Grrrr, Fuel Pump

**SixSick6** · 11-7-04, 20:36

Took out my stock fuel pump in preparation for a Walbro 190 lph.

While torqing the + 7mm terminal, it decided to break off (very little torque at all)

The screw that broke was a permanent fixture in a grommet with the + wires protruding on the outer portion of the fuel pump. The inside of the fuel pump fixture has to be a completely closed system to allow pressure without any leaks. In other words, if I didnt get this broken screw fixed- I'd have nothing to bolt the + wire to, and no way to get power to the pump without buying a whole new fixture.

So, when life gives you lemons, you make lemonade and when all else fails, McGuyver that it.

The plan was to drill through the grommet, drill the lower portion of the screw completely out, and replace with another screw-seal it up, and jump up and down.

But how to do it?

A drill press of course:

The inside portion where the threaded section broke off:

The outer portion which contains the wiring itself:

This brass linkage is what connected the inner and outer portions:

Where there is a will, there is a way. Better picture of what the screws look like that snapped off:

There's got to be some brass inside to work with:

But finding it is the hard part. But thats what countersinking is for:

Ahhh, starting to see brass:

But not enough, notice that the voltmeter isnt showing continuity. disclaimer-not my fingernails

So back to the drawing board, Dremel and a dental tool later...progress finding buried treasure:

Continuity check, 0.0- wo0t....we have lift-off:

Hey, it works : shrug: lol

The inside looking ghetto fabulous..but hey..it works flawlessly and there were no junkyards nearby:

The only thing left was to seal it with silicone, follw it up with JB weld:

Crack a beer and watch the sun set:

Credit goes to MSGT-R

**Dyoel182** · 11-7-04, 20:40

Huge difference in the fingernails there guys. Good thing she was there to help you out.

**SixSick6** · 11-7-04, 20:43

I was at her house, drove up there to install the 330's and Walbro 190. Sadly, while I was there...a compression check showed horrible numbers that I'd rather not discuss untill I test compression again with a different gauge (not that I think it'll be all that much different...but I'm crossing my fingers I guess? )

**SixSick6** · 11-8-04, 12:12

So, question. The wiring harness in my car is different from 2rusty's 92:

http://www.mx6.com/forums/attachment...tachmentid=847

Notice that mine are all seperate:

I wanted to do Alter Ego's fuel pump rewire mod, but noticed that Julio's wiring harness is the same as 2Rusty's.

Mine has a double wire lead on each + & - side of the fuel pump (notice the black wires with white stripes)

So my question is, what changes in this wiring setup than the wiring harness setup?

I'm thinking that the only thing that changes is the setup and I'd still only need to snip the hot wire on my side and connect both wires to on wire to and from the relay?

http://members.cox.net/turboprobe/fuelpage.htm

Questions, comments, Julio?

**Mx6MaZTer** · 11-8-04, 13:06

Dude that very same freaking thing happened to me a long time ago!!!!!!
I ended up going to the welding shop, had him clean, prep, flux, and solder the wire directly to the terminal where the bolt snapped.

I never did the continuty check tho. All of my sending unit bolt stripped whenever removine them so i had to get new ones from a hardware store; i havent put them back in so i think i'll pull the pump again and check continuty!

Sick.... Did you even try to call a dealer?? I remember i did and when mine broke. They told me i had to buy it with the fuel pump for $550 I said "Fu* You... Peace! click"
LoL J/k

**SixSick6** · 11-8-04, 13:11

Quote:

Originally Posted by Mx6MaZTer

They told me i had to buy it with the fuel pump for $550 I said "Fu* You... Peace! click"

because it was the guy who answered the phones fault that the price is so high right?

I never even thought about calling the dealer because I knew I'd have to buy the whole part as an assembly and I know that it is an expensive buy. There also arent any junkyards close to where I was (MSGT-R's house)

So, you gotta do what you gotta do

And it worked!!!!!

**MSGT-R** · 11-8-04, 13:24

I was having a bad-manicure week...

**Mx6MaZTer** · 11-8-04, 17:22

That for sure. "Improvize" is my middle name

P.S. I didnt really swear @ the Mazda Duedez I just got frustrated and told them I Have an upgraded pump and didnt need the entire assembly nevermind then.
I do Have Manners ya know..
Besides $500, I could buy that Apexi Boost Conroller I want

**Mr.JasonBH** · 11-9-04, 22:17

For some one who knows as much as you do 6, you sure develop some serious problems

**MSGT-R** · 11-10-04, 10:21

Quote:

Originally Posted by Mr.JasonBH

For some one who knows as much as you do 6, you sure develop some serious problems

Hey, I'm the one who fixed the broken connection, Sick was having a bad Murphy-day, and a maximum stress-out when the bolt twisted off...

