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Old 05-29-2006, 12:58 AM   #21
Poolside
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Joined: Apr 2003
Location: Long Beach, CA
Oddometer: 11,604
Bypassing a faulty Fuel Pump Controller


If you are in a fix, the controller can be bypassed. The fuel pump can be powered directly from the 3-pin connector that plugs into the fuel pump controller.

The fuel pump controller isn't part of the CANbus.

Jumper from Pin 1 and Pin 2 on this connector shown below . . .







. . . to Pin 1 and Pin 2 on this connector shown below. The numbers 1 and 2 are molded into the connector housing.





The 2 pins of this receptacle below are connected directly to the fuel pump.





The two pins are +12V and Ground, just like other fuel pumps.




Got it? Connect two jumpers, Pin 1 to Pin 1, and Pin 2 to Pin 2, to bypass the faulty electronic controller. This connects power and ground to the fuel pump directly. Just like other fuel pumps that don't have a controller.

The wire colors in these pictures are different from some versions of the factory wiring diagram. But the pin numbers are correct. The numbers 1 and 2 are molded into the connector housing.



- - - What does the controller do?

The controller operates the fuel pump at 80% to extend the life of the fuel filter. The motor ECU switches the fuel pump controller between 100% and 80%.

The pump can operate at 100% all the time, just like it would without a controller, so a jumper will not be an issue.

The fuel pump on the 1200 is the same as on the 1100/1150. The only thing new on the 1200 is the 80% controller.

The fuel pump controller isn't part of the CANbus.



Another way to bypass the controller is to cut the 2-pin connector from the controller. Use the connector leads to connect Pin 1 to a fuse and the battery positive. And Pin 2 to the battery negative post or chassis ground.

The pump will be running all the time when the engine is running. But it already is running all the time, just like every other fuel pump.

If you chose this method, a switch of some kind will be needed to turn the fuel pump on before starting the motor, and off after stopping the motor. The fuse may be plugged/unplugged to serve as a switch.

Either solution can get you home if you are stuck out on the road or trail, or at a dealer if the controller isn't in stock.

- Jim

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Poolside screwed with this post 07-03-2008 at 06:08 PM
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