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Hi MacDuff,
>I found my 1991 240 has corrosion at ground collection that use a screw or bolt to secure to the plate or sheet metal. I did this service like in 2012 on all three 240s and all ran much better with better throttle response and improved fuel economy.
Which ground are you talking about here?
How did fuel economy suffