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Malfunctioning main fuel pump? 200 1982

240 Turbo main pump is super noisy and loud. When i turn the key (but don't turn it all the way to start the engine) the fuel pump comes on for a few secs and then should turn off, right? At least that's how my friends turbo is. He'll turn the key to the accessories setting and you'll hear his main fuel pump kick on for a few seconds and then go silent. That is, of course, until you start the car, and then you hear it whirring all the time. My fuel pump kicks in when i turn my key to accessories too, but it won't shut off - and it's really really loud too. I'm also having driveability issues with sputtering and stuff and i have really bad cold start issues. Sounds like a main pump problem in my view. Any ideas or thoughts otherwise?








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    Malfunctioning main fuel pump? 200 1982

    do you have sputtering issues when your tank is full? There is a section of fueline leading out of the gas tank that rubber. It immersed in gas till you get down to about half a tank. if you have a whole in that line it would cause sputtering problems at about half a tank








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      Malfunctioning main fuel pump? 200 1982

      The sputtering is intermittent...sometimes it does, sometimes it doesn't, but mainly does so after the car's been running for a while, and had nothing to do with how much gas is in the tank - full tank, half tank, 1/4 tank - makes no difference.

      I just hooked a multimeter up to where the number 5 fuse goes and took a reading for the prepump while car was running - I got nothing so prepump must be dead.

      I hooked the multimeter up to where the number 7 fuse goes and took a reading for the main fuel pump and got 0.02 for a reading. I think it should be like 9.5Amps if operating properly.

      Anybody know what to make of this?








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        Malfunctioning main fuel pump? 200 1982

        I just hooked a multimeter up to where the number 5 fuse goes and took a reading for the prepump while car was running - I got nothing so prepump must be dead.

        Maybe — but how were you using the meter? Pulling fuse and measuring current, or what?

        When looking at the fuses, the unfused or Hot side is on the left, as shown below.

        Hot (+) side —*—<<—(FUSE)—>>— fused (–) side goes——> to the tank pump

        For a quick pump test, with engine off, remove fuse 5 and hotwire the hot side of fuse 7 to Fuse 5 (hot) side (for Main Pump), or (fused) side for Tank pump. You should hear them run if it's not too noisy where you are.

        The Hot side of Fuse 5 is directly from the FI relay output.

        P.S. Your pumps are NOT supposed to come on with key on. Not an '82. Can't say about your friend's car. Maybe flaky FI relay.
        --
        Bruce Young,
        '93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.








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          Malfunctioning main fuel pump? 200 1982

          Okay.

          Hot wired like you said.

          Heard the main pump come on.

          Heard the in-tank come on.

          Neither sounds are like the one I hear when I turn the key to accessory function. The sound I hear when I turn the key to accessory is much louder and more strained.

          Perhaps it's BOTH pumps that I hear when I turn the key?

          Here's something else, the car will run with the number 7 fuse (main fuel pump) out of the box. I thought it wasn't supposed to do this! I had the engine running for about 5 minutes without the number 7 main fuel pump fuse in before I just shut the car off.

          What's going on here?!








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            Malfunctioning main fuel pump? 200 1982

            Alright. I just tested the draw on my friend's 240 turbowagon and it's showing 3 amps for his after-market high-flow in-tank prepump and 9.9 to 10.3 amps for his main fuel pump.

            Obviously, I'm using my multimeter correctly then!

            So, it stumps me why I can't get reading now off of my own fuse box and why my car will run and my main fuel pump will run even with the number 7 fuse out!

            This is beginning to sound like an electrical nightmare from Volvo hell.








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            Malfunctioning main fuel pump? 200 1982

            Perhaps it's BOTH pumps that I hear when I turn the key?
            Probably. Jumper 7 to 5 with the fuse in place, Should run both pumps.

            Here's something else, the car will run with the number 7 fuse (main fuel pump) out of the box. I thought it wasn't supposed to do this! I had the engine running for about 5 minutes without the number 7 main fuel pump fuse in before I just shut the car off.

