Melting Fuel Pump Relays Volvo Penta 5.0 GXi

[Maxx117]

Hello names Maxx. I joined the forums because I have an electrical issue with my Volvo Penta 5.0 GXi. I’m not too good with electrical issues. My fuel pump relays keep melting after about an hour or 30mins of run time on the water. I’ve put 2 new ones in today and had to get a tow back to the dock. The first time the relay went out i didn’t check it (like a dummy) and went ahead and put a new fuel pump in it. But the problem still progresses and I am stumped

 

[dypcdiver]

Check they are for the correct amperage for the pumps.

 

[Maxx117]

Check they are for the correct amperage for the pumps.

Alrighty I will get one of the boxes and check. Is the correct rating 20 amps?

 

[Maxx117]

Alrighty I will get one of the boxes and check. Is the correct rating 20 amps?

Checked the box. The relays that I’ve been using as replacements have been some from orileys. They’re 20amp relays

 

[Nheels]

Checked the box. The relays that I’ve been using as replacements have been some from orileys. They’re 20amp relays

My relay went out last week. Replaced it. Have run about 10 hours on it since and no issues. I still have the original fuel pump.

I thought it was due to the fuel pump working extra hard due to that paint issue or some other type of restriction. Now that you mentioned you have replaced the pump, I'm also very curious what is causing these to go..

 

[NoExcuses]

Depending on the version of GXi you have, there was an issue with vibration causing the box to fail. You can Google Service Bulletin P-37-2-1 for the details.

 

[Maxx117]

Depending on the version of GXi you have, there was an issue with vibration causing the box to fail. You can Google Service Bulletin P-37-2-1 for the details.

Thank you very much for the information. I ordered a replacement fuse box yesterday. I’m hoping that’s the issue

 

[joelewis73]

Amazon.com: 5 Pack 40/30 AMP 12 V DC Waterproof Relay and Harness - Heavy Duty 12 AWG Tinned Copper Wires, 5-PIN SPDT Bosch Style Automotive Relay : Automotive

Buy 5 Pack 40/30 AMP 12 V DC Waterproof Relay and Harness - Heavy Duty 12 AWG Tinned Copper Wires, 5-PIN SPDT Bosch Style Automotive Relay: Starter - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

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I did away with the block and put these in instead. A little more heavy duty than the blocks that come with the engine...

 

[Mirage232]

Amazon.com: 5 Pack 40/30 AMP 12 V DC Waterproof Relay and Harness - Heavy Duty 12 AWG Tinned Copper Wires, 5-PIN SPDT Bosch Style Automotive Relay : Automotive

Buy 5 Pack 40/30 AMP 12 V DC Waterproof Relay and Harness - Heavy Duty 12 AWG Tinned Copper Wires, 5-PIN SPDT Bosch Style Automotive Relay: Starter - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

www.amazon.com

I did away with the block and put these in instead. A little more heavy duty than the blocks that come with the engine...

Sounds like a great solution, any pics of how you did that. I dont want to pay 400 bucks for a new block.

 

[Maxx117]

So I put my new fuse box on that I got off eBay for about $250 and I’ve taken her out 4 times and she runs perfect. Thank you everyone for your help