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'89 740 Turbo, requires jumpering fuse 1 & 11 to run main pump (relays are good). 700 1989

posted by  FitzFitzgerald on  Thu Jun 10 11:36 CST 2004
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last visit: Wed Jun 25 23:15 CST 2014
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This is the second time that I've come across this problem and I'm hoping that somebody can shed some light on it. Both vehicles are '89 Turbos, automatic trannys, Jetronic 2.2, 541 ECUs, USA market. When the key is turned to Position 2 or Position 3 (start), the main fuel pump does not run. However, I can force it to run (and start the vehicle) by jumpering fuses 1 & 11 together (the main pump and the in-tank pump).

I've confirmed that the main fuel injection relay (white, 2nd row) is not to blame for the situation. (I've tried three of them now.) I can remove the cover of the relay and observe the two solenoids on the relay as I turn the ignition key through the various positions. The first solenoid closes immediately when it reaches position 2, but the second solenoid (that runs the fuel pumps) does not close at all. I can manually push the solenoid closed with my finger and force the pump to run, -but it can not engage by itself. Of the three '89 Turbo vehicles that I've worked on in the last 6 months, two of them have this problem.

Does anybody out there have any suggestions or possible solutions? Is there a wiring fault somewhere, a bad ground connection that I've overlooked, or are the Bosch 541 ECUs to blame for this? I'm struggling to find a solution and have not been successful yet. -another night of reading wiring diagrams awaits me...

God bless,
Fitz Fitzgerald.
--
'87 Blue 245, NA 239K






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