Crank and start, crank and shut down(3 sec) crank and no start

[WorkInProgressK]

Originally Posted by Gelbster

The weakness in our relay test was that nobody insisted on wiggling the coil pins during the resistance test. The relay tested perfectly.
It is possible that the loose pin was caused by an overheating coil in the relay or arcing contacts ? Hence the suggestion to feel if it got hot.
Anyone got a circuit diagram for the fuel pump fuse - just to close the loop ? The 5th pin, the small one is the oddity.
Pelican Parts

Well I did say to bypass the fuel pump relay entirely. But you are right that you would not have know what was at fault on the relay unless you opened it.

Wow, that tab. It just looks like porsche decided you couldn't use a standard 30 amp bosch relay which i am certain is identical inside. Their solution is to change one tab to a smaller one and turn one 90deg.

If you have a soldering iron, you could open it up and re-solder the joints.

[Gelbster]

Originally Posted by WorkInProgressK

Well I did say to bypass the fuel pump relay entirely. But you are right that you would not have know what was at fault on the relay unless you opened it.

Wow, that tab. It just looks like porsche decided you couldn't use a standard 30 amp bosch relay which i am certain is identical inside. Their solution is to change one tab to a smaller one and turn one 90deg.

If you have a soldering iron, you could open it up and re-solder the joints.

But it is not a 4 pin relay so the 5th ,small prong must be NC ?I agree ,it would be interesting to dissect it and observe the reason it failed.

[Camibox]

Same relay number (KAE) I tested a few more times and got a few where it didnt activate. The 87 pin is loose which may have been an issue. Will get the top on and have her test it out. Now about the leak I saw at the water pump.......

[Gelbster]

Originally Posted by Camibox

The 87 pin is loose which may have been an issue. ...

That would do it ! Good diagnosis for others to follow - wiggle the pins ! If you can do this with an Multi Meter set to 200 ohms and attached to the coil pins it may be conclusive.
You mentioned W/p - look for water/mineral stains on the pump -just under the shaft. If there are none ,look elsewhere for leakage.
Consider upgrading to the low temp T-stat (Wahler)at the same time .Pelican have it.

[Camibox]

Well opened up the relay. The "loose" prong was not an issue, but, one of the connections to the relay coil was just laying on the connection but not soldered on. Glad I bought 2 when I ordered

[Gelbster]

Originally Posted by Camibox

Well opened up the relay. The "loose" prong was not an issue, but, one of the connections to the relay coil was just laying on the connection but not soldered on. Glad I bought 2 when I ordered

Always good when a thread concludes with finding the fundamental cause of a problem.Thanks for sharing.

[geraintthomas]

Glad you've sorted out the problem bud, it's gut wrenching when you get a problem like this. Happy days!