[fuel pump woes]

No,it means power is "consumed" at the resistance thus overheating it.

Power loss = current squared times the resistance

A side effect would be lower volts and amps available to the load(the pump).

 

I would cut the offending wires from the plugs and solder them together.

 

There is nothing wrong w/your pump.Problem is a bad connector.

 

Thanks, so I'll cut the offending wires and solder new ones. Can I reuse the old connector? I tried looking on rockauto and they don't have the 6 pin connector.

[fuel pump woes]

IMHO, I think you would be better off swapping in a OEM Subaru pump. Something seems to be wrong or defective with the deatchwerks dw200 fuel pump.

 

 

Thanks for the input! I actually spoke to deatchwerks tech support on Friday. All the testing they told me to do I did and seems like its a pass, but the tech told me it shouldn't just stop working. I have to call them back for an RMA number since it has a 3 year warranty. But I want to rule out the electrical since of the car to make sure. 

 

I bought this to replace my OEM pump, at the time I was on a tight budget. DW200 was $130 OEM was $240 or so. 

[fuel pump woes]

There is really only one reason for melted plugs.

High resistance at a connection.

 

I would jumper the plug for those wires by soldering in some wires.

 

Your pump may draw a little more than stock,but,I do not see it being an issue.

 

Im apologize I'm not a electrical guru, when you say high resistance, does that mean not enough power is going through the connection, thus overheating it?

 

Do I cut the old wires and solder new wires for the ones burnt?

[fuel pump woes]

aftermarket pump requires more current than the OEM?

To be honest I'm not sure what the OEM specs are. the DW200 has Current Draw (40 psi)9 amps (13.5v)Current Draw (80 psi)12 amps (13.5v) according to the site.

 

Does the pump draw more amps to compensate being faulty? 

[fuel pump woes]

I have a JDM ver4 STi wagon that I fitted a deatchwerks dw200 fuel pump. This pump is appx 12-14 months old. 

 

Pump was great until last month it stopped priming so I couldn't start the car. I tapped and jiggle the connector and that seems to do the trick. 

 

So just a few days ago the car wouldn't start and I don't hear the pump priming on startup. I tried to tap and jiggle the connector like last time with no luck.

 

I had the tow truck deliver my car to my home. I told him about my issue and he said to try and bang on the bottom of the tank. I was banging on the tank while he turned the key and the pump started to prime and the car started. Tow truck driver mentioned the motor is seizing up.

 

The relay, rear harness (plugs 1 and 4), and the pump is getting 11 volts. I removed the pump assembly and just reconnected the plug to test it. The connection and wiring from the pump to the top connector looks clean and tight. The plugs on 1 and 4 look melted, I'm hoping this is the reason. Any idea why it would melt? Just old wiring?