Car was running and died as if ignition had been turned off while driving. Felt fuel pump relay and fuse for main pump - very hot and fuse blown. Replaced fuse turned key to start position and fuse blows immediately. Replaced fuse and relay with known good relay - same results. Suspect ignition switch (tell u why in point #6 below).

Recent work before this happened and car was running fine:
new fuel filter, new (used) ECU (got water in it), new fuel pump relay (was not a problem old and new one are good), new (used) AMM. New cap, rotor, wires. I'm not saying any of this is related but this is what has been done prior to current no start problem.


What I have done since no start problem:

1) checked both fuel pumps (main and intank) with pump relay removed and both work and are providing adequate fuel pressure and volume.

2a) car would not turn over well - checked and found engine ground broken barely attached, repaired car now turns over very well but still no start.

2b)Checked spark at coil - yes and strong.

3) swapped out ECU with known good one still no start - put original back in.

4) removed fuel pump relay, jumped #30 amd #87/2 terminals to run both fuel pumps and cranked car - no start.

5)Examined Hall sender plug attachment point , noted casing is dangling by the wires perhaps was not placed properly into distributor housing "slot" on last removal (car ran ok for 2 days after distributor cap removed - I was checking for another earlier problem to examine the condition of cap, contacts, rotor - all was excellent at that time)

6) Isolated all contacts (removed all wires to the fuel pump relay and then reattached one at a time, cranking in beteween attachings) and discovered that if the fat blue and yellow wire that goes to the ignition switch from the fuel pump relay was left disconnected (all other wires connected) the fuse would not blow on engine crank. As soon as this wire was reconnected and engine cranked - fuse blows immediately.

Is this the proble (ignition switch related) or is there something else in that circuit (or elsewhere) that may be at fault?



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1985 740 GLE, 1981 245 Ice racers