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Bad Fuel Pump Melted the Fuel Pump Fuse Wire
Trouble shooting a potential fuel pump failure tonight I noticed that the hot wire on my fuse box (top red wire to fuse # 16) appears to have overheated (coating on wire is melted back and the screw down and frayed wire is welded in place)
 .It had the correct 25 amp fuse in place, not sure why it didn't blow prior to the wire heating up enough to damage it... Any ideas? Also hot wired my fuel pump to see if it still worked. It did but I'm thinking I should replace it (assuming it was worn drawing too much current). Thoughts? Bummer, I hate dealing with electrical problems. Thanks, Gordo
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Don "Gordo" Gordon '83 911SC Targa |
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07-08-2004, 10:31 PM
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Join Date: Jan 2002
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I had the exact same problem. My fuel pump wires got so hot that I burned my finger when I touched one.
I replaced the fuel pump, but that wasn't the problem. It's simply a build-up of corrosion at the fuse causing the heat. I cleaned up the fuse holder, and replaced the fuse with a new one. Problem solved. -Rob 1980SC |
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07-09-2004, 03:51 PM
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Join Date: Feb 2002
Posts: 6,930
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as fuel pumps fail they usually draw less amperage.
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07-09-2004, 04:24 PM
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Location: Brighton UK since 11/2012
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Bad fuel pumps generally draw more current, which burns out the fuse, relay and connector.
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From November 2012; Precision Porsche Specialist Sussex UK, +44 (0)1825-721-205 2001-2012 Gerber Motorsport Inc. 206-352-6911 07.15.06 1996 Ducati 900SP. Suprisingly enough, it's red 08.16.09 1999 Kawasaki ZRX1100. Green. |
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07-09-2004, 05:44 PM
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Join Date: Dec 1999
Location: TX USA
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Gordo,
There are several possible reasons, some listed above ... for the overheated wire. Another is rust buildup in the steel fuel lines, and another is a clogged fuel prefilter screen in the fuel tank! To see if your pump is still within spec for current drain ... you need to measure its' current draw with a multimeter or clip-on Ammeter. The factory max current limit is 8 Amps. Worn pumps can draw 16 Amps or more. At a drain of 16 Amps, the fuse will not blow ... unless run for an extended period, such as on a long trip! At 16 Amps, the fuel pump relay socket terminals can corrode or overheat and melt the surrounding plastic, just as you found on the OEM PVC wiring!
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Warren Hall, Jr. 1973 911S Targa ... 'Annie' 1968 340S Barracuda ... 'Rolling Thunder' |
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07-09-2004, 07:45 PM
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Good Calls
Early_S_Man,
Thanks for getting me back on track looking at the fuel pump vice being wrapped around the axle over the wiring. Will break out the multi-meter to spec out the pump tomorrow. Of course now I have it in my head that I should replace the screen on my fuel tank as well. One thing always leads to another... Gordo
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Don "Gordo" Gordon '83 911SC Targa |
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07-09-2004, 09:57 PM
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