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Fuel Pump dilema. 200 1982

This is a tough one. I think the main pump should only draw 5-6 Amps. However, I don't believe the pump could be the problem when you replaced it twice. You say you measured the current at the fuse. Fuse 7 carries the power for both pumps. The relay output has two wires, one to the main pump and the other goes back through fuse 5 and then to the prepump. I believe there are separate connectors for each pump under the rear seat (inside the car), drivers side. This may be a better place to measure current to each pump. The noise may be a separate problem. I had a main pump make noise because the mechanical contacts inside the pump relay were burnt and arcing thus causing a fluctuating current to the pump and it also occasionally blew fuse 7. In addition to rechecking the current you could jumper the pins in the relay's harness socket, pins 30 to 87 (not 87b), to see if bypassing the relay makes a difference. You won't need the engine running or even the key on. The injectors won't spray either because the air meter will be in the closed position. The pump will just be pressurizing the system.






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