The Project Pad

Extreme heat would cause discoloration on the wires, but something is shorting out somewhere in the fuel system wiring...

This is the fuel pump relay, and it smells.... Yuck





Sent from my HTC One using Tapatalk

remind us of which fuel pump you're using and how it's wired?

Either there is a short or simply too much current for those wires/relay

I'm thinking to much current... I've got the Walbro Part #F90000267
It's wired the 034 way... I'm trying to find out what Amperage this is rated for... I purchased it 2 years ago for convenience sake...
http://store.034motorsport.com/c4-fuel-pump-relay-kit.html
http://store.034motorsport.com/docs/C4S4%20Relay%20Kit%20Install%20Docs.pdf
Sent from my HTC One using Tapatalk

Sent from my HTC One using Tapatalk

Brah u got issuez

Upon inspection, it's only the direct power leads across relay that seem to be affected...

Sent from my HTC One using Tapatalk

What is the wire gauge on that relay harness? Looks like 14ga?

Here is some info on the pump. It could be pulling over 20a

034 rep "ah they say it's 12ga"... I will grab 12ga from my stash and compare... I might even rewire and repin it all with 10ga along with new upgraded relay and harness just to be safe.
What size wire is usually used when relaying? I don't think there's such a thing as "overkill" by going lower than 10ga and higher amp relay, is there?

Sent from my HTC One using Tapatalk

I run 10ga wire and 40a relays with my 044's - no need to go any larger than that.

044's draw 15.5amps @ 75psi, and mine are not working nearly that hard.

mushasho wrote:034 rep "ah they say it's 12ga"... I will grab 12ga from my stash and compare... I might even rewire and repin it all with 10ga along with new upgraded relay and harness just to be safe.
What size wire is usually used when relaying? I don't think there's such a thing as "overkill" by going lower than 10ga and higher amp relay, is there?

Sent from my HTC One using Tapatalk

the signal wire should be fine in stock form,

Id run 10 gauge for the rest as 20 amps is borderline for 12 gauge (for intermittent use).

Dude - What you were gettin nostalgic for a backseat fire and thought you'd cook one up?

No way that is 20a constant draw, however it looks likely to be running reguarly in the 15-17a range which is still considerable and designing for 20a is the way to go.

I looked up the data sheet on that relay and it should be fine for your application as long as temps aren't crazy.

What does worry me is:

• Is that fused? The 034 kit includes a fused relay... you better have a nice solid fuse on the power line to the pumper...
• The socket itself could be not rated for that level amperage even if the relay is - if that's a cheap relay socket for headlights or car stereo then it its contacts might be the current handling limiting factor

Good luck!

PS - sorry didn't hit ya back up on weekend, didn't get your text until way later and then forgot to shoot reply... had stuff goin' on so no GTG cruise for me...

EDIGREG wrote:I run 10ga wire and 40a relays with my 044's - no need to go any larger than that.

044's draw 15.5amps @ 75psi, and mine are not working nearly that hard.

So that's 15.5x3pumps? 46.5amps total?... or 15.5amp all 3 running in tandem?

FRCFD5 wrote:
the signal wire should be fine in stock form,

Id run 10 gauge for the rest as 20 amps is borderline for 12 gauge (for intermittent use).

Yeah the signal wire leads looks perfect... I'm wondering if 034 kit was designed for stock pump usage or if the Walbro is seizing up (already) and causing additional current draw... Things to consider...

Sent from my HTC One using Tapatalk

mushasho wrote:So that's 15.5x3pumps? 46.5amps total?... or 15.5amp all 3 running in tandem?

Yes, 044 pumps draw 15.5amps each @ 75psi. But I'm not running even close to 75psi. Feed pump is under "zero" pressure, and pressure pumps run 37.5psi base pressure.

They're all wired/fused/relayed separately.

mushasho wrote:Yeah the signal wire leads looks perfect... I'm wondering if 034 kit was designed for stock pump usage or if the Walbro is seizing up (already) and causing additional current draw... Things to consider...

Sent from my HTC One using Tapatalk

Obe - for the smaller older Walbros the failure mode was never high current draw AFAIK - I think it was 'dead'. But this is a different model clearly so who knows...

Is your positive battery cable/terminal hot?

High resistance will make issues too, a few cars have had corroded + cables

The wires on my 034 FP relay are a tiny bit burnt as well. Not nearly as bad as yours currently though. I'm just running a stock 040 and before that a replacement pierburg. Not sure if the pump is just old and takes more juice than needed to stay running causing a lot of draw on the wires or what?

how snug are the connectors? a loose connector will cause overheating as well...

pilihp2 wrote:The wires on my 034 FP relay are a tiny bit burnt as well. Not nearly as bad as yours currently though. I'm just running a stock 040 and before that a replacement pierburg. Not sure if the pump is just old and takes more juice than needed to stay running causing a lot of draw on the wires or what?

Just swap in a 40amp(per Ed's Suggestion) relay and you should be fine... I did and all well again, all is nice and cool... Of course I still need to repin a new relay socket and bump up to 10ga at some point, but she runs again...

RePin the hazard harness


Loop the relay back into the leads that were unplugged from the Hazard harness


Sent from my HTC One using Tapatalk

Totally confused. You've wired your fuel pump relay to the hazards?

Or this is your W/M install and you are activating w the hazard switch?

Quattro-JC wrote:Totally confused. You've wired your fuel pump relay to the hazards?

Or this is your W/M install and you are activating w the hazard switch?

This is a Komfort Mod,,,

Part # 000-998-229 (000-998-229A can be used too) - comes as a kit with a relay, harness, splice connectors and a zip tie.




1 tap on the stalk gives you 3 blinks, perfect for highway cruising...

But I got mine locally, Talk to MAtt at Quirk VW Parts Warehouse
Here

I saw Nick do this on his 200... does this same kit work on the 80/90 cars?

Love this on D's jeep

PRY4SNO wrote:I saw Nick do this on his 200... does this same kit ...work on the 80/90 cars?

Should, but I'm not sure...

themagellan wrote:Love this on D's jeep

Tell D I said Hi... And thank her for diagnosing your cars issue so nonchalantly...

Sent from my HTC One using Tapatalk

nice, I've been meaning to buy one of those Komfort kits. First I need to fix my clockspring so the turn signals actually cancel