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Too many AMPs? Fuel pump

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Old Jan 2nd, 2022, 18:51   #1
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Last Online: Jan 5th, 2022 00:47
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Smile Too many AMPs? Fuel pump

Just fitted a new fuel pump and tank fuel pump to my 1990 (but still) k tronic 200e 240.

But it is using too much current (or so I believe). The cables and relay get really warm when in use, so much so I would think they would maybe melt in time.

When checked at the fuse box, about 15 amp are being drawn. At the tank pump about 1.5a are being drawn, but at the main fuel pump 14.5a is flowing!

I know the main is the main, but this seems too much to me (as shown in the picture).

Do any of you know what it should be about, it is easy to check with a clamp meter (very useful device) around the main cable under the rear seat? I have cleaned the earth cable too, so not sure what else to do other than get another pump?

I hope someone wise can advise.
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Old Jan 3rd, 2022, 19:02   #2
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As with many of us here the K-jet can through up many problems, I have changed a number of both on-tank and main pumps over the years. I also rewired the pump relay behind the glovebox.

The condition of the connections between the fusebox, relay and pump does contribute to raised current and as you'd expect heat leading to loose connections and even more chances to burn a fuse or relay.

I'd start with cleaning all the connections in the fuel pump circuit, be prepared to replace the crimped terminals.

As you know the main pump fuse is rated at 16A this is a safety measure as with all fuses I would imagine the main pump shouldn't draw much more than 10A at most.


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Old Jan 5th, 2022, 00:47   #3
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Smile Thanks you your reply

I thought the area around the fuses could be the issue so purchased one of those new spade fuse blocks, it does seem to manage the current better. But the relay and cables still get hot with just a few minutes of use.

I would say too that the pump shouldn't draw that much current and with testing it is certainly from this cable onwards is where the draw is coming from, as once disconnected and only the tank pump in place every thing goes down to just 1.5a.

I'll have to take the main pump out again and as you say replace the crimp connectors and check for shorts :-).

Thank you for replaying Daniel.
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fuel pump, fuel pump electrics, fuel pump relay, fuse box

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