Plug for Fuel pump relay damaged - How do I fix this? See Pic

Thanks for the post. I need to replace the socket for my relay too. Any idea what gauge the wires are? I will need to extend mine since the harness wires are so tight. Also, what crimping tool did you get?

Thank you for the assist. Looking forward to having my boat running again.

What size relay is it? 30 amp? 40 amp?

You can buy relays with a prewired socket so all you need to do is splice it in. Use some water resistant heat shrink butt connectors and you should be good to go.

5ZMU8_AS01


Do you have a picture of the damage you can post?
 
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You will need a removal tool, a crimp tool, various replacement connectors and new relay from Ballenger Motor Sports. This is what I ordered, I may have ordered some metripack that I didnt need, but it was cheap enough I didn't care.

https://www.bmotorsports.com/shop/index.php/cPath/111_112_170

CONN-33555 GM Delphi / Packard - SPDT Relay, 30AMP, 12 volt with skirt for sealing MP 280 $9.991 x $9.99 CONN-91254 GM Delphi / Packard - 2 Way Metripack 150 Plug Assembly, Black $3.491 x $3.49 CONN-31568 GM Delphi / Packard - 2 way metripack 280 sealed connector assembly, black (connector and TPA) $3.491 x $3.49 CONN-75818 GM Delphi / Packard - 2 way Walbro 450 pump connector Kit & larger fuses $5.251 x $5.25Sub-Total:$22.22UPS Ground (Estimated 2 Business Days):$12.37Total:$34.59

Removal Tool
TOOL-02001 GM Type Metri-Pack ( Metripack ) and GT Removal Tool - Thin Blade ( 150, 280 and others ) $6.99

Crimping Tool

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Pricing
1 + $31.99
5 + $31.49
10 + $30.99
50 + $28.49
Information
Bmotorsports Part # TOOL-01000

 
I forgot that you also need this (which has a relay with it)

GM / Delphi Sealed Metri-Pack ( Metripack ) 280 Medium Current Sealed Relay Kit SPDT 30 AMP Part # CONN-75575
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Pricing
1 + $19.49
 
I did a similar repair last May. I cut off the fuel relay harness, spliced in 4 quick connects, then connected them to an automotive relay, 40A, 14v, have not had any issues since. Prior to that, I replaced the relays multiple times and mechanic fixed the harness once. I did shrink wrap the connections between the quick connects and the relay to try to keep any corrosion at bay. I tried a 30A 12V relay initially, lasted about 15 minutes. Relays were about 9-15$, quick connects were cheap. I also purchased the new MerCruiser replacement harness which is suppposed to correct the issue, but never installed it since this has been flawless for the last 15 trips.
 

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