r-s-turbo

im on my 4th fuel pump relay now in about 2 months!! theyre expensive at £17 discount too!
the relay keeps melting around where the pin slots in for a thin black and red wire. ive looked through wiring diagrams and it seems this wire goes to aux air device and fuel pump. my thoughts are that something is drawing too much current and heating this up...so sumthin is fucked! ive just bought a brand new uprated pump as i thought this was most likely cause........ive fitted this and the relay is still heating up and melting. ive looked at the aux air device today and although plastered in abit of oil it doesnt have any obvious signs ov being mullered.
has any1 else had this problem with the fuel pump relay and actually cured it because most people just seem to keep replacing the relay, which im sick of doing and my wallet is sick of being raped 4 it.
when i was looking at it earlier i thinkt he knock sensor has black and red wire too, so has that got anythign to do with it either?
if any1 can help me id really appreciate it!!!

Rick

could be short. first thing to do, is measure the current draw.

Wardy257

If your pump is old it could be drawing extra current. As above do an amps draw test and maybe a volt drop too.

Moonie

You could really do with measuring the current draw in the circuit's the relay feeds.
I would start off by checking all the connections and earths in the circuits. Make sure the terminals in the relay base have good tension on the pins of the relay and the crimp connection to the relevant wires in the relay base is ok. A poor connection in this area will cause the relay to overheat.

SafeChav

Your pump is blatantly ragu then

Buy a new pump and never melt another relay.

Or you could always wire a bigger relay in series with the standard relay as they are a bit on their limit in terms of current draw.

r-s-turbo

ive fitted a new pump an uprated one too.........im gettin so fucked off with this car!!! if its not the fuel pump relay its somethin else!! every weekend im under the bloody thing......it needs to come apart for a proper rebuild on EFI!!

ivorbiggun

And you bought a 20 year old Ford for its reliability?

SafeChav

The uprated pump may well be your problem then.........check the wiring for shorts and if all is ok wire a bigger relay in series, those purple relays are crap.

ivorbiggun........my 1985 Orion Ghia I with 112k on the clock is reliable, never skipped a beat...........whats your point?

ivorbiggun

Well, I doubt this would be an issue with a 20year old Nissan Toyota or Mercedes.
Also, we know the 'uprated' pump isn't the problem as the problem was
evident before it was fitted.

SafeChav

I disagree there, as i say my Orion has been good as gold and thats a 22 year old motor! Never had anything significant done to it either.

I missed the bit saying he had the problem before he uprated the pump though, so well spotted