Hi,

Yesterday I had problem with engine. I started engine on gassoline and drove on LPG but when changed on gassoline engine stoped. After that only cranking but not started, I had to back home in emergency LPG mode ( In this mode car not use gassoline, starts and runs only on LPG ).

I connected my Superchips Flashpaq F4 and showed P0231. I searched and found that it is a problem with fuel pump relay but relay is not changable - is soldered inside box.

Ok. I removed junction box:



dissasembled everything



Relays looked good ( fuel pump relay is on the middle ) On photo in internet I saw almost burned.



but on bottom side I had this :



and after removed relay:



I checked it with 12V power and not worked. Only one posibility was , to replaced it with new one... but I didn't have a relay.

I need car and done custom relay instalation. I used regullar 30A 12V relay. I soldered harnes in place of OMRON. First checked all connections and now I have this:



and now relay is outside the box:




I cut hole in cover



and now I can close everything



and change relay when one more time something goes wrong... but I think that problem with fuel pump relay was in only 8A value. Now with 30A should work longer than my Expy.

Maybe repair was not in orginal way but took about 2 hours and regular car relay can buy everywhere.

 

Nicely done. I've replaced that relay on my 03 too. Cost me about $30 for a new relay and solder removal tool. Much cheaper than $300 for a new junction box.

 

I paid for normal relay about 0,75 USD . I used it because I don't have a time to wait for OMRON.

 

It's too bad you didn't work in Ford engineering in the early 2000's . They could've used your idea for a fuel pump relay instead of that Rube Goldberg design they came up with. Good work !

 

Ha ha ha... thanks

But maybe this resolv can be helpful for somebody. Here, I need to wait about 10 to 14 days for this type of relay or spend many hours with catalog to find similar. It's reason why I posted it.

 

Your fix should work fine.
I've been reading about this issue for a few years.
The OEM relay is rated for 20A and after measuring the resistance of the fuel pump motor I think it draws 15A.
The contacts are usually what fail, increasing resistance and eventually burning it up.
I installed a 40A relay outside the fuse box for the fuel pump and use the OEM relay to trigger it on our Excur and Exped.
Splice into the wire going to the Inertia Switch.
The 40A relay coil draws .2A so there is very little current going thru the OEM relay contacts, should last a lot longer.
Also added a bypass switch for testing/emergency.