects the spring force on the pin.
Those are common failure modes.
Additionally, when using 2 pins to apply power (splitting) sounds like a good idea.
However, in reality it doesn’t work that way. If the resistance (ohms) is higher in one circuit. The other circuit will see higher amperage from the flow of power seeking the path of least resistance. This can also lead to overload and failure as pictured.

I am running e85 so it is very corrosive . As I mention to my response to BeataV8, I am only running one positive wire to the blue wire in the bulk head connector . I’m guessing I need to spiltting them .

 

[scgnx2]

Sure, those contacts are tiny. I’m guessing that they would not handle 5 or so amps per circuit. So, you’re probably exceeding that especially at 60 psi. Amperage draw is higher. That would explain the melt down as well.

 

[BEATAV8]

. Do I just add a certain wire of the same gauge ? I did find that weird that red wasn’t connected to anything . This is the HD bulk head connector I have .

Both the blue and the red should go to the + on the fuel pump connector. Crimp them together in the same terminal.

 

[BEATAV8]

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As this pic shows, both red & blue on one terminal, and 2 grounds on the other terminal.