Ride of shame 2 "Almost" - Fuel pump hanger connection fail - FFCars.com : Factory Five Racing Discussion Forum
 
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post #1 of 5 (permalink) Old 04-14-2019, 11:29 PM Thread Starter
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Exclamation Ride of shame 2 "Almost" - Fuel pump hanger connection fail

I took my Mk4 roadster to a great local Early Rodders show on Saturday morning. With a few spectators standing around after the show I tried to start my car and it would not fire. My friend started giving me grief about flooding it. After some trouble shooting we determined that my fuel pump was not working. Checked the fuses, relays and finally the connection at the fuel tank. It was not immediately obvious but eventually we noticed the melted nylon. Plugged it on and off a few times and the pump fired up. Made it home and when I went to check the connection it was really hot.

I do not know the root cause but I do know that my friend and I have experienced the exact same failure in under 5000 miles of driving. The only thing I can think of is that our fuel pumps are high performance and perhaps overloading the connector. Both of these pump assemblies came from HighFlowFuel (Now Quantum Fuel) and assembled by them for our application.

This is pretty scary to me as I do not know how close we got to having a fire at the fuel tank. I am in contact with HighFlowFuel and also Promracing as both companies sell very similar assemblies for high performance applications. So far I am getting the famous "never seen that before" BS.

Here is a short video showing the loose ring terminal on the underside of the hanger.
https://youtu.be/p5Yq_5cPRoA

Ron Francis Connector


Here you can see where the nylon was melting. I suspect this also allowed the post to slip down a bit


Here you can see the ring terminal that has come loose and also the insulation on the wire that is starting to burn from the heat.


Attached Images
File Type: jpg Ron Francis Harness.jpg (190.4 KB, 37 views)
File Type: jpg Connector.jpg (165.9 KB, 36 views)
File Type: jpg In tank connections.jpg (213.7 KB, 38 views)


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Last edited by CDXXVII; 04-14-2019 at 11:41 PM.
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post #2 of 5 (permalink) Old 04-15-2019, 12:40 AM
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Wow, glad the fire scenario was averted. Sorry for all your troubles lately, but at the same time this should be an easy fix and back on the road just in time for sunny days and summer.


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post #3 of 5 (permalink) Old 04-15-2019, 08:05 PM
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Ride of shame 2 "Almost" - Fuel pump hanger connection fail

As I always say, “once is an event, twice is the birth of a pattern.” Hopefully it leads to better quality control before someone loses their car or their life.

Chris

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post #4 of 5 (permalink) Old 04-15-2019, 09:42 PM
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What is the nominal flow rate of the pump that High Flow Fuel installed? It appears they are using the stock 1/4" OD return port on the stock 1994-1995 Pump hanger. Chris at Pro-M was the first to do the experiment/demonstration that trying to get a 255lph or higher flow rate pump to pump through the 1/4" return is not a good idea due to aeration of the fuel in the sump and back pressure exceeding the set-point of your fuel pressure regulator. Maybe it also puts an excessive and continuous load on the pump and the current drawn caused heating of the connector pin. I recommend backing down to a 255 LPH pump and a high flow fuel return (Breeze 70750) or a 190lph pump and you can get away with your existing return. The 190lph pump (Walbro GSS242 supports 470hp at 13.5v with a 10% safety factor) or get a Pro-M hanger which has 3/8" supply and 3/8" return and you can use your existing pump.
Hope that helps and no I have not seen an overheated fuel pump connector before.


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post #5 of 5 (permalink) Old 04-16-2019, 01:36 AM Thread Starter
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Fuel Pump Update

I just received an email back from HighFlowFuel and they have offered to replace my assembly with their upgraded unit.

Much like PromRacing, HighFlow has upgraded the connector and wire along with up sizing and lengthening the return fuel line.

I am going to drive out and pick up my new assembly from HighFlow in Ventura on Wednesday. Not a huge drive and I always prefer to deal with people in person.

My other concern is that the wiring provided in the Ron Francis harness is not large enough for my application. I did not think it would be a huge deal as I only went up to a 255LPH pump. I am considering adding a relay near the fuel tank and taking a #12 gauge wire directly from the (trunk mounted) battery to the fuel pump via a new fuse and relay.


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