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I've been hunting down a random problem where my car dies without warning. Since this problem has been random it has been difficult to get any instrumentation on the car when it happens.
Today I went to start the car in my driveway and it wouldn't start. So I quickly grabbed my fuel pump gauge, noid light, laptop computer w/TunerPro RT and found to my surprise that I had no fuel pressure. 0 PSI. All other systems were GO.
I tried running 12 volts directly to the fuel pump and got no pressure. I checked the fuel pump with my ohm meter and got an open circuit.
So I decided to pull the fuel pump/sending unit out. When I removed it this is what I saw:
The in-tank wiring harness had over-heated and damaged the connector and the outer tank harness.
I applied 12 volt power to the fuel pump directly and it spun-up without any problems.
So, are there any parts available to service this unit or am I looking at buying a whole new sending-unit and fuel pump?
Last edited by LWesthaver; Aug 12, 2016 at 08:06 PM.
In this thread I posted a couple links to what I felt was a likely repair for your situation. The Racetronix "pass trough" - read through the thread and check the links yourself to decide. I believe that I actually used to buy this in a package from another vendor for some "fleet vehicles" I serviced. I don't recall the vendor and it's been many, many years. Racetronix commented a couple times in that thread but how reliable the comments? I've no idea. I believe it can be repaired without the purchase of their more expensive harness etc. I haven't tried and I've not looked else where BUT I have meant to.
I may have actually been buying a GM package that accomplished the fix. If you've a relationship with an ACD jobber or a GM dealer take the images of the connector etc to them. Is it worth an attempt from NAPA? Maybe!
The BCWS-001 will get you the pass through and a super long pigtail you likely don't need. Nearly all pumps come with a short harness for the bulk-head to pump connector, Racetronix product? Heavier wire Gage always helps. Always ...
The BCA-4W would require some rewiring and a mating connector but I doubt you'd have an issue accomplishing it.
Depending on car year I believe that Racetronix actually has the "in-tank" harness also.
One thing I'm curious about, the old in-tank wiring has a white plastic block molded onto the wires that someone said is a capacitor for noise suppression. The Racetronics harness doesn't have this. Does it matter? GM doesn't usually put something in the car that isn't needed.
One thing I'm curious about, the old in-tank wiring has a white plastic block molded onto the wires that someone said is a capacitor for noise suppression. The Racetronics harness doesn't have this. Does it matter? GM doesn't usually put something in the car that isn't needed.
New fuel pumps have this filter built into the head of the pump. It is no longer required.
Your factory pump is probably near the end of it's life and this melted connector could be an indication that it is drawing more power than normal. The EMI/RFI filter is a liability which hampers pump performance anyhow.
Last edited by Racetronix; Aug 2, 2016 at 12:49 PM.
If those positive splices come in contact with the hanger body you will blow a fuse or cause a fire. You must insulate those. You should have used Nylon butt connectors: http://www.racetronix.biz/items.asp?...atus=0&Tp=&Bc=
Do I need a new fuel pump/sending unit?
