Jumper to avoid being stranded with a failed Primary Fuel Pump
 

After the fourth time that a failed primary fuel pump "stranded" a ZR-1 (mine once and three friends' ZR-1's). I decided to make an extension cable that swaps which fuel pump acts as pump # 1.

Background: If number 1 fuel pump fails, the LT5 will start properly but then die after a short period of time. When the engine is cold, the period may be almost a minute. When the engine is at operating temperature the engine will die immediately after starting.

This happens because the ECM energizes BOTH fuel pumps on engine start. So the Secondary Fuel Pump supplies fuel to the injectors while the primary pump does nothing. Once the engine is operating properly, the ECM turns off the Secondary Fuel Pump and the car stalls.

Here is my solution:

http://i407.photobucket.com/albums/p...c/IMG_0105.jpg

This jumper switches the wires in the plug to make the Secondary Fuel Pump get power from the Primary Fuel Pump's source. The jumper is pretty easy to install:

1. Pull back the rubber boot around the gas filler neck to access the wiring harness that is clipped to the rear facia:

http://i407.photobucket.com/albums/p...c/IMG_0182.jpg

2. Remove the small gray lock pin from the connector clip:

http://i407.photobucket.com/albums/p...c/IMG_0184.jpg

3. Separate the male and female halves of the connector:

http://i407.photobucket.com/albums/p...c/IMG_0196.jpg

4. Then connect the ends of the jumper into the circuit to the pumps.

5. Start the car to test the connections. As soon as possible, replace the failed primary fuel pump and remove the jumper.

6. I recommend that if you use the jumper to swap a failed primary fuel pump, you should turn the Power Key OFF (Normal). Without the second fuel pump operating, if the secondaries opened, there might be a problem with a lean condition due to insufficient fuel supply.

Based on the rules of Murphy's Law and Good Mojo, when I carry this jumper, I will never need it, just like the alternator that I have carried for about 30,000 miles of road trips that I haven't needed to use.

Enjoy the Road,

Jim

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Genius!

Part numbers and source(s)...sorry if I missed them.

Ted

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Just so I understand this Jim......

The jumper you made up can be much shorter as it is only used to just switch wiring within the connector?

Exactly which wires are switched?
We have green, white, red, black wires from bottom to top on each side of the connector.
Green (on right) now goes (in your jumper connector) to what color (on left) and so on? I assume only two wires are switched....which two wires?

http://i287.photobucket.com/albums/l...d99bb9e88b.jpg

Great concept/solution Jim :thumbsup:
Thanks :handshak:

Oh....Jim I do carry tools and a volt meter (drivers side box), Jumper Cables and Nylon Tow cable (passenger Side Box) behind seat. I also carry a Tow Bar Adapter located between passenger seat and door sill with Lug Nut Wrench.

I have never carried a spare alternator ;)

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

I need one of these

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Clever. Thanks for sharing.

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Me too

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Why not jump the secondary fuel pump test connection to the battery?

Isn't that easier?

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

The Fuel Pump Test Connection in the wire bundle near the ECM cannot power the fuel pumps when the ignition is ON.

The fuel pump test connection is very useful when 12 Vdc is applied with an ammeter. A running fuel pump will draw about (I don't remember the exact number) 4 amps. If the ammeter reading is > 8 amps, then two pumps are running in test mode.

Jim

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

There are four wires in the connector:

Black - DC ground
Purple - Fuel level sensor signal to the fuel gauge display
Gray - 12 vdc to a fuel pump
Lt Green (or Green/White) - 12 vdc to the other fuel pump

My short jumper is just a cross-over jumper, as Cliff said. By switching (crossing) the gray and green wires, the 12 vdc from the Primary Fuel Pump is routed to the Secondary Fuel Pump.

The part number for the connector on the harness (car side) is:

Connector, elec, Fuel Pump, Male GM 12085534 (AC Delco PT145)

Here is the part on Amazon:
http://www.amazon.com/ACDelco-PT145-.../dp/B000C9SNX0

I haven't verified by ordering the connector for the pump side of the connection. I got the connector I used from a take-out fuel pump assembly from WAZOO donated parts. I THINK (but haven't verified) that GM 88861069 is the female connector, but I can't find a source with a picture.

