Electrical fault - possibly...

[kraM]

Hi

Another thing that was going wrong with the mighty MK1...

Last year I did a charity run in the golf (MK1 1600GTi).  After about 4 hours of hard driving in the hot sun, it started missing and then it would clear and be ok.  Then as the afternoon wore on, it spat its dummy out and died.  I had a spark, so assumed no fuel, pulled the fuel pump relay out and it was warm, but not too hot.  Put is back together, it fired up, pump sounded ok, smooth etc.  No further faults.  Doing the same again in two weeks, don't want it to happen again.

I have got the best fuse box and wiring loom I could find in the car, the fuel pump relay has been changed, but the fuse box area where it plugs into looks a smidge burnt 

I think the two are linked, what do you think of taking the relay out of the fuse box and hard wiring a manually switched ignition feed relay in for the fuel pump?  I know the relay also feeds the cold air valve and cold start injector, but those arn't fitted to my engine any more.

Any thoughts or further ideas would be great please,

Cheers

kraM 

[rubjonny]

I wouldnt advise doing that, if you had a crash the fuel pump wouldnt cut out unless you switched off the ignition.  you could wire in the factory relay like this though, it needs live, ign live, earth and a rev counter feed

[kraM]

A very wise point.  I must admit the thought of 2.5years of resortation being pressure feed fuel whilst buring would suck somewhat!

Cheers

kraM

[rubjonny]

The k-jet fuel pump relay is wired up like so:
1 - 31 - earth
4 - 15 - ignition live
2 - 30 - live
5 - 31b - rev counter input
3 - 87 - fuel pump power

If you get a new one take care which one you buy as some have a built in rev limiter and some do not, this relay from gsf 93592 does not have a limiter.  IIRC you mentioned yours was a 1.6, the one GSF listed for that shouldnt have one, and iirc the pinout is different from the relay i mentioned above, though the pinout woulnt matter either way if you were going to wire up your own relay socket, so get whichever is cheaper

[kraM]

IIRC - wtf does that mean?  I pride myself in knowing a lot about these motors...   :embarassed: but I have to admit defeat, I have no idea.  Please put me out of my pain!

[rubjonny]

if i recal correctly 

[kraM]

 :embarassed: ahh, cool, cheers


kraM