This whole fuel pump procedure can be credited to AlterEgo and his incredible website! Check it out sometime.

**Panther37** · 8-5-05, 1:15

I'm a little confused on the fuel mod. Oh, you have a 1genA and rusty has a 1genB.

**SixSick6** · 8-5-05, 1:18

That doesn't mean anything. He has a 90+ and Julio (AE) has an 89, just like me. The modifications is to assure that the pump recieves 12+ volts.

**Panther37** · 8-5-05, 1:36

Does it normally not get 12 volts? Wannt throw any of this up in the FAQs?

**SixSick6** · 8-5-05, 1:49

It's supposed to but isn't always the case. Not really.

**antval** · 8-5-05, 2:41

The same thing happen to mines when my bro installed my walbro!! So I went to the junk yard and bought one only to find out that it dosen't work...
Can you fix my old one...LOL,,,,,,

11-7-04, 20:36	#1 (permalink)
SixSick6 Join Date: Sep 2001 Location: San Diego, CA, USA Age: 32 iTrader: (2)	Grrrr, Fuel Pump Took out my stock fuel pump in preparation for a Walbro 190 lph. While torqing the + 7mm terminal, it decided to break off (very little torque at all) The screw that broke was a permanent fixture in a grommet with the + wires protruding on the outer portion of the fuel pump. The inside of the fuel pump fixture has to be a completely closed system to allow pressure without any leaks. In other words, if I didnt get this broken screw fixed- I'd have nothing to bolt the + wire to, and no way to get power to the pump without buying a whole new fixture. So, when life gives you lemons, you make lemonade and when all else fails, McGuyver that it. The plan was to drill through the grommet, drill the lower portion of the screw completely out, and replace with another screw-seal it up, and jump up and down. But how to do it? A drill press of course: The inside portion where the threaded section broke off: The outer portion which contains the wiring itself: This brass linkage is what connected the inner and outer portions: Where there is a will, there is a way. Better picture of what the screws look like that snapped off: There's got to be some brass inside to work with: But finding it is the hard part. But thats what countersinking is for: Ahhh, starting to see brass: But not enough, notice that the voltmeter isnt showing continuity. disclaimer-not my fingernails So back to the drawing board, Dremel and a dental tool later...progress finding buried treasure: Continuity check, 0.0- wo0t....we have lift-off: Hey, it works : shrug: lol The inside looking ghetto fabulous..but hey..it works flawlessly and there were no junkyards nearby: The only thing left was to seal it with silicone, follw it up with JB weld: Crack a beer and watch the sun set: Credit goes to MSGT-R

11-7-04, 20:40	#2 (permalink)
Dyoel182 Join Date: Jun 2002 Location: Granbury, TX iTrader: (0)	Huge difference in the fingernails there guys. Good thing she was there to help you out.
	I'ts a piece of cake to bake a pretty cake, if the way is hazy You gotta do the cooking by the book, you know you can't be lazy

11-8-04, 12:12	#4 (permalink)
SixSick6 Join Date: Sep 2001 Location: San Diego, CA, USA Age: 32 iTrader: (2)	So, question. The wiring harness in my car is different from 2rusty's 92: http://www.mx6.com/forums/attachment...tachmentid=847 Notice that mine are all seperate: I wanted to do Alter Ego's fuel pump rewire mod, but noticed that Julio's wiring harness is the same as 2Rusty's. Mine has a double wire lead on each + & - side of the fuel pump (notice the black wires with white stripes) So my question is, what changes in this wiring setup than the wiring harness setup? I'm thinking that the only thing that changes is the setup and I'd still only need to snip the hot wire on my side and connect both wires to on wire to and from the relay? http://members.cox.net/turboprobe/fuelpage.htm Questions, comments, Julio? Last edited by SixSick6 : 11-8-04 at 12:21.

11-8-04, 13:06	#5 (permalink)
Mx6MaZTer Join Date: Jul 2003 Location: Cp McKeesport, PA, USA iTrader: (0)	Dude that very same freaking thing happened to me a long time ago!!!!!! I ended up going to the welding shop, had him clean, prep, flux, and solder the wire directly to the terminal where the bolt snapped. I never did the continuty check tho. All of my sending unit bolt stripped whenever removine them so i had to get new ones from a hardware store; i havent put them back in so i think i'll pull the pump again and check continuty! Sick.... Did you even try to call a dealer?? I remember i did and when mine broke. They told me i had to buy it with the fuel pump for $550 I said "Fu* You... Peace! click" LoL J/k Last edited by Mx6MaZTer : 11-8-04 at 17:26.

