Trunk Fuel Resistor - Page 6

theflystyle · #76 04-22-2019, 09:34 AM

The relay has been ordered

theflystyle · #77 04-25-2019, 06:57 PM

The relay did not fix the issue.

I tested and compared the readings between the old/new relays and they were essentially the same.

theflystyle · #78 04-26-2019, 01:46 PM

Update on more things tried...

Removed the fuel tank cap and tested the 6 pins on both sides for continuity - Pass
Used power probe to double-check the new fuel pump works while in the tank - Pass
Checked multiple grounding points on the car - Pass

I also hooked up my multi-meter to pins 1 and 4 on the male fuel pump connector and checked for voltages. When the key was first in the ignition voltage was over 12. Then on the 5th beep of the chime the fuel pump relay clicked and then voltage dropped to 0. I am not sure if this is normal or not but as the fuel pump plug was not connected to the tank it could be expected behavior. At least I know power to the tank is there.

Sigh...

oab_au · #79 04-26-2019, 05:10 PM

Quote:

Originally Posted by theflystyle

Update on more things tried...

Removed the fuel tank cap and tested the 6 pins on both sides for continuity - Pass
Used power probe to double-check the new fuel pump works while in the tank - Pass
Checked multiple grounding points on the car - Pass

I also hooked up my multi-meter to pins 1 and 4 on the male fuel pump connector and checked for voltages. When the key was first in the ignition voltage was over 12. Then on the 5th beep of the chime the fuel pump relay clicked and then voltage dropped to 0. I am not sure if this is normal or not but as the fuel pump plug was not connected to the tank it could be expected behavior. At least I know power to the tank is there.

Sigh...

When you turn the key on the pump will run for about 2 seconds than stop till the the engine is turning over.

Maybe the fuel is not the problem. Start at the engine and see if there is spark at a plug and fuel at the injectors.

theflystyle · #80 04-26-2019, 07:08 PM

There is spark but its the fuel that is not being delivered to the engine. I still agree with trevor that it is a grounding issue, I just have yet to actually find it.

oab_au · #81 04-26-2019, 07:17 PM

Quote:

Originally Posted by theflystyle

There is spark but its the fuel that is not being delivered to the engine. I still agree with trevor that it is a grounding issue, I just have yet to actually find it.

OK If it is a grounding issue, then some electrical unit won't be working.
You have found that the pump and modulator is working, that leaves the filter, the roll over valve, the fuel regulator and the lines to check.

Trevor · #82 04-27-2019, 01:51 PM

Quote:

Originally Posted by theflystyle

There is spark but its the fuel that is not being delivered to the engine. I still agree with trevor that it is a grounding issue, I just have yet to actually find it.

I have not specifically referred to an overall grounding issue. You have not properly followed up on my suggestions. Bouncing from pillar to post will not solve your problem.

theflystyle · #83 05-04-2019, 06:33 PM

There has been progress!!!!

I believe to have isolated the issue to a faulty/intermittent connection between the fuel pump plug on the outside of the tank. When checking continuity between both ends of that plug, I found that the continuity would drop when the plug was moved or jiggled.

After getting the plug in just the right place I was able to consistently start the car.

My next step is to determine if there is just a loose connection or if the wire has been compromised anywhere else during its run.

More details to follow.

oab_au · #84 05-04-2019, 08:25 PM

Quote:

Originally Posted by theflystyle

There has been progress!!!!

I believe to have isolated the issue to a faulty/intermittent connection between the fuel pump plug on the outside of the tank. When checking continuity between both ends of that plug, I found that the continuity would drop when the plug was moved or jiggled.

After getting the plug in just the right place I was able to consistently start the car.

My next step is to determine if there is just a loose connection or if the wire has been compromised anywhere else during its run.

More details to follow.

Good news, must be somewhere between the backseat plug and the tank plug. Either the wire taking power to the tank or ground coming back, or their connections.

theflystyle · #85 05-05-2019, 05:57 PM

No surprise but I have been unable to find this part 81802PA100.

