Overloaded wiring

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John Larkin

Sublime Master of Turbology
Joined
May 25, 2001
Messages
5,013
People think about this stuff for stereos but not so much for engine components. This weekend my fuel gauge dropped out after working properly. I went to check the ohms at the tank connector after just coming in from a few runs. The wiring to my pump was hot. I recently put in a larger pump and a volt booster. The pump draws alot more amps than the wiring should be handling. As a result I am getting a heavier duty harness. Word to the wise: think about all aspects of your upgrades. I got lucky and didn't go boom.
 
Have a hot wire. This is the harness from the hot wire connector at the rear bumper to the pump, the harness connected to the pump hanger. Those are the wires that got really warm.
 
.... The pump draws a lot more amps than the wiring should be handling. As a result I am getting a heavier duty harness. Word to the wise: think about all aspects of your upgrades. I got lucky and didn't go boom.

John, I think your subject line would fit better as "Inadequate Fuel Pump" wiring as that is what I have been seeing as our cars get older and have increased fuel demands as HP increases for the now "normal" street car! :)

We have seen increasing engine damage resulting from lean conditions. With the power level needed for low 11's and into the 10's, the factory fuel delivery system is no longer marginal, but becomes inadequate, especially the wiring. A hot wire kit may help, but that is not the final answer.

Yes, it does bring 12 volts or so to the fuel pump connector, but there is still 3 feet of wire and a crappy 25+ year old connector before it can reach the pump. The Racetronics pump hanger has helped this with better wire and a REAL connector.

One issue the hot wire kit does NOT address is the ground wire. A DC circuit must have the same return path [wire size] as the supply. Also, grounding the pump through the chassis is not good as the frame is a very poor conductor with much resistance. We solve this by running a 10 ga. ground wire from the pump directly back to the battery.

When building a 9 sec. and faster GN, we budget at least $2000 for the fuel system, and almost 1/2 of that for a reliable 10 sec. build.

And for the guys that say just add an akly kit and you are good to run 10's or whatever, you MUST have a VERY good fuel delivery system as well, or you will end up with damage. :oops:
 
Nick, where do you attach the grounding wire?
 
dave hahaha

As nick said, upgrading the ground to a 10g is the best thing to do when you really start taxing the fuel system.

Nick, atleast 2K. ATLEAST is right ;)

also when i was talking to a electrician a few weeks back he said those weather pack connector were not good for more the 20amps. That always made me wonder if they are not good for 20 amps why is the relay we find in most our howire setups rated at 30?

any idea how much a dual walbro pulls amp wise? i was think around 22-24 amps at 70psi?

so one walbro with hotwire is ok but anyting past that your going to run into issues. the question is when? hopefully when its not to late ;)
 
wow, pulls some amp for sure.

i know on most of the hotwire kits they get feed by a 10g wire. but look at the small wires that feed the pump. also the ground is far from ok. just an example i have showed a few people. on stock setups with or without hotwire kits. Take a wire 10g wire and clamp it to the tank. Then clamp the other end to the bumper, you will here the pump pick up speed. just doing this method which is not good imop i have seen pressure increases of 3psi at idle just a FYI
 
............... talking to a electrician a few weeks back he said those weather pack connector were not good for more the 20amps. That always made me wonder if they are not good for 20 amps why is the relay we find in most our howire setups rated at 30?.............. ;)

If you check the connector plug in the tank side of the sending unit, you will see 2 VERY small pins that carry the 12v power and signal for the sender. These pins corrode and build lots of resistance over the years, and you have twice the problem when you try to power 2 pumps through one small pin. :eek:

John, you cannot get a harness to solve these problems, you will need to make one yourself. As you well know, those wires being so hot, you have lots of resistance in the pump circuit.

I am installing 2 modified senders into GN's tomorrow, both of which have fresh engine builds - guess what? Both cars had lean issues that damaged their engines.
 
i know nick . those pins are supper small. suprised they carry as much power as they do. but over time you need to do something about them. at the very least replace it with the racetronix aftermarket one
 
I ordered a Racetronix hanger with their upgraded pump harness Monday, supposed to arrive today. The specs say it uses two 14 gauge power wires. The stocker is 16 gauge single. That has to be plenty of amp capacity.

I'm having agita over having to basically re-engineer almost every project I've started lately. Whoever said Grand National means you spend a grand on everything you do to one was rather prophetic.
 
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