Well, it wasn't the fuel pump relay after all...

Anyone want to venture a guess as to why it fired right up after I put
the new fuel pump relay in, and started first try (second click, as
usual) several times after that.
(I tried to start it just before changing the relay, just to be sure it
still wouldn't start.)
It fired up OK in the AM yesterday to go to work.
Then, last night it started and died and only started after many, many
tries.
Today it started really hard and died for good on the way to work.

....Back to plan B. Change the fuel filter, ohm out the in-tank pre-pump
and main pump.

At least the turn signals work really well now. (htf could they be
related to the fuel pump relay!?)

'83 245 auto, for those who haven't been following along

 

Have you check the wiring harness for self-composting insulation?

 

And you've replaced the engine wiring harness already I assume? If not
and it's original, it's bad, stop, do not pass go, replace it, otherwise
you're just wasting your time chasing your tail.

 

Oh, the harness is really bad. It does need replacing.

I've thought about that being the problem.
That would be a show stopper though. Although I have the tools and
ability to change it out, I don't have a place to do the work or
alternate transportation while it's down.
I'd probably have to sell it or scrap it and buy another one, if the
only fix is a new harness.

I gooped up all the bare wires with some brush on insulation when I
bought it so there aren't any exposed wires. Could be that a key wire
has fatigued and broke though...

 

Only takes about an hour to swap, I did mine on the side of the road
near my house in the middle of winter, hardly ideal but I needed the car
and I was stupid enough to procrastinate until it failed. Hardest part
is untangling the crusty mucky old harness from around the intake
manifold and then where it goes around under the front of the engine to
the alternator is usually real grimy but it's only two nuts down there
to remove the clips. The rest is all topside and a straightforward case
of unplug the old and plug in the new in its place. Dave Barton sells
good late model used replacements for reasonable prices.

 

Fellow procrastinator here...

Wow, that's news. I recall reading you had to pull the intake to do it.
Not something I wanted to attempt out front of the condo.

I was planning to make it my Holiday week project... replace the
harness, r&r the injectors and intake bits and generally tidy things up
in there. Fully expected it to take 2-3 days to get it going.

Now if I can get a harness by tomorrow, I might just be able to save
this one!

 

Before you spend the big bucks, Dave Barton has sold harnesses starting
at $100 on up. I bought one from him for a VERY reasonable price and it
was in great condition.

Contact Dave
http://personal.linkline.com/dbarton/WireHarnesses.html

 

Just sent him an email. We might be neighbors as I'm in So Cal. too.

Next question is, do I get the ignition harness also or just the engine
harness..?

 

As far as I know, there is only the main wiring harness you need. I
think the ignition harness is only special circumstances.

Also, I don't think the manifold needs to be removed, I think it's only
a convenience. I had mine replaced when I pulled the engine, but the
technique is to mark every connection before you do the work, maybe
take lots of digital pictures. Another way is to lay the new harness
beside the existing one and match up all the connections. You might be
able to swap connections as you go.

Good luck!

 

Rent a car to drive for a couple of days while you change the harness
wherever you normally park your car. You'll come out ahead.


Gary

 

Pulling the intake makes it easier, but in the 240 and the 740 I did
this on I didn't do that as I didn't have a new gasket. If you did have
to pull it it's only 9 bolts and a few hoses, it really doesn't add much
to the project.

 

In my case it was just the engine harness, the ignition wiring is less
exposed to heat and oil so it seems to hold up better.

 

You guys make it sound too easy. Why didn't I do it 8 years ago..?
Dave's out of stock with a waiting list so I'm going to have to shop
elsewhere.
Thanks for all the tips!

 

There are 2 on eBay, but I can't vouch for the seller. Maybe a phone
call might help:
http://search.ebay.com/search/searc...from=R8&satitle=740+wiring+harness&category0=

 

It was the main pump.
I put an aftermarket one on it until I can order a Bosch unit.