Hi I've got a 4x4 Saph which I've just had msd stage 2 conversion. On boost after a couple of days the rev counter started jumping around and then smoke started coming from the ignition barrel. Had a look and someone's wired in an extra wire from the ignition barrel to the ignition live on the yellow ecu relay next to the pump relay. This wire was totally melted. The normal black wire is still connected but gets no power with ignition on unless I run another wire directly from ignition barrel to the black ignition live on relay. I've bought an msd fuel pump rewire loom but I'm worried there's something wrong with the wiring to the old relay. What could cause this?
Any help appreciated

 

doesn't sound great, can you take some pictures? the other relay next to the fuel pump one should be the ECU relay.

 

 

Cant believe someone has used scotch blocks on a saff. There gash electrical connectors.

 

I think that's the result of a few alarms in the past. Gonna have to cut it all back and do it properly. Need to find out why the remote live that someone added in melted and why it's there in the first place :-(

 

whats the extra live connected too? the fuel pump relay or ecu?

 

The extra live joins the black wire going into the ecu relay. If I disconnect this wire the fuel pump won't prime so I'm guessing there's a break in the original remote live. Haven't had a chance to check it with a voltmeter yet

 

mmm, sounds a bit weird, check the ecu relay pin out and see whats been added and lost, then try to find where the old issue lies,
if the ecu relay is not powered up the fuel pump won't prime thats normal as the ecu energises the fuel pump relay.

 

I'll try and have a look Friday when I'm off work. Is there any reason why that extra remote live would melt when the car was under hard load? Wouldn't have thought the pump demanding more power would have anything to do with the remote live

 

the pump won't have anything to do with the ecu relay

what did you change before this happened?

 

Haven't changed anything on the wiring after the stage 2 I had done by you back in February. The turbo died just before I got home so sent that off for repair and it took a few weeks then after getting it running again it lasted a day before it started playing up with this issue. I did think the extra load on the fuel pump for the increased power could of caused the wiring in it's poor condition to fail

 

woudnt have thought it would cause that issue, especially not on the ecu relay,

 

Yeah that's what's confusing me. There's gotta be a break in the original remote live as it's still connected but doing nothing although it has a few dodgy joins in

 

I really do wish that people who know fuck all about electrics dont mess.

Lucky you still have a car mate.
Sounds to me the ecu is not triggering the fuel relay hence why some muppet has taken a live feed from ign

Hope you sort it

Paul