I'm fitting a Walbro 225 to my VVT. The original VVT pump loom does not connect to the Walbro 225; you have to splice in the connector. Bearing in mind these connections will be submerged in fuel, is it OK to use plastic bullet connectors?

 

I used open barrel splice crimp connectors which I then used fuel resistant heat shrink over it.

 

I don't have heatshrink; what's the risk of just using plastic bullet connectors alone?

 

Do you mean like these?

I'd worry of the plastic dissolving in the fuel tank.

 

Yes. Oh, great!

 

Well this has put my mind at rest: https://www.fullsizebronco.com/threa....273426/page-1

 

I've used the heat shrink butt connectors before. I've also soldered and used standard heat shrink. Both have held up when pulled out years later.

I would never use the bullet style connectors for anything high current.

 

Common butt connectors will do fine. I wouldn't use bullet connectors, or any connectors that simply rely on a friction fit made for convenience to remove. You want some mechancial lock. The risk of it coming undone sorta low, but if it happens, being stranded or getting hurt overshadows something costing pennies.

I'm no longer a fan of heat shrink if you solder. You need to pay attention to the chemical resistance and even then I'd still test it. Too much work, see my pics below.

In my case, I wanted to solder the connection. My fuse blew and left me stranded. The heat shrink absorbed the fuel and ballooned up. Then it vibrated off the joint. I'd visually checked it before a couple times - it looked fine, because I'd inspect on a near empty tank after it dried back up.

I know my solder joint here is junk, but it held up. My new approach is to use a larger butt connector (like yellow) over a solder joint instead of heat shrink. You get the mechanical lock, solid protection with common parts. And you don't have to rebuy/research/test what you bought for 3" of clippings.



Heat shrink absorbed fuel and got loose. Once dried, shrank back. Wouldn't have known if I removed pump with full vs empty tank.