Jim

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

I did something similar, but not as nice. I just cut the two FP wires and inserted crimp-on bullet male/female connections, so it's pretty easy to unplug them and reattach them Gray to Green and Green to Gray.

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Outstanding Mod. Im an electrical noob. Who wants to make a run of these? Jim? tell me where to send the money.. Outstanding :handshak:

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Thanks Jim :thumbsup:
I am not so sure about that GM88861069 for female connector. I cannot find that on Amazon. If someone finds a source of that female connector that would be great......

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Hmm i'm piecing some parts together. If it works out I could make a small run of these to those who are interested if Jim is not adverse to it. Jim any issues since its your idea ?

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

I like the idea of having one to throw in the storage bin. If somebody orders a bag of the connectors, I'll chip in. I think this same plug is used in a couple of different spots so it may also be possible to find another GM car that has this and clip a few next trip to the wrecking yard. Sometimes just buying new parts is less work though.

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

I also had trouble finding the female connector, which is why I cannibalized an old unit to get the connector.

There are many uses of the four-tower weather pack connector, but you have to get the one that is "keyed" for this application. There are slots and ridges that have to be in the right places. I will try again to ID the correct connector.

If some one wants to make these it is fine with me.

Jim

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

The connector shell on the "TANK UNIT" is actually MALE but is a female gendered connector because of the terminals inserted.


These are very basic Weather-Pack and the most economical approach is just by the appropriate male, female connector "shell" and create your own indexing. You need to remember when discussing GM/Packard/Delphi connectors that it's the terminal that dictates the "gender" and NOT the shell. Weather-Pack is unique because either a female or male terminal can be inserted into the shell. It depends on the component just how it's configured. A VSS uses a backward assembly procedure.

Any NAPA, or truck parts supplier can supply you with the shells, the terminals, the seals used in the assembly.

These people catalog Weather-Pack pretty well and have all of the correct seals, terminals and cavity plugs needed. They actually have pig-tails also and theirs would be actual Weather-Pack and not a similar assembly done by PICO or some other "off-shore" supplier. You could pin and unpin theirs at will.

http://www.whiteproducts.com/weather_pack.shtml

I buy from another vendor but these guys image things pretty well.

I have an application reference for "indexed" shells but most are discontinued so it's somewhat irrelevant.

If you wanted you could "tidy up" yours just by using two way Weather-Packs, one pair to correct where the "bullets" are now and a second pair done to accomplish the "cross-over".

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

In my stash of connectors, I found the second connector that I ordered

The connector that is on the Fuel Pump Assembly (Tank Unit) is in fact the male (my info above was in error, thanks WVZR-1). It is GM 88861069, AC Delco PT2141.

http://www.amazon.com/gp/product/B00.../ref=as_int_dp

If you want to assemble a jumper from two replacement (new) connectors, take care to keep the wire sequences correct. The new connectors are pigtail sets that are not color coded.

The terminals are marked A - B - C - D The normal wiring ID is:

A - Black - DC Ground
B - Purple - Fuel gauge signal
C - Gray - Fuel Pump
D - Green/white - Fuel Pump

To make the crossover, switch the C and D terminals on one end of the jumper.

A-------------------------A

B-------------------------B

C---------\ /-------------C
D---------/ \-------------D

Jim

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

These I believe would be the correctly "indexed" shells for the harness:

12020832 looks to be indexed A @ 12:00 (black) and D @ 3:00 (green/white) with the latch on top, this is what is currently on the sender with female terminals in it. Several vendors have that shell. 12020830 should be an appropriate shell for mating and would require just the appropriate male terminals. I don't know why you would need the CPA but 12020833 would get you that if you wanted a couple.

15324982 should be the correct green seals for the individual wires in the connectors.

I'll post back with what I believe should be the appropriate terminals. I don't recall the wire sizes and I'll need Jim to verify the indexing of the shell on the tank unit. I'm doing that mostly from memory but I believe it's appropriate.

Mouser it appears seems to have the correct shells and the CPA. Just use the part numbers I mentioned above to search. They could be available from many others and I don't buy often from Mouser but I've had good service in the past. Their "minimum" best I recall was very realistic and if someone was doing a few of these it would likely be appropriate to just let that person do the procuring from whomever. I didn't check the vendor I use for these part numbers.

http://www.mouser.com/

12089040 for male terminals I believe (I assumed .5 - .8 wire) and 12089188 for the female terminal.

