Editing Fuel Pump Upgrade (section)

==UPGRADE OF WIRING==

Upgrading the wiring is necessary to ensure you have maximum fuel pressure in the rail. Due to inefficiencies of the stock wiring, the pump can be receiving as little as 10V. By installing a relay, we can ensure the pump receives a healthy 13.8V at all times, thus working the pump to its maximum potential. (Note: I have used 8GA wiring to supply power to the pump, this is overkill, but I found that it worked well when it came to sealing the wires to the pump assembly. You can chose not to use this setup, but this is what worked for me.) 

Parts needed (all available from jaycar):
- 50cm length of 8GA wire (red)
- 50cm length of 8GA wire (black)
- FuseHolder x 1
- 5AG 30AMP Fuse x 2
- 60amp Horn Relay x 1 (Nice big terminals to suit the 8GA cable and its spade connectors)
- Red/Black Large Eye Terminals for 8GA x 1
- Yellow 5.3mm Insulated Eye Terminal x 1
- Yellow Large Insulated Spades x 1
- Blue 6.4mm Insulated Spades x 1
- rubber grommets, ID 6mm, OD 9.5mm
- soldering iron
- electrical tape
- wire strippers
- 10mm drill bit and power drill

1. Right, first step is to disconnect the battery, as we don’t need any sparks getting involved when there is fuel in the equation.

2. Next step is to run the 8GA to the pump. Also the most complicated step. There is no provision on the top plate of the assembly to run larger wires through. You will see the stock wiring is run through the tops of 4 plastic ‘hats’. What we are going to do, is cut away two of those plastic hats, leaving two neat holes in the top of the bracket to pass the wire through.

3. Following the original power and ground wires from the pump, you can see that the 1st and 3rd ‘hats’ need to go. Using the sharp knife, cut these away from the others, and using a screw driver, pry them off. Don’t worry about damaging them, they’re going in the bin – so dig in. What you will see is two neat holes. They are ‘just’ large enough to run 8GA through – which is great, however, we must seal the wires off to make sure no petrol escapes the tank – and it will.

4. Using the power drill, drill out these holes to 10mm. insert the grommets through the holes. Pass the black and red 8GA through the grommets. 


[[Image:fuelpump011.jpg]]

5. Using the large eye terminals, place those over the fuel pump terminals and screw down. Solder all connections. Run the 8GA out through the top cover. Reinstall pump.

[[Image:fuelpump006.jpg]]

6. Now we’re ready to hook up the relay. There are numbers on the relay that relate to what each connection is. I have put in brackets which wire needs to go to which number

7. Reconnect the factory loom at the connection in the boot. Now, looking at the wires that run between the connector and the fuel pump, you need to find the white with purple stripe wire. This is +ve power for the coil (86). Then, you need to find the thick black wire (85), this is ground for the coil. IMPORTANT. With this black wire, it is a shielded wire, meaning there is a wire running within a wire – strip back the outer wire and cut it away as it is not needed so don't leave any of it exposed – we’re interested in the inner wire; this is the wire that must be connected to (85). 

8. (30) is the connection direct from your battery - insert your fuse holder and fuse in-line with this wire. Finally, (87) is the red 8GA that runs to the fuel pump +ve. 

9. Last thing, the black 8GA wire must now be grounded to the chassis. Find a good solid spot to ground it, sand back any paint to bare metal and screw it down tight. A good ground is as important as a good power supply. Using a multimeter between the +ve 8GA on the fuel pump, and this black 8GA you should read the same voltage here as what is read at the battery itself. 

10. Turn the key to accessories. It should prime the pump for 5-10 seconds, then stop. If it doesn't prime at all, make sure that the outer wire of the shielded wire isn't grounding to anything, and isn't touching the connector on the end of the inner wire. If it is constantly priming and doesn't stop, that means you have grounded the outer wire instead of the inner wire. Beyond this.....

11. Grab another beer cos you’re done!

[[Image:fuelpump013.jpg]]

- '''SMOKEY'''