Weird relay fault
Discussion
Every now & again my R8 won't start - I turn the key & get
BEEEEEP: ESP Fault!
Then 3 BEEEEEEPs and the message Brakes!
I can replicate the fault 100% of the time by removing the fuel pump relay, but on putting it back the fault seems to go away (although then it does come back when I think it's fixed)
Here is the relay which has a very slight whiff of electrical / component burn to it. Note the scorched pins. Is that acceptable / normal?
It seems obvious to replace the relay and I will do but would rather understand / fix the root cause. Now I have ferreted about with it it is working perfectly again and if I swap it with the other identical one (that is also scorched in the same way) it is still fine
I am not a mechanic as you can tell. The car has never had a fuel filter changed as it is meant to be 'for life'. Could this have caused the relay to cook perhaps & worth changing? Sometimes it takes a long time to crank too.
Any ideas.
BEEEEEP: ESP Fault!
Then 3 BEEEEEEPs and the message Brakes!
I can replicate the fault 100% of the time by removing the fuel pump relay, but on putting it back the fault seems to go away (although then it does come back when I think it's fixed)
Here is the relay which has a very slight whiff of electrical / component burn to it. Note the scorched pins. Is that acceptable / normal?
It seems obvious to replace the relay and I will do but would rather understand / fix the root cause. Now I have ferreted about with it it is working perfectly again and if I swap it with the other identical one (that is also scorched in the same way) it is still fine
I am not a mechanic as you can tell. The car has never had a fuel filter changed as it is meant to be 'for life'. Could this have caused the relay to cook perhaps & worth changing? Sometimes it takes a long time to crank too.
Any ideas.
That is definitely not OK. Either the relay isn't getting enough voltage to clamp the contacts properly, or there's too much current through it, or the terminals in the relay socket are not making a good connection. For two different relays to exhibit the same problem suggests there may be some common cause (eg corroded terminals).
PaulKemp said:
Only if the relay is earthed near the same point
However you should replace the relay, they are cheap and if you have same issue them move the earth.
You need to be systematic, change 1 think at a time.
I don't know if they are close enough for it to be connected however I don't believe in coincidences and the fault occurred after I finished installing the stereoHowever you should replace the relay, they are cheap and if you have same issue them move the earth.
You need to be systematic, change 1 think at a time.
Green star is where the relays ground
Red star is where the amp grounds
I'm wondering if it is connected as other relays on that same board are not affected however they are a different type of relay so it doesn't necessarily follow...
Aside of the above it could also just be that the relay contact "buttons" aren't getting a good contact, this will increase the resistance of the circuit & also could cause heat as shown.
As above check the voltages, check the terminal wiring contacts & change the relay & see how you get on.
As above check the voltages, check the terminal wiring contacts & change the relay & see how you get on.
I can't see any burning where the cable terminals make contact with the relay terminals
The discoloured areas of terminals 30 and 87 are very likely caused during the relay manufacturing process when the terminals are welded to the coils armature and contact post or due to the relay itself not being able to cope with its task and it overheating inside the case
The relay holders terminals would have burnt if too much current was being drawn through the relay or the fuel pump fuse would have melted or blown
Look closely at the contact area between wiring terminals and relay terminals and you will see that they are very good
Don't misunderstand me here, I'm not saying the relay isn't faulty but..............................
Often relays do smell a bit iffy
I suggest you open the relay up and inspect its internals, you could post a few images of its guts
The discoloured areas of terminals 30 and 87 are very likely caused during the relay manufacturing process when the terminals are welded to the coils armature and contact post or due to the relay itself not being able to cope with its task and it overheating inside the case
The relay holders terminals would have burnt if too much current was being drawn through the relay or the fuel pump fuse would have melted or blown
Look closely at the contact area between wiring terminals and relay terminals and you will see that they are very good
Don't misunderstand me here, I'm not saying the relay isn't faulty but..............................
Often relays do smell a bit iffy
I suggest you open the relay up and inspect its internals, you could post a few images of its guts
Oh OK, well they still have a burning smell and my tech who is probably the best regarded R8 specialist in the UK recommended replacing them
So I've replaced them and interestingly the part has been superseded with an uprated model
The old ones say 614 and the new ones say 644
So maybe like you said earlier, the circuit was drawing more current that the relay could handle causing it to overheat but not enough to blow a fuse? ANd tat 's why the new model relay is uprated
Fingers crossed that will fix it and if not I have identified the circuit that needs investigating further
Thanks
So I've replaced them and interestingly the part has been superseded with an uprated model
The old ones say 614 and the new ones say 644
So maybe like you said earlier, the circuit was drawing more current that the relay could handle causing it to overheat but not enough to blow a fuse? ANd tat 's why the new model relay is uprated
Fingers crossed that will fix it and if not I have identified the circuit that needs investigating further
Thanks
Edited by jakesmith on Saturday 15th June 16:16
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