i have the same problems/symptoms as numerous members have describe through numerous threads with starting the car. my hatch would not start after a hot sunny day, i kept turning the ignition switch from off-on-off-on. finally the fuel pump came on and my car started. so i changed the fuel pump. then after another hot sunny day same problem. use the SEARCH button on h-t, narrow it down to the main relay. replaced the main relay and the problem hasn't been back since.

what is the main relay?
the main relay actually contains two individual relays. this relay is installed above the hood latch usaully. one relay is energized whenever the ignition is on which supplies the battery voltage to the ECU, power to the injectors, and power for the second relay. the second relay is energized for 2 seconds when the ignition is switched on, and when the engine is running which supplies power to the fuel pump.



now i have a spare/bad main relay, decided to do some experimenting and took it apart thinking i would be able to clean the contacts and resolder loose connections. the relay is seal tight. there is no taking this thing apart without damaging it.







a comparsion between a walboro fuel pump and the stock pump

 

ha ha, i thought this thread was going somewhere....

oh ya, if anyone ever needs a main relay, pm me, i've got like 15 of em

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by DnB TeK &raquo;</TD></TR><TR><TD CLASS="quote">
decided to do some experimenting and took it apart thinking i would be able to clean the contacts and resolder loose connections. the relay is seal tight. there is no taking this thing apart without damaging it. </TD></TR></TABLE>

That's what we do all the time. Just resolder the connections and the main relay is good to go. Most of the time it's the leads to the inductors (as shown in the ckt diagram) that gets bad, giving the hesitant fuel pump problem and starting issues. Cheaper than spending another $80 from the dealership getting a new one, which I've seen many people do.

 

bump for good info but check this one out too for more info.............http://www.markl.f9.co.uk/howt...y.htm

 

i used the link above to solder mine, it worked out even though i have never soldered on pcb before, i think i used too much , but it hasnt been a problem