Part #'s required per car:

12020832 X 1, 12020830 X 1, 15324982 X 8, 12089040 X 4, 12089188 X 4 and 12020833 X 1 if you wanted the CPA.

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Dumbassed question. I should know that.
Sorry.:(

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Ive talked to my local electrical guy about making these. We figure $30 shipped Lower 48. I have asked him about making a run of 20 if we have enough interest. Once we have ten signed up I will tell him to start making them and start ordering the connectors and wire and post up the prototype

1. GOLDCYLON
2. PHILLIPSLT5
3. GEEZER (Canada)
4. ZR1North
5. GSJOE X 2
6. CHRISKINZEL
7. CVETTE98PACECAR X2
8. DYNOMITE X4
9. NELSON007 X2
10. WEGONE
11. SCOTTZ95ZR-1 x2
12. MYSTICZR-1
13. DEMPS
14. ROADSTER
15. HAWAIIZR-1
16. ANDY
17. HIZNHRZ
18. 90206

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

I am in, no need to ship, just a cold 1

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Ok any others out there ?

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

I'm in-- with additional cost to ship to Canada.

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

I am in as well.

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Joe Rose (GS Joe)...I'll need two, one for me and one for my godson, Clint Morgan. Where and when do I send money?

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

I'm in. Never needed one before, hope to never use the one. But...

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

How long is the jumper you are making and I assume it plugs right in to each each end of the disconnected existing plug shown below?

What is the shortest jumper you can make? It would appear that the shortest jumper would be with two new connectors back to back with just enough room to cross wires green and gray (white).

http://i287.photobucket.com/albums/l...d99bb9e88b.jpg

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Count me in for 2.

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

I would think you would want sufficient length between connectors to maybe pass the four wires through a "heat-shrink" tube when constructing and then shrinking to keep the bundle secure. Wouldn't need to be long but I believe needs to have some length to avoid struggling when connecting.

I'd think Jim has first-hand knowledge of a practical length and I'd certainly inquire/enlist his help before constructing.

Cliff - did you check the "clocking" of the black and green/white on yours?

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Good suggestions and what I was thinking also in terms of installation without having too long a jumper to try and stuff back into position under the rubber boot :handshak:

I am going with what Jim described as follows.......and I am assuming 90's and 91's are identical.

Black is Black,
Purple I call Red,
Gray I call White,
Green/white I call Green.
http://i287.photobucket.com/albums/l...d99bb9e88b.jpg

Why does the ECM have to energize BOTH fuel pumps on starting?

Four Jumpers for Dynomite.......;)

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Count me in for two sets.

Nelson007

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Not what I meant but I'm pretty confident that what I mentioned in my post is correct A - black 12:00 to latch and the D - green/white 3:00 to latch. That would have confirmed my shell part #'s.

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

For the length of the jumper, I recommend 8 to 12 inches. That length allows the harness to be pushed below the rubber boot one "lump" at a time. Then the wire can be pushed in. If the jumper is too short, the whole rigid part becomes bigger than the opening.

All that said, there is plenty of room below the rubber boot for the connectors and wiring.

On a different subject, I recommend that if you use the jumper to swap a failed primary fuel pump, you should turn the Power Key OFF. Without the second fuel pump operating, if the secondaries opened, there might be a problem with a lean condition due to insufficient fuel supply.

Jim

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Add one here... Thanks

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Yes, the tank unit connector is indexed A @ 12:00 and D at 3:00 with the latch up.

Jim

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

OK count is at 19 we will make a round of 20 for lot 1

Guy said he will do a long custom measurement with end to end wiring. It will be heat shrinked or wire wrapped to prevent chaffing. Once I have the proto type in hand I will post up the pics and the ordering instructions. Sound good? GC:cheers:

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Sign me up for one.
Hope I never need it...

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

I'm in for 2 also

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

If there is an option to buy surplus backshells and pins, I would be interested for that as I can (and would prefer) to make my own wiring to keep it cheap.

Re: Jumper to avoid being stranded with a failed Primary Fuel Pump
 

Ok 17 and the parts have been ordered