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OVP, Fuel relay help please
Topic Started: Tue Jun 21, 2011 8:23 am (3,606 Views)
RuaphuNZ
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Newbie
[ * ]
HI all,

I have a bit of an issue with the 190e I look after, it's mates son's car that I look after for him. It just stopped and refuses to start. Checking things out I have found the fuel pump does not operate. I believe the fuel pump relay (FPR) is at fault and has stopped operating. I can get the fuel pump to work remotely via seperate power source so the pump is OK. However, I have no voltage supply to the pump, hence why I think it is the FPR at fault.

Having only a basic Haynes manual it provides little info on the subject. I'll start with the basics, where do I find the FPR? is it behind the battery or is it the big relay at the back of the fuse box? I take it the OVP relay is the one next to the ICU module on the right. What is the other silver relay with the 10 Amp fuse plugged in at the top? How do you test the FPR once you extract them?

I know from hunting around the FPR's suffer from dry joints. If I can locate it, can you pull these apart and go over them checking for dry joints or are they sealed units?
Any help would be great,

Cheers, Andy
PS, It's an 87 four cyl, injected 2.0l, Auto.
Edited by RuaphuNZ, Tue Jun 21, 2011 8:25 am.
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JustbeCoz
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FPR is usually next to the OVP relay which is the one with the red top and 10amp fuse behind the plastic shroud behind the battery. FPR sometimes has rev limiter info printed on top eg 6000l/min as well as part number. worth pulling top of shroud behind battery forward and tapping top of relay with a screwdriver with ignition on to see if it makes contact and you can hear the fuel pump prime. FPR usually has black plastic casing which just prises off the terminal base to expse printed circuit etc. grab relay unit and pull straight out to release from connector block behind battery.
i hadintermittent problems with mine and just bought a new one but you could probably get one off an e-bay breaker that would do the job.

Part No is 0035452005 or similar hope this helps.
Edited by JustbeCoz, Tue Jun 21, 2011 9:50 pm.
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balamb37
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Grumpy Old Grampa with Dog
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Before you start dismantling the relays just pull it or them out and plug them back in as

sometimes they suffer from bad connections at the pins due to age. ;)

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RuaphuNZ
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Ok Many Thanks for that advice ;) .

I have removed and replaced the FPR, no difference. I have stripped the FPR and resoldered everything, even though all looked good. The part No. 201 540 38 45. siemens part (5wk1 763) I notice of all the connections only the 15 (switched supply to FPR coil-from the via ignition key) 31 (Earth or -tive) 30 (main +tive supply) and the 87(to pump) are in use. The others have no connections in the base. Re-Assembled and still no go??

My next move is to remove and check the OVP and checking supply to pin 15 of the FPR to ensure this is doing what it should. I have also checked the fuel pressure relay, all good.

Does anyone know where I can get a decent wiring diagram as the Haynes manual diagrams are not accurate, only a basic overview, i.e. I can find no correlation to the fuel pressure relay anywhere and how it is wired into the fuel control circuits. I take it the pressure relay will interupt the FPR 15 pin supply some how either directly or indirectly, i.e via the ecu.

I have even checked the BOSCH injection guru book but this only covers the injection systems directly not periferal equipment.

Cheers, Andy.
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1stMerc
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This may help
http://www.autolib.diakom.ru/CAR/Mercedes-Benz/1987/190E/WIRING%20DIAGRAMS/
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RobertE
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Serial victim...
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Provided it's a fuel-injected car, then also check the fuel distributor relay - a little black box (about the size of a box of Swan vestas) nailed to to the body of the distributor itself. They either work, or don't. It's a major drawback and cannot be 'jumped'. It's called the EHA valve (Electro Hydraulic Actuator) and can be a serious pain. As far as I know, they are all the same on a Bosch KE system.
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