Interestingly there was a tag on the cord itself with this information - how convenient! If I am unable to source it new then I may consider rebuilding it myself. Ideally with new plugs as the ones on the car are no longer ideal.

Attached are pictures for reference.

You can see you really would not be able to tell there is an issue with the connection based on the looks of the plug. There is an ever so-slight discoloration on the upper left male plug that could be some corrosion but that is a guess.

While on the subject. Does anyone know how to remove the body plug for this cable? I attempted to push it in but it did not want to budge free. I did not want to exert excessive force without taking a look from underneath.

oab_au · #86 05-05-2019, 08:33 PM

Quote:

Originally Posted by theflystyle

No surprise but I have been unable to find this part 81802PA100.

Interestingly there was a tag on the cord itself with this information - how convenient! If I am unable to source it new then I may consider rebuilding it myself. Ideally with new plugs as the ones on the car are no longer ideal.

Attached are pictures for reference.

You can see you really would not be able to tell there is an issue with the connection based on the looks of the plug. There is an ever so-slight discoloration on the upper left male plug that could be some corrosion but that is a guess.

While on the subject. Does anyone know how to remove the body plug for this cable? I attempted to push it in but it did not want to budge free. I did not want to exert excessive force without taking a look from underneath.

They don't look that bad, that discoloured pin is the power wire connection, what is the male pin on the tank plug that goes into it look like.
Don't know how to pull the plug out of the floor, look from under to see, and check the wire there also in case it has been damaged.
Getting closer.

theflystyle · #87 05-07-2019, 04:51 AM

I spent more time cleaning the connector to see if I could find more to the story. As it turns out there was something I missed under the grime that I did not see before. On the side of the bad connector there was a brown mark where it seems to have melted slightly. On closer inspection the portion on the plug also appeared to have melted slightly. Yes I have not yet gone under the car as I need more free time but I believe this to be my smoking gun. I will upload pictures later of my attempt at capturing the failure.

Now I am still searching for a new/used part but I essentially just need to replace the connector. I have found a couple of online stores that sell just the plugs but they are at a ridiculous price - $75 to $88 just for the connector!!!

https://findpigtails.com/product/y42a6/
&
https://connectorexperts.com/i-26243...tegory:1261632

Nearly anything else would be a cheaper option but I am stuck until I find how I want to proceed. I should also mention the crimped wire connector was so brittle it broke while removing it from the plug during my inspection.

If anyone has this plug or knows the universal name instead of these propriety model numbers these sites are using that would be greatly appreciated.

svxcess · #88 05-07-2019, 09:08 AM

Can you re-wire the “ good” ebnd of the connector, as well as the bad one?

6-pin male /female connectors are less than $8.00.

https://www.amazon.com/Molex-Circuit...ateway&sr=8-11
.

theflystyle · #89 05-07-2019, 09:16 AM

Quote:

Originally Posted by svxcess

Can you re-wire the “ good” ebnd of the connector, as well as the bad one?

6-pin male /female connectors are less than $8.00.

https://www.amazon.com/Molex-Circuit...ateway&sr=8-11
.

The bad end is the portion that connects to the top of the fuel tank. I can't rewire that end unfortunately.

theflystyle · #90 05-07-2019, 02:00 PM

As promised here are the pictures of the damaged/burned area. From the side you can see the discoloration and from the front you can see the melted divider which is no longer straight as the one next to it.

More good news... I hope.

After hours of searching it looks like this connector is used on various other cars/motorcycles. Most notably on a Suzuki ignition switch on GSXR 05-13' and the Dealer mode connector. I found a 5-pack online for less than $20 shipped so it is definitely worth trying. Attached is a picture of the Suzuki replacement OEM part 6180-6771. To my untrained eye they seem the same. I was unable to find measurements to verify but in about a week I will find out.