Return of the No-Start 4kq--Oh, Oh addendum

[Kneale Brownson]

It got so hot because I mistakenly took someone else's advice that I could
put any relay into the fuel pump relay's spot.  I'd jumpered the two big
slots in the fuel pump relay station earlier with no problem.  But as soon
as I put a non-fuel-pump relay with the same configuration of male parts
into the fuel pump relay spot in the tray, the smoking began.

That brown from position 31 goes into a small harness with maybe 10-12
wires that goes into a larger harness with dozens of wires.  My concern is
whether the "hot" brown ground wire from position 31 burned into some of
the other wires.  

At 02:08 PM 6/18/2005 -0500, Chris Hall wrote:
>Brown in Audi's = Ground Wire.
>
>I'd say if the wire got hot enough to melt the insulation off, you
>first have to find out why it got so hot it melted...
>
>
>
>On 6/18/05, Kneale Brownson <kneale at coslink.net> wrote:
>> I managed to get the relay/fuse tray off all that jumble of wiring.  The
>> wire with the insulation burned off had a brown covering.  It was connected
>> to the tray through a connector at the position that's marked "31".  It
>> goes immediately into a harness with a bunch of wires from adjacent
>> positions in the tray through the first two connectors from the front.  I
>> don't see any other burned wires from any of the connectors to the tray.
>> None of the fuel pump relay slots in the tray is marked "31".  The relay
>> itself has one leg marked "31" that goes into a slot in the tray marked
"50".
>> 
>> Do I have to try to disassemble that harness to check the burned wires
>> inside, or can I just replace the brown wire with another brown that goes
>> from the tray to wherever the current one goes?  Can anyone tell me where
>> that brown goes?
>> 
>> 
>> At 12:32 PM 6/18/2005 -0400, Kneale Brownson wrote:
>> >Someone reported earlier to me that I could put in "any" relay in the fuel
>> >pump relay slot, so I went through my collection of about 15 relays from a
>> >5ktq parts car and found one that has the same configuration of  plug ends,
>> >although the blades for the big slots were slightly smaller.  When I
>> >inserted it, I let a bunch of the smoke out of the wiring.  I hoisted the
>> >tray up and can see a bare wire with the insulation burned off it that
>> >looks like it comes from the area of the horn relay, not the fuel pump
>> >relay.   How do you disengage the wire connectors for the various harnesses
>> >from the bottom of the tray? Looks like I'll have to take off the tray in
>> >order to search for more burned wires.
>> >
>> >At 11:20 AM 6/18/2005 -0400, you wrote:
>> >>I jumpered the fuel pump relay today and the pump runs.  So I put the
relay
>> >>back in and the car started OK.  When I had similar experiences with my
>> >>200q20v, I ended up having to replace the relay and then having the pump
>> >>fail a few weeks later.  My surmise was that the pump going out caused the
>> >>relay to fail.  Should I expect the same here?  Should I get all the pump
>> >>"fixings" ala Huw's report on renewal of his system and prepare to replace
>> >>everything on the fuel pump tray?  What relay can I use for the 4kq?  The
>> >>contacts configuration on my spare 200 relay is different from the one on
>> >>the 4kq.
>> >>
>> >>At 08:23 PM 6/17/2005 -0400, Kneale Brownson wrote:
>> >>>The wife's 4kq that had the funky starter wiring and a no-start-when-hot
>> >>>experience has been starting just fine ever since I replaced the funky
>> >>>parts of the wiring.
>> >>>
>> >>>Today we had another no start event.  This time, while she was
turning the
>> >>>key, I had my hand on the fuel pump and could feel no activity.  Thing 
>used
>> >>>to Hum  (Not an Huw tune, I'm sure) quietly when running.  I can't find a
>> >>>fuel pump relay like in the 5k/200 cars I've got.  Is there a fuel pump
>> >>>relay?  Am I most likely looking at a new fuel pump?  It's very rusty
>> >>>looking there.  What should I replace with the fuel pump while I'm at it?
>> >>
>> >>_______________________________________________
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>> >>quattro at audifans.com
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>> 
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>
>
>-- 
>Chris Hall
>badcomrade at gmail.com
>"making girls cry since 1974"