11-8-04, 13:24	#7 (permalink)
MSGT-R Join Date: Apr 2003 Location: , CA Age: 50 iTrader: (0)	Ya caught me in my work-rags. I was having a bad-manicure week...
	1st Gen 4WS and a 3rd Gen Mazdaspeed 6 GT http://www.cardomain.com/ride/595967 http://www.cardomain.com/ride/2252648 http://www.bikepics.com/members/msgt/

11-7-04, 20:43	#3 (permalink)
SixSick6 Join Date: Sep 2001 Location: San Diego, CA, USA Age: 32 iTrader: (2)	I was at her house, drove up there to install the 330's and Walbro 190. Sadly, while I was there...a compression check showed horrible numbers that I'd rather not discuss untill I test compression again with a different gauge (not that I think it'll be all that much different...but I'm crossing my fingers I guess? )

11-8-04, 17:22	#8 (permalink)
Mx6MaZTer Join Date: Jul 2003 Location: Cp McKeesport, PA, USA iTrader: (0)	That for sure. "Improvize" is my middle name P.S. I didnt really swear @ the Mazda Duedez I just got frustrated and told them I Have an upgraded pump and didnt need the entire assembly nevermind then. I do Have Manners ya know.. Besides $500, I could buy that Apexi Boost Conroller I want Last edited by Mx6MaZTer : 11-8-04 at 17:25.

11-9-04, 22:17	#9 (permalink)
Mr.JasonBH Join Date: Mar 2004 Location: Vancouver, Canada Age: 25 iTrader: (0)	For some one who knows as much as you do 6, you sure develop some serious problems
	88 LX-T K&N,2.5" Turbo Back.15" KonigHoles.STS.ZombieChip.MBC.MSD SS,Boost guage.A/F Guage.Eibach Springs.FSTB/FSTB,R Disc's,Larger F/R Sway's,440's,FPR,FMIC,TB Turbo,Hardpipes. Sold 06/06, 14.2@97.51MPH. 94'LS KLZE,S-AFC,MSD6AL,SS-Headers,2.5" CB,CM Stage3,MX3 FW,CAI,Probinator chip,Konig 15",RRMounts, Illuminas, Sprint Springs, Brembo Slotts Rotors, Hawk Pads.

8-5-05, 1:15	#11 (permalink)
Panther37 The Mod With the Mostest. Join Date: Apr 2001 Location: Patrick AFB, FL, USA Age: 27 iTrader: (0)	I'm a little confused on the fuel mod. Oh, you have a 1genA and rusty has a 1genB.
	Where did all the common sense go? \| A tweel is a tire without air. \| Used to have a 1genA GT 1gen AND 2gen Custom Gauge Faces For Sale: White and Indiglo Are you going to beat me with your Jesus stick? (RIP Charlie) Loch is the one in the casket?

8-5-05, 1:18	#12 (permalink)
SixSick6 Join Date: Sep 2001 Location: San Diego, CA, USA Age: 32 iTrader: (2)	That doesn't mean anything. He has a 90+ and Julio (AE) has an 89, just like me. The modifications is to assure that the pump recieves 12+ volts.

8-5-05, 1:36	#13 (permalink)
Panther37 The Mod With the Mostest. Join Date: Apr 2001 Location: Patrick AFB, FL, USA Age: 27 iTrader: (0)	Does it normally not get 12 volts? Wannt throw any of this up in the FAQs?
	Where did all the common sense go? \| A tweel is a tire without air. \| Used to have a 1genA GT 1gen AND 2gen Custom Gauge Faces For Sale: White and Indiglo Are you going to beat me with your Jesus stick? (RIP Charlie) Loch is the one in the casket?

8-5-05, 1:49	#14 (permalink)
SixSick6 Join Date: Sep 2001 Location: San Diego, CA, USA Age: 32 iTrader: (2)	It's supposed to but isn't always the case. Not really.

8-5-05, 2:41	#15 (permalink)
antval Join Date: Sep 2002 Location: West Covina, CA iTrader: (0)	The same thing happen to mines when my bro installed my walbro!! So I went to the junk yard and bought one only to find out that it dosen't work... Can you fix my old one...LOL,,,,,,
	RIP 88 MX6T MY 06 EVO IX