Melted fuel pump relay and persistent fuel pump issues

[rapidyellowxr6t]

Hello brains trust.

 

I have been having intermittent starting problems with my 2005 ford xr6 turbo. The car was ran very low on fuel in December last year and had subsequent issues starting. It blew a couple fuses but seemed to sort itself out (or so I thought). Initially had put it down to contaminated fuel and a dicky relay. The problem has now reared its head once again where the car would completely not start this morning nor the accessories come on. With cycling the key I can hear in the IAC clicking repeatedly and once I disconnected that loom it was the fuel pump relay repeatedly clicking. Upon inspection the fuel pump relay has completely been melted and has damaged my fuse box terminal where the relay should go. It’s clearly shorting out and causing different components to cycle their processes. What do I need to do to properly diagnose this issue. 

[k31th]

well, the relay "melting" is probably caused by an a short-circuit upstream of the relay which presented in the relay itself... or just the relay itself... I assume you've replaced the fuel pump relay and cleaned up the terminal? that'd be the first step...

[rapidyellowxr6t]

That is the plan tonight after work. If the short circuit is coming from upstream of the relay what else do I need to check. Is there a way to check the fuel pump to see if it’s drawing too much current (walbro 340). I also assumed that the fuel pump fuse would have popped before the relay would get so hot and damage the fuse box.

[Ralph Wiggum]

Did you fix it?

 

Running the pump low has probably cooked it causing it to draw more current.

 

Keep in mind a 10 amp fuse is desgined to support its rated currenr as a constant and not blow at that rating.

 

Some fueses will support 25 to 50% above rated current to prevent fuses blowing on a minor current spike.

 

Down side is this can allow the circuit to run on the top end of it's capacity resulting in meltage