Melted Connector (Plug) Due To Larger In Tank Pump [Pics]

[Reese69]

in tank fuel pump standard wire -

each 044 pump has own wiring apart from, wire from battery splices to each relay the rest is individual wiring from relays to pumps

wire roll says 3mm 10a

hope what i am describing makes sense

Edited July 10, 2013 by Reese69

[Hanaldo]

The setup sounds fine, just need to make sure you are running the right gauge wire. Does it look like this:

3mm 10a wire:

Or like this:

8-gauge (round about 50a) wire:

That 8-gauge wire is the absolute minimum I would feel comfortable running from battery to relay for a single pump. If I was splicing that wire into relays for 3 pumps I'd be using 4-gauge wiring, which would admittedly be overkill but wire isn't such a great expense that I feel the need to be stingy about it.

[Reese69]

the top one.. is the gauge running all round..

should i just upgrade the power from battery to relay? or all wires?

[Hanaldo]

All round. I'd use minimum 12-gauge wire, preferably 10-gauge, from the relays to the pumps.

[Reese69]

thanks will go shopping today and re wire everything

[C4a0s]

10a wire is whats generally used...

8 gauge is way overkill... not to mention really thick and hard to hide around the car.. besides, how do u crimp and wire it to relays etc?

[Hanaldo]

10a wire is whats generally used...

8 gauge is way overkill... not to mention really thick and hard to hide around the car.. besides, how do u crimp and wire it to relays etc?

On a setup that can potentially see over 20a just in normal operating conditions, 10a wire is never going to cut it. Look at this:

These pumps draw 15.29 amps just at base fuel pressure. Hence why Resse69's 10a wire burnt out.

8-gauge is not that big, it's your general sound-system size wiring. Not that hard to get around the car, in fact when I had amps and my battery in my engine bay I had three 8GA cables all running the same route and they were invisible. You don't want your wiring to be the weak point of any electrical setup, but especially not in your fuel system.

As for wiring, that's easy. Use a horn relay with big terminals, and connectors to suit the wire size.

[Ben C34]

10a wire is whats generally used...

8 gauge is way overkill... not to mention really thick and hard to hide around the car.. besides, how do u crimp and wire it to relays etc?

As mentioned, 8 gauge isn't hard at all to use. I can't remember exactly but pretty sure the wiring should be capable of double the intended load. Not to mention reese had burnt out 10a wire numerous times, how can you say it is ok?

Edited July 12, 2013 by superben

[battery]

From memory 8ga is 6mm2, Its enough for the 3 pumps, I'd go overkill and use 6-4ga just to be on the safe side as its a critical load.

from the relays to the pumps 2.5mm2(14ga) is plenty.