See how i work my magic when my game is on... This is how you rewire a fuel pump... fo Rizzle. I dont play around neither.

This is the connector that comes with the Walbro 255 standard pressure, as well as the High Pressure unit. Its a harness that plugs directly into the Fuel pump itself. Its not a "Weather pac" type connector with sealing gaskets, so fuel can seep into the electrical connections... but thats alright, fuel is non-conductive. The Orange clip retains the wires in the main connector body. I pried the orange clip out, and then the connectors crimped to the ends of the wires were held in by yet another retaining clip, which was molded into the Black clip body. I tried to release it w/ a paper clip, but failed... the locking clip inside the black connector busted off, but thats of no consequence (youll see later ).

but this is basically what comprises the supplied harness that Walbro intends for you to splice into your stock fuel electrical supply... me being the fabricating-kinda guy, i wasnt satisfied.

 

These are the new wires that im putting in.

These are 8 AWG wires, Oxygen Free, Oil resistant sheath, Ultra Fine strand, multitwist. these are actually Stereo Amplifier cables that are intended to supply 45+ Amp's of current @ 13.7v, rated for Amplifiers of 600+ Watts of continuous power. These wires barely fit into the Yellow crimp connectors. i Used Female blade connectors since the Fuel pump has Male blade connectors. Obviously, i put the Red wire on the + side and the Black wire on the - side.

I was going to put these blade connectors into the stock harness connector, except these wires were Entirely too large to fit inside that connector. You can see the Yellow insulation that i had to cut off the female blade connectors so that it would actually fit into the female recepticle of the fuel pump connector; i just split it down the side, spread them apart, and slid them off. I only stripped ~3/8" of insulation off the cables and crimped the now-bare female blade connectors onto the cables.

 

Here you can see the new cables that im using compared to the supplied wires. I just did this so you can see the difference between the two; here you have a point of reference to compare: 14 AWG against 8 AWG... pretty big eh?

 

Thats badass way to go mr over achiever

 

So after the female blade connectors are crimped on, the cables can now be pushed onto the male blade connectors that are recessed inside the top of the fuel pump itself. They are now installed, but i cant leave them bare. what would happen if something fell down in there and shorted them out??? bad stuffs, for sure. So, i got some Ultra Gray RTV silicone sealer, used for sealing valve covers and oil pans and what not. I poured it on, and pushed it all the way down into the female connector receptical, and back-filled the whole cavity so there was no gaps. I brought it out the top and up the sides of the wires to help stabilize the wires so they dont flex around so much.

 

Now heres a close-up of how much the silicone is pushed in; its starting to flow out the holes. Ill probalby zip tie them togeher to keep them from doing the splits and ripping the silicone.

Btw, i was only joking about how im better than you Feel free to duplicate this mod... if you want. Ill call this the "Supra-Sized Fuel pump Man-wire Mod"

So, im thinking there is a good chance this pump may flow MORE than 255 Liters Per Hour... espeically since im running more of this 8 AWG cable up thru the trunk floor, to a Gold plated Junction block. On the other side of this junction block, will be a few feet of 4 AWG Cable, leading to an Optima Red top or maybe a Dry cell so i can save on some weight. Of course, itll be mounted in my trunk for 2 reasons:

1. relocate the weight to the rear passengerside tire for maximum traction and weight transfer
2. Shortest route of cable to my fuel pump: remember, extra wire length = Extra resistance. The shorter the wires, the least resistance, the most usable current.

 

its a sight to see in person, thats for sure, it looks like those wires should be coming out a fuel pump 3x its size

 

does it really make a difference? cuz ive never rewired mine

 

Niether did ricky and harry.

 

so to answer my question, i guess it doenst make a big diff, eh