Fuel Pump wiring cut (chewed?) in half?!
Fuel Pump wiring cut (chewed?) in half?!
So I thought my fuel pump had died, but when I went to replace it I realized that the entire wiring harness leading to the pump was cut cleanly in half - I don't know if it was chewed by a rodent or broke by some other means, but either way I have some wiring work to do before my car will start again. Does anyone have a recommendation for how best to approach this repair? Do I need to drop the fuel tank and work from below? What about the wiring itself - can I just crimp each individual wire back together, or should I use a different method?
If you can access the broken wires through the top, then it's a no brainer to do from above rather than dropping the tank.
I would recommend using crimp connectors that have a built-in shrink tubing sleeve (you can find them at most auto parts stores). Use a proper crimping tool and then hit it with a heat gun to shrink the tube which seals it off from the elements
I would recommend using crimp connectors that have a built-in shrink tubing sleeve (you can find them at most auto parts stores). Use a proper crimping tool and then hit it with a heat gun to shrink the tube which seals it off from the elements
If you can access the broken wires through the top, then it's a no brainer to do from above rather than dropping the tank.
I would recommend using crimp connectors that have a built-in shrink tubing sleeve (you can find them at most auto parts stores). Use a proper crimping tool and then hit it with a heat gun to shrink the tube which seals it off from the elements
I would recommend using crimp connectors that have a built-in shrink tubing sleeve (you can find them at most auto parts stores). Use a proper crimping tool and then hit it with a heat gun to shrink the tube which seals it off from the elements
Success! I reconnected the wires (6 total) using heat shrink butt splices (2 blue, 4 red), a heat gun, and without having to lift the car or drop the tank. The wiring comes out near the left rear wheel, and I was able to pull the harness end out to within reach of the fender, allowing me to work next to the car instead of completely under it. There are two brown/black/white wires that looked almost identical, but if you look closely one of them has a slightly narrower black line than the other. Everything else was fairly straightforward, and the reconnected harness was just long enough to reconnect to the fuel pump. If you have to remove any significant length from your harness, it will almost certainly require additional lengths of wire.
Thread
Thread Starter
Forum
Replies
Last Post
Chey Horton
Stock Problems/Issues
2
Feb 4, 2019 07:09 AM
R50/53 Fuel pump not working. . .
DeadErnie
R50/R53 :: Hatch Talk (2002-2006)
2
Oct 2, 2018 10:14 AM
b14nismo
Stock Problems/Issues
9
Aug 28, 2017 05:52 AM
candemresurrection
Stock Problems/Issues
7
Mar 31, 2015 08:58 PM




