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Old 07-05-2005, 12:12 AM
1997 1997 is offline
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97-4.3 fuel relay overheating

97 c/k 1500 4.3 liter w-series. I recently replaced the fuel pump (master-aftermarket) and I was having stalling and killing problems. I pulled the fuel pump relay and it was melted at pin #30 this happened after the fuel pump was replaced. I replace the relay and it seems that it is still gettin hot but the stalling and killing has stopped. But now I have a hesitation on acceleration and a miss when cruising at 2000 rpms. Any ideas would be greatly welcomed.
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Old 07-05-2005, 12:11 PM
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GMMerlin GMMerlin is offline
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Re: 97-4.3 fuel relay overheating

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Originally Posted by 1997
97 c/k 1500 4.3 liter w-series. I recently replaced the fuel pump (master-aftermarket) and I was having stalling and killing problems. I pulled the fuel pump relay and it was melted at pin #30 this happened after the fuel pump was replaced. I replace the relay and it seems that it is still gettin hot but the stalling and killing has stopped. But now I have a hesitation on acceleration and a miss when cruising at 2000 rpms. Any ideas would be greatly welcomed.

Did you replace the mating terminal?
The melted terminal was caused by a bad connection (high resistance=high heat)
This may be the cause of all your problems.
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Old 07-06-2005, 09:47 AM
roadrunner_70 roadrunner_70 is offline
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Fuel pump wiring harness in tank can overheat and melt too. Have seen the connector and wiring insulation melted before. If your relay connection does not solve the problem, it may be in the tank. There are a number of posts on this subject in the Chevy Astro forum.
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Old 07-06-2005, 11:08 AM
sherman69 sherman69 is offline
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Re: 97-4.3 fuel relay overheating

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Originally Posted by roadrunner_70
Fuel pump wiring harness in tank can overheat and melt too. Have seen the connector and wiring insulation melted before. If your relay connection does not solve the problem, it may be in the tank. There are a number of posts on this subject in the Chevy Astro forum.
Yes, Some brands of fuel pumps have reminders to replace the pump harness, and they stock it in NAPA stores.
My last pump bound up and melted after only 1 year, so I replaced the harness to be safe.
Bob B
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