My '89 240 (2.3) after running a little off for a few weeks, poor idle and hesitation under load (intermittent), I changed the coil, distributor cap, rotor arm, plugs and air filter.

It atarted first time and all seemed well, drove a short distance and stopped to re-fuel. I then took it on a run and the hesitation was worse than ever and it stalled frequently at idle.

I limped home checked all connections around the coil and plugs, tried to re-start the engine. From this point on it would only turn over but not fire.

I turned the ignition on and could not hear the fuel pump. Removed the relay and jumped pin 30 to pin 87(2, no joy. Dropped the fuel pump and disconnected the wiring with the relay jumped the pump had voltage. Re-connected the wires to the pump and it whirred into life, but still refused to start and is silent with the relay fitted.

It was at this point that I realised that the wire corresponding to pin 30 on the fuel pump relay is permanently live. As I understand it the relay should only be powered with the ignition on.

I have been advised to check the ignition switch, I shall be doing this today.

Any idea what I should be looking for with the switch?
Any other suggestions?

UPDATE

I have removed the electrical part of the ignition switch, the wiring to the fuel pump relay is still live.

I have removed the fuse for the fuel pump relay, the wiring is still live.

I have removed the 25 amp use in the engine bay, this finally kills the power to the fuel pump relay.

Any suggestions?

Michael