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Old 11-02-2019, 01:31 PM   #1
neurotopia
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Default Keep blowing fuse to fuel pump

Hi there,

My daughter (2002 L200, 2.2) drove through a big ass puddle a few days ago and somehow blew the 15 amp fuse to the fuel pump circled in red in the attached image. I replaced it, drove it around for a while, and it keeps blowing if you have to get the tach over about 2500 rpm. Other than looking along the wires to see where if it is grounding out, any ideas? Should I replace that other larger thing (labeled "Fuel Pump") to the upper right of the 15 A fuse?
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Old 11-02-2019, 02:42 PM   #2
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Default Re: Keep blowing fuse to fuel pump

I think I may have found the problem. There's a pigtail harness in the back that flopped against the exhaust pipe and melted the insulation off a couple wires. I'm betting they go to the fuel pump that's the problem.

Anybody have a wiring diagram?

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Old 11-02-2019, 07:19 PM   #3
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Default Re: Keep blowing fuse to fuel pump

What part of the diagram do you need? The harness that comes out near the fuel fill pipes does go to the fuel pump and gauge sender.

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Old 11-02-2019, 07:50 PM   #4
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Default Re: Keep blowing fuse to fuel pump

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Originally Posted by 02 LW300 View Post
What part of the diagram do you need? The harness that comes out near the fuel fill pipes does go to the fuel pump and gauge sender.
Yeah anything for that whole area of the rear crossbeam, back by the ABS cables and their connectors. I'm sorry I can't be more specific, I'm not sure the names and such.

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Old 11-02-2019, 11:44 PM   #5
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Default Re: Keep blowing fuse to fuel pump

The factory service manuals that I have are designed for professional mechanics not do it your selfers. They break down wiring by circuits not just basic rear harnesses. The abs sensors are in the brake section and the fuel pump is with the engine controls and the fuel level is with the bcm.
The fuel pump wires at the four wire connector are gray in position A and that is the 12v+ from the fuse through the relay. And black at position B is 12- or ground. The other two at C and D are the fuel level sensor wires.
I hope this helps, Chilton may have schematics that are more what you are looking for.

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Old 11-03-2019, 11:42 AM   #6
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Default Re: Keep blowing fuse to fuel pump

Any chance of some snapshots of the damage?

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Old 11-03-2019, 06:59 PM   #7
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Default Re: Keep blowing fuse to fuel pump

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Originally Posted by fdryer View Post
Any chance of some snapshots of the damage?
The red circle. Its dark but you can see a couple of the wires are missing insulation (some stranded copper peeking through) and the connector is a bit melted at the corner. It is part of the same harness that goes up to the fuel filler neck.
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Old 11-03-2019, 08:59 PM   #8
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Default Re: Keep blowing fuse to fuel pump

Pull the melted wires apart so that noting touches each other and see if your problem goes away. If so then repair the wiring properly, solder and shrink tubing. You can eliminate the connector with no problems.

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Old 11-05-2019, 06:18 PM   #9
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Default Re: Keep blowing fuse to fuel pump

Quote:
Originally Posted by neurotopia View Post
The red circle. Its dark but you can see a couple of the wires are missing insulation (some stranded copper peeking through) and the connector is a bit melted at the corner. It is part of the same harness that goes up to the fuel filler neck.
That location should've had a AL shield in place I know I have 2 Saturn L300 and that location has a AL shield in that location. Get some brake parts cleaner and blast those salt and dirt away and then look more at it.

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Old 11-05-2019, 11:35 PM   #10
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Default Re: Keep blowing fuse to fuel pump

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That location should've had a AL shield in place...
I appear to be ignorant of the shield you're describing - I have no idea what it is. What does "AL" stand for?

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Old 11-05-2019, 11:44 PM   #11
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Default Re: Keep blowing fuse to fuel pump

Aluminum shield to protect the fuel fill and wiring from exhaust heat. The shields seem to crack around the small bolts. Maybe his fell off and let the harness touch the exhaust.

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Old 11-06-2019, 02:18 PM   #12
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Default Re: Keep blowing fuse to fuel pump

Quote:
Originally Posted by 02 LW300 View Post
Aluminum shield to protect the fuel fill and wiring from exhaust heat. The shields seem to crack around the small bolts. Maybe his fell off and let the harness touch the exhaust.
Maybe.

I'm just gonna wire around the melted plug. Can I get by with butt connectors and heat shrink tubes? My soldering iron sucks.

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Old 11-06-2019, 08:04 PM   #13
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Default Re: Keep blowing fuse to fuel pump

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Originally Posted by neurotopia View Post
Maybe.

I'm just gonna wire around the melted plug. Can I get by with butt connectors and heat shrink tubes? My soldering iron sucks.
After looking at it more closely, it is only a patch of insulation on two wires that melted off, the connector is only damaged around the edge. I put some of that liquid electrical tape on it and that honestly might be enough.

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Old 11-06-2019, 10:28 PM   #14
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Default Re: Keep blowing fuse to fuel pump

I use that stuff at work when I want to not cut an original wire but solder another wire on. It works great you should be ok with that type of repair. Make sure the wiring canít get back near the exhaust.

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Old 11-06-2019, 10:34 PM   #15
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Default Re: Keep blowing fuse to fuel pump

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Originally Posted by 02 LW300 View Post
I use that stuff at work when I want to not cut an original wire but solder another wire on. It works great you should be ok with that type of repair. Make sure the wiring canít get back near the exhaust.
Yeah I made sure to hook it back where it goes, and to put a zip tie on it so it can't fall on the exhaust again if it comes loose.

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