            Are you sure it was #7? If so, I'm stumped. On paper, that just can't happen with an '82 K-jet turbo, and I haven't got a clue.

            --
            Bruce Young,
            '93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.








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              Malfunctioning main fuel pump? 200 1982

              I know Bruce - it makes no sense!

              Even with the number 7 fuse out, I can turn the key to accessory and I hear the pumps (i'm guessing here) going, loud and grainy as hell and they won't turn off. I put my hand on the main fuel pump and sure enough it's vibrating.

              All this with the number 7 (yes, 7) fuse out of the box.

              My friend's telling me my wiring harness it a disgrace. The previous owner seemed to have replaced it with a home-made kit and has black plastic tubing over most of the wires.

              I think the harness is just the tip of the iceberg. I'm scared most of the car's wiring has been MacGuyvered by somebody who wanted to save a few bucks and didn't really know what he was doing.

              Has anyone heard of electrical problems on a 240 turbo like the ones I'm describing?








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                Malfunctioning main fuel pump? 200 1982

                Had the car idleing for 5 to 8 minutes with the number 7 fuse out.

                I went down and felt the main fuel pump. Sure enough, it's humming right along.

                I scratch my head and think.

                I decide to pull the number 5 fuse, the in-tank fuel pump (as indicated on the fuse panel sticker no less!) and the car suddenly dies.

                I try to start it.

                No good.

                I pop fuse number 5 back in.

                Car starts right up.

                What's going on here?!

                Can somebody have mis-wired the fuse box or something so the number 5 fuse is no for the main pump and the number 7 is now for the prepump?

                If so though, why would they still have an 8 amp fuse for number 5 and a 25 amp (yes, I know - it should be 16 amp, but it's not) for fuse number 7?

                HELP!

                PLEASE!








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                  Malfunctioning main fuel pump? 200 1982

                  Sure sounds like wiring. It would be good if you had a manual — even a Haynes. But I'll try to describe how it should be...

                  Fuse 7 carries Battery +12 to FI relay 30 (the armature) (Red wire)
                  When FI relay is up, the +12 leaves relay 87 (Y/R) to Fuse 5 hot side...
                  At that point the +12 splits, to Main pump and thru Fuse 5 to Tank pump

                  What picks the FI relay?
                  Key ON (not acc) +12 thru fuse 13 to relay 15 (BL/R), AND (supposedly)...
                  Coil negative pulses on relay 31b (W/R) from Coil #1

                  Find the FI Relay, above driver's knees, maybe tucked behind left panel. Should be Red or Green (maybe aluminum), the only one with Y/R, BL/R, W/R, R, and BL wires. Feel it to see if it picks with Key (in Acc or ON. If Acc, maybe bad ign. sw.)

                  Lacking a wiring diagram, I don't see where this can go. Too screwed-up.

                  I'll be back in the AM
                  --
                  Bruce Young,
                  '93 940-NA (current) — 240s (one V8) — 140s — 122s — since '63.








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                  Malfunctioning main fuel pump? 200 1982

                  Sorry I can't help you much, but just to let you know that my '88 also runs when you take the main fuel pump fuse out. I wanted to relieve the fuel pressure for a repair I was doing and tried to shut the main pump down, and couldn't do it by removing the #7 fuse! I ended up disconnecting it at the pump to shut it down, though if I knew what I was doing back then I'd just take the #5 fuse out to relieve the fuel pressure.

                  Perhaps wanting to remain in denial, I didn't investigate the fuse situation, so I don't have an explanation for you, or even a theory. But in my case I'm not too worried about the wiring harness. I'm just posting this to tell you to relax; if your car and mine have the same thing going on, and mine functions perfectly well, then there's probably an explanation for it. Maybe this weekend if it's warm enough I'll get under there and figure it out.

                  Do you know your fuel filter and fuel pressure regulator are both good?







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