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Subject: Relay is overheating due to excess load (long)
Author: Area52 : member since August, 2006 : 534 posts
Posted on: 2008-04-30 23:12:12

...sounds like the fuel pump, restricted fuel filter causing pump backup (overpressurization before the filter resulting in reduced flow through pump causing heat buildup in pump), or the pickup screen in the intank pump is almost totally restricted. If you've recently run very low on gas or run out of gas, the pickup screen will be clogged and you will also have to change the fuel filter.
To verify, check your idle fuel pressure (3.0bar) and if possible, try to setup the pressure gauge to where you can see it while you drive. There should no dip...in fact a slight increase in fuel pressure when accelerating. As you back off the throttle, pressure should settle back down to 3.0bar.
You can also do a fuel delivery test...should get a little over a quart of fuel in about 40 seconds if the pump is functioning properly. You will have to pop the top off the FP relay and manually push the contacts together with your fingers to get the pumps to run. (USE CAUTION: ELIMINATE ANY SOURCES OF IGNITION...OUTDOORS OR WELL VENTILATED LOCATION...ABC EXTINGUISHER HANDY...GOGGLES...NEOPRENE GLOVES)

1986 L7 (04/86)
1985 528e (10/84)



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