Reluctance to start/fueling issues

[entirelyturbo]

Sounds interesting Vikash This is in addition to the original relay, or replacing it?

By the way, where is the original fuel pump relay? I can't find it... I'm pretty sure the relays in the box under the hood are for either headlights or A/C...

[vrg3]

This goes in addition to the existing relay. The idea is that instead of modifying existing wiring you just add your own. With the new setup, the stock wiring is given the easy task of powering a relay coil instead of the hard task of powering the fuel pump.

The fuel pump relay is mounted way under the dash on the driver's side. It's on the same bracket as the ignition relay. If you search for "ignition relay" with me as the author you should be able to find a couple of posts where I've mentioned how to reach it.

[entirelyturbo]

Awesome, thanks Vikash. Andrew (petridish) and I both thank you!

[vrg3]

Yer welcome.

[petridish38]

Yeah... I dont know what to do... My friend's 91 Legacy won't start, and it has NO fuel pressure... I can crank the engine over and over and it has zero fuel pressure. No fuel pump sound with or without the test connectors plugged in. I fear that this will be a difficult job for me seeing as I am just as bad with electricity as Mike. I read all the crap in the FSM on how to diagnose it, but even that is kinda vague. Any help would be great!

Andrew

[vrg3]

My post here should help you find the fuel pump relay:

http://bbs.legacycentral.org/viewtopic.php?p=4451#4451

In test mode with the ignition on the relay should click about once a second. You should be able to feel it if you put your fingers on it.

If the relay is clicking, then pull back the trunk carpet and remove the 4 Phillips-head screws holding the fuel pump cover on the passenger side. Unplug the little white connector from the fuel pump assembly and measure the voltage between the pin of the black wire and the pin of the blue-with-yellow-stripe wire (on the car side).

If you find about 12 volts there, the pump is most likely bad. If you don't, check at the connector under the passenger side of the back seat -- the black wire and the black-with-red-stripe wire.

If you find about 12 volts there, that connector is the problem. Otherwise, it may well be the relay.

[petridish38]

Welp... I think I found the problem... Looks like the fuel pump power supply connector in the tank was burned up...

Here is a pic
http://www.thawa.net/petridish/legacy/conn.JPG

Is there any way to fix that? Or will I need a whole need a new connector, which will probably mean a whole new fuel pump bracket?

Thanks
Andrew

[vrg3]

Yikes.

I wouldn't monkey with fixing it if I were you... Most off-the-shelf electrical repair stuff isn't specified for use immersed in gasoline.

Someone on the board could sell you a stock fuel pump assembly (if your friend's car is a non-turbo you can still use a turbo pump if necessary) for cheap; then you just bolt it in and go.

[petridish38]

Thanks, that sounds like it could work...

Question is... Why did the connector burn up, and will it happend again? What do you think Vikash? Could a pump that seizes up or something cause that?

Thanks for all your help!
Andrew

[vrg3]

I would guess that the metal contacts corroded enough that the connection resistance became high enough that the power radiated in the connection made it hot enough to melt and char the plastic. This can be aggravated by a pump whose bearings are failing, since it would draw more current than normal. And of course a seized pump would draw a lot more current than normal.

Or maybe it was removed in the past and not firmly reconnected. Or removed and reinstalled often enough that the contacts became loose.

[petridish38]

that was the problem alright, found a connector at u-pull-it and put it in and it works!

Thanks again Vikash

Andrew

[vrg3]

Great!

No problem.