My fuel pump is dead, please help!

[BoostedAWD]

I recently installed a Walbro 255 HP in my car.

The car ran for a while yesterday, even took it out on the road for a mile or so. Brought it home, shut it off. Came back an hour or so later, started it up, was running a little rough. Not a huge deal since the engine just went back in a few days ago. So I let it run, to see if it will smooth out some.

Eventually it starts to run rougher until it finally stops and won't restart. Tried cranking a few times until it won't even turn over. Traced the no-crank problem down to a blown IGN fuse. Replaced that, it cranks now, but will not start since there is no pressure being built in the fuel rail. So I did a few checks, eventually ending up connecting the fuel pump test connector.

That was hooked up for a while, still no fuel pressure. When I disconnected the test connector, I noticed a bit of smoke coming from the IGN fuse, which was red hot, but not blown at this point.

So, I pulled that, let it cool, and re-installed it. It did not heat up again. After that, I was pretty much out of ideas, so I called it quits for the night.

I went out this morning to do some more checking, only to find that the fuel pump connector in the hatch has fused itself together and the wiring is partially melted. Get that apart, cut off the connector, and hook the fuel pump directly to a power source, which still provided no results--the fuel pump will not run.

So, my question is, what would cause the FP to short out like that other than just being bad to start with? Are they wickedly fragile? It's not like it's been abused, but it may have had a few extra bumps along the way.

Also, I started off with the stock pump, which is also dead. I originally attributed that to the fact the cats knocked it off of my bench onto the concrete floor.

Does anyone have any ideas/suggestions/comments?

 

[eclipse_20g]

Not that I'm an electrical expert or anything, but it sounds like you are having power surges in your elec. system for some reason or another.

Your IGN fuse obviously blew all of a sudden, and when replaced the new one got overly hot as well before you caught it. Fuses that tend to blow or overheat like that are falling victim to a power surge. Too much voltage for the particular fuse to handle, and it blows.

Now, only to back up the theory of having power surges in your system, your fuel pump connector is melted. To melt wires, your connector, and blow the pump itself is a pretty big surge. Seems the same thing may have happened to your stock pump and thats why it blew. Merely speculation though.

Again, I'm no electrician, so I cant really tell you exactly where to start. But I'd be checking every one of my grounds on the car for starters and make sure they arent corroded or loose. I'm sure more suggestions will be added. Maybe throwing a voltage meter onto the pump wires to see if you can find any sudden jumps in power. I know this doesnt really help to fix your problem, but just my thoughts on what may have happened. Good luck man.

 

[staticbrainwash]

Actually, amps blow fuses. The only reason you'd be having an amperage problem is if you're shorting or grounding out somewhere. Check all the wiring btwn the fuseblock and the pump and any wiring associated with it.

If possible try to bypass the wiring and run jumper wires right from the fuse block and see if you get it to crank.

Why you would be blowing the IGN fuse though and not the pump fuse/relay is beyond me. Have you rewired the pump when you installed?

I'd just break out a multi-meter and go to work with it checking your wiring.

 

[BoostedAWD]

It appears that the positive wire got smashed in between the lid and the rim. It works like a charm now.

There's also potential for the pump filter being plugged. When I hooked it up after removing it from the tank, the pump ran, but nothing was being pumped. Took the filter off and away she went.

 

[staticbrainwash]

Or a clog up past the filter in the feed line to the rail. But putting in a new FF isn't a bad idea.

Glad you got it all worked out though, good luck getting it all back up and running.