Zerkster

iTrader: (22)

Hey guys see if you can help me out. Did searching but nothing...

I have replaced the relay. Before I replaced the relay I had replaced the pump and the filter. But when that failed to work I connected a multimeter to the fuel pump connector and Im only getting 2.5 volts when the key is turned to the "on" possition. and the same when trying to turn the motor over.

Any help would be appriciated.

Thanks guys

HAILERS

How much voltage if you put the jumper in the fuel pump check plug, then turn the key to ON? No starter action doing this, just key ON.

Zerkster

iTrader: (22)

Fuel pump check plug as in the yellow? plug on the harness by the passenger strut tower?

Zerkster

iTrader: (22)

VOltage at the connector is still between 2.5 and 4 while key is at the "ON" position. While going through my Shop manuals Im thinking it could be the circuit opening relay under the dash?

HAILERS

The fuel pump works if the ENGINE fuse is good and the key is to ON and the yellow fuel pump check connector is jumpered.

The fuel pump runs if the key is HELD to Start.

The fuel pump runs if the engine is running.

The fuel pump does NOT run if the key is simply put to Start.

The large BLUE wire at the fuel pump connector is the wire that suppleis power to the pump. The black is the ground. The others are non players in the fuel pump working.

wvumtnbkr

Well, I guess you found the problem!

Any chance that the ground is not contacting well?

WHat year and model is this car?

I hope you get it running!



P.S. Going to Charlotte tonight to pick up an FC for Julie!

NJGreenBudd

iTrader: (1)

Search for "fuel pump rewire", basically you're going to replace power and ground to make sure the pump gets good voltage. I just did it a few weeks ago, not hard but helped a lot.

Zerkster

iTrader: (22)

I have replaced the main relay in the engine bay and also replaced the circuit opening relay under the dash. Neither worked. I have since ran a hot from the batter with a fuse and switch to manualy operate the pump. This solved the starting issue.

Clearly the issue is the pump not turning on, or the voltage to the pump. So what could it be? I will not leave the pump hardwired like this due to obvious safety issues

HAILERS

The Main Relay has zip to do with feeding the fuel pump. That was a waste of time.

You NEVER say what this car is. A series four or series five.

ANYBODY, even my grandmother could ohm out the Circuti Opening Relay to the fuel pump plug and then the check the gnd wires of the Circuti Opening Relay and the input voltages for that relay, and figure out what the problem is.

Again, the pump does not get voltage just by putting the key to ON.

You pull the Circuit Opening Relay out. You check the BLACK/WHITE wire in the middle of the socket for batt voltage with the key ON.

You check the BLACK'/WHITE wire on the top left (Might be Black/Red depending on the version car) for batt voltage with the key HELD to START.

You check the BROWN wire for a ground of 2-3 ohms (key OFF) with the afm vane moved aft and then again check it with the jumper in the yellow check connector.

You check the BLACK wire for a gnd of 2-3 ohms. Key OFF.

You'd check the BLUE wire for continuity to the fuel pump plug or jumper the Blue to the B/W in the middle of the socket and then check for batt voltage at the Large Blue wire at the fuel pumps plug. One or the other. Key On.

If any of those things does not happen, you fix it.

There is one connector b/t the FRONT and REAR harness that carry the output of the Circuit Opening Relay to the pump. See FSM wiring manual.

ITSWILL

iTrader: (12)

bad ground, corroded connector, short?

Just rewire the power wire going to the pump from the relay, (unless there isn't proper power at the relay either) and double check/ rewire the ground.

Or you could find the exact problem and fix it, its your choice.

Zerkster

iTrader: (22)

Chassis is S5. Hailers I appreciate you helping me. I will try what you said today and let you know.

HAILERS

Series five is different that the series four I posted a jpg of. So I'll revise it a bit.

I would pull the Circuit Opening Relay and probe it, but with some differences since all the series five have a Fuel Pump Relay. You can ID the fuel pump relay, by it having a metal ribbed body. I've no jpg of it here.

In fact, that might be a better place to start. It's in front of the afm/filter assy. Move that afm/filter out of your way. Then pull the plug off the Fuel Pump Relay.

Now go jumper the fuel pump check relay. It's yellow, two sockets and near the afm/filter and boost sensor area. Jumper it with a piece of wire.

Now key to ON. Then go to that Fuel Pump Resistor Relay (called Fuel Pump Relay in the jpg attached). See if the Blue/Red wires have batt voltage or not. They should and probably will. I should have mentioned that you need the Circuit Opening Relay fully installed to do this.

If it has batt voltage on those Blue/Red wires (3), then it's probably a bad Fuel Pump Relay. To prove that, you can jumper any one of the Blue/Red wires to the Blue/Green wires in that plug. Just a piece of wire bare at each end. One end in one of the Blue/Red and the other end in one of the Blue/Green. Now, if the key is still to ON, the fuel pump should run or you can check the power at the ..............Blue/Green wire at the fuel pump plug. On a series four it's just a pure blue wire. ON series five it seems to have changed color to Blue/Green.

Any way, see how things turn out and write back. It shouldn't be too hard to figure out.

I threw in two jpgs. Same thing with both, just one is a little clearer.

Zerkster

iTrader: (22)

I went and I cant find which connector your talking about. Any better description?

HAILERS

If it's a series five, the Fuel Pump Relay should be mounted on the bulkhead the right front headlight is mounted to. Then maybe that's the problem. Maybe it's MIA. But the electrical plug should be there on the harness. Look for the plug while I TRY to find a picture of it's location.

I don't have a series five but do have a series four turbo that has this item. I'm ASSUMING the series five has it in the same location. IF someone KNOWS that this a fallacy, then say something now, please. I'll take a picture of my series four turbos.

EDIT: Here's a jpg. Mines not mounted quite like the original, but that is the area where it should be. You might have to remove the air filter to see it better. IF one is not there, then look for it's electrical plug. I think your problem MIGHT be that yours is missing.

Zerkster

iTrader: (22)

Is it a big *** metal box? with one connector on it? about 5 or 6 inches wide and 3 or 4 inches high? I could take a pic of it for you.

Zerkster

iTrader: (22)

sorry for the bad pic

HAILERS

Thank you. That is it. It seems the air filter should be removed to actually see it good.