Corsa C20LET fuel pump feed wire getting hot.

[CamaroZ28]

1995 Corsa with C20LET:

As the title suggests, the red/blue live feed to the fuel pump is getting hot just around the first few inches by the fuel pump relay. So hot it made the blue insulation on a crimp-on connector shrink around the spade connection to the point it pierced through.

The corsa red/blue fuel pump wire is only 1.5mm so I'm going to try replacing the whole length with a larger gauge wire. I would have thought the original wire should have been up to the job though? I'm using a new walbro pump and the pressure is good on my afpr.

Has anyone else had this problem, and would this be a likely cause of an rpm specific misfire?

[Dale]

Have you checked for short to ground causing the wire to melt, stiff motor causing high amp draw! I would advise measuring amp draw. I ran walbro 255 on my corsa was fine!

[tiff_lee]

Is the crimp on connector standard or something someone else has done? either way a poor crimp will cause high resistance causing it to heat up

[CamaroZ28]

I checked that it wasn't shorting to ground, the wire itself appears to be intact. I will mention however that powering the pump independently without the engine running reveals what appears to be an intermittent bumping sound coming from the pump as well as the whine you'd expect.
The pump is brand new and has done only 7 miles.

The blue connector was on the first loom I tried, I replaced it because it was a mess and was giving me headaches - I put the connector on originally. I noticed the melted connector when I was using it as a reference to check the replacement loom. This made me check the same area on the new loom and sure enough the wire is getting hot in the same place right out of the relay. I didn't have to use any connectors here as the wiring is good.

I might try measuring the amp draw next, any ideas as to what it should be for reference?

Cheers

[debeerd]

Either the pump is faulty drawing too much current.
Or check for bad earths or bad connections.