Seears Member 11 Member For: 14y 1m 9d Gender: Male Location: Canberra Posted 15/02/25 05:23 AM Share Posted 15/02/25 05:23 AM Hey guys, I’ve had an issue with my Ute where it drives fine but comes up with fuel system fault but goes away. New Year’s Day it didn’t start at the shops. Towed it home and left it for a week and then it started but then wouldn’t start again after I turned off and on a couple times. November 2022 I had a fuel pump assembly and a wiring kit installed. I did a search today and read on this forum that a 525 will/can melt the standard wiring without the kit so having it installed makes me think that’s not the issue. Today my mechanic and I pulled the tank out and found a melted connector. These are the two parts I had installed (November 2022): https://www.spoolinboost.com.au/product-page/upgraded-fuel-pump-wiring-loom-for-ba-bf-fg-fgx https://www.ebay.com.au/itm/292706252256?mkcid=16&mkevt=1&mkrid=705-154756-20017-0&ssspo=qmGIti0ORkS&sssrc=4429486&ssuid=fmDNhWGtSG6&var=&widget_ver=artemis&media=COPY Not wanting to knock any brands/companies, just wondering if anyone has any ideas or has had any similar issues. cheers and have a good weekend Link to comment https://www.fordxr6turbo.com/forum/topic/97389-melted-connector-in-525-fuel-pump-assembly/ Share on other sites More sharing options...
k31th less WHY; more WOT Site Developer 29,442 Member For: 17y 19d Gender: Male Location: Melbourne Posted 15/02/25 09:47 AM Share Posted 15/02/25 09:47 AM either you're really unlucky or the specifications of that wiring kit installed wasn't up to snuff... hmm Link to comment https://www.fordxr6turbo.com/forum/topic/97389-melted-connector-in-525-fuel-pump-assembly/#findComment-1725623 Share on other sites More sharing options...
Puffwagon Puff Gold Donating Members 16,303 Member For: 10y 2m 30d Gender: Male Location: South Australia Posted 15/02/25 11:28 AM Share Posted 15/02/25 11:28 AM I've already documented this in my territory thread I ended up drilling holes through the top of the pump assy and running seperate wires through for each pump. I ran 2 pumps. The wiring burnt with just one pump and the only fix is to update the wiring inside the tank, whilst bypassing the stock connector. You will need to run a single 255 in the tank and run a proper surge tank in another location, or modify your stock setup similar to mine. Just go the surge, it's what you need to do. 1 Link to comment https://www.fordxr6turbo.com/forum/topic/97389-melted-connector-in-525-fuel-pump-assembly/#findComment-1725624 Share on other sites More sharing options...
k31th less WHY; more WOT Site Developer 29,442 Member For: 17y 19d Gender: Male Location: Melbourne Posted 15/02/25 11:44 AM Share Posted 15/02/25 11:44 AM On 15/02/2025 at 11:28 AM, Puffwagon said: I've already documented this in my territory thread Expand This post mentions it... solid throwback -> https://www.fordxr6turbo.com/forum/topic/95767-puffwagons-territory-adventures/?do=findComment&comment=1717247 Also some good advice here -> https://www.fordxr6turbo.com/forum/topic/96495-safe-to-put-in-bigger-fuel-pump/?do=findComment&comment=1709117 Link to comment https://www.fordxr6turbo.com/forum/topic/97389-melted-connector-in-525-fuel-pump-assembly/#findComment-1725626 Share on other sites More sharing options...
Puffwagon Puff Gold Donating Members 16,303 Member For: 10y 2m 30d Gender: Male Location: South Australia Posted 15/02/25 11:56 AM Share Posted 15/02/25 11:56 AM Fairly sure I posted a picture as well, that's some solid searching though Link to comment https://www.fordxr6turbo.com/forum/topic/97389-melted-connector-in-525-fuel-pump-assembly/#findComment-1725627 Share on other sites More sharing options...
k31th less WHY; more WOT Site Developer 29,442 Member For: 17y 19d Gender: Male Location: Melbourne Posted 15/02/25 11:59 AM Share Posted 15/02/25 11:59 AM didn't see a pic around there, no big deal though... there's one in this thread on topic for this thread, I wonder if you can re-pin the stock connector with higher gauge wiring... I guess not? Link to comment https://www.fordxr6turbo.com/forum/topic/97389-melted-connector-in-525-fuel-pump-assembly/#findComment-1725628 Share on other sites More sharing options...
Puffwagon Puff Gold Donating Members 16,303 Member For: 10y 2m 30d Gender: Male Location: South Australia Posted 15/02/25 12:23 PM Share Posted 15/02/25 12:23 PM In this case op should use the correct gauge wiring to the pump, whether half assed through the top of the pot or with a proper surge setup. I wouldn't bother trying to use the stock connector, more than likely it will burn out. Link to comment https://www.fordxr6turbo.com/forum/topic/97389-melted-connector-in-525-fuel-pump-assembly/#findComment-1725629 Share on other sites More sharing options...
k31th less WHY; more WOT Site Developer 29,442 Member For: 17y 19d Gender: Male Location: Melbourne Posted 15/02/25 12:30 PM Share Posted 15/02/25 12:30 PM I guess the pins in the connector have a "amp" rating, also... Link to comment https://www.fordxr6turbo.com/forum/topic/97389-melted-connector-in-525-fuel-pump-assembly/#findComment-1725630 Share on other sites More sharing options...
Puffwagon Puff Gold Donating Members 16,303 Member For: 10y 2m 30d Gender: Male Location: South Australia Posted 15/02/25 12:39 PM Share Posted 15/02/25 12:39 PM They do and iirc it's nowhere near enough Link to comment https://www.fordxr6turbo.com/forum/topic/97389-melted-connector-in-525-fuel-pump-assembly/#findComment-1725631 Share on other sites More sharing options...
Seears Member 11 Member For: 14y 1m 9d Gender: Male Location: Canberra Posted 16/02/25 02:00 AM Author Share Posted 16/02/25 02:00 AM Thanks ke1th and puffwagon for responding and doing a deep dive for the other threads. I can always bank on this forum having the answers to specific questions I will get onto that this week and sort it, I think a surge tank will be the go from the sounds of it. Just wondering if you have a recommendation for the size/shape of the surge tank. Would something like either of these two be okay for what we are talking about? I can’t really afford something like a plazmaman or process west unit at the moment Link to comment https://www.fordxr6turbo.com/forum/topic/97389-melted-connector-in-525-fuel-pump-assembly/#findComment-1725633 Share on other sites More sharing options...
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