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240 relay prob

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Old Sep 24th, 2020, 14:35   #1
morwenna240
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Default 240 relay prob

Hi. I have an 1989 240, 2litre estate. No start. Fuel pump works, relay seems to, that is, if u hold it an turn key you can feel it click, an click again when turn off. If, as says in Haynes, i jump fuse 4 and 6, engine starts straight up. I bought a new fuel pump relay, no change. Can't see any wiring faults, an as car runs with fuse jump, main wires to pump, ignition switch, etc, must be ok. Any pointers, people?
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Old Sep 24th, 2020, 17:16   #2
Clifford Pope
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There are two kinds of fuel pump relay - white and green. I'm not sure what the difference is, nor whether they are even interchangeable in fitting. You do presumably have the correct one?
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Old Sep 24th, 2020, 17:32   #3
Bugjam1999
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The fuel pump relays are not interchangeable - green for a k-jet car, white for a 2.4lh car.

Cheers
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Old Sep 28th, 2020, 19:24   #4
morwenna240
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Well, it had green one when i got it. In glove box was another green one, date stamped july '87. The one fitted was stamped 2007, so i assumed green correct. certainly it ran fine with it, until recently. Car had stood for ten yrs, so i renewed underneath completely, brakes, suspension, exhaust, wheels.
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Old Sep 29th, 2020, 09:13   #5
Clifford Pope
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Jumping fuses 4 and 6 bypasses the rely and lets the pumps run continuously.
If the engine then starts and runs properly then it surely can only be the relay faulty, or perhaps the socket it plugs into, or the connections at the fuse board?
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Old Sep 29th, 2020, 22:02   #6
morwenna240
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Ummm, that's what i thought, but couldn't find anything. But. . . i noticed that fuse 6 had got hot, to the extent of melting the foreward end of fuse enough to sink in the actual metal strip. Does that imply resistance? What could cause that?
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Old Sep 29th, 2020, 22:21   #7
Stephen Edwin
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Quote:
Originally Posted by morwenna240 View Post
Ummm, that's what i thought, but couldn't find anything. But. . . i noticed that fuse 6 had got hot, to the extent of melting the foreward end of fuse enough to sink in the actual metal strip. Does that imply resistance? What could cause that?

"Received Wisdom" in the forum is that heating and melting of individual fuses is caused or exacerbated mainly by most fuses available now for that fuse box do not meet the original specification.

1. The end caps tend to be aluminum or similar. That reacts with the copper/brass terminal in the fuse box. Resistance results and heat follows

2. The fuse body tends to be plastic. That often melts when hot. The body should be ceramic.

True ceramic and cuprous fuses can be found. If you search the forum you might find the information.

Thorough cleaning of the fuse box has been tried and in at least one instance, the problem still re-occurred.

There is a body of opinion in the forum to by-pass those two fuses using inline flat bladed fuses. The name for those fuses escapes my memory.

I hope this helps.




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Old Sep 30th, 2020, 00:12   #8
morwenna240
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Izatso? Interesting. Merci.
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Old Sep 30th, 2020, 03:27   #9
Stephen Edwin
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P.S. ... I believe the name for flat bladed fuses is ...

Blade Fuses ...




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Old Sep 30th, 2020, 09:27   #10
Clifford Pope
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You could confirm this diagnosis first simply by bypassing each fuse and holder separately, rather than together.

I think what often happens is that having once run hot, the plastic base holding the terminal strips is then irretrievably weakened and does not hold the terminals properly. Also the metal terminals themselves have possibly been softened by over-heating.
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