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Fuel Pump wiring warm... 140-160

...with everthing operating normally, (that is, no extra abnormal currents added in...this is possible with a motor if it working harder than normal for some reason, the extra load requires motor to draw more current to maintain constant speed) warm wires indicate too small a gauge wire for the currents passing through them...

I suggest you measure the current and determine if it is normal or raised, then proceed accordingly...short of making an engineering investigation out of it, you may just want to increase wire gauge...

Additional:

...warm terminals indicate a poor connection (either due to corrosion, or a bad crimp...which can be as simple as not getting all strands into the crimped area...effectively decreasing the cross-sectional area for current conduction, or some combination of the two.

Use Anti-Corrosive-Zinc-Paste on terminals, especially those under the vehicle and subject to even more environmental nastiness, NOT "dielectric paste"...why anyone would want to put a total INSULATOR on electrical connections is beyond me!!! ...maybe because the word dielectric has the word "lectric" in it, so it must be good for 'em...WRONG!

See: http://sw-em.com/anti_corrosive_paste.htm

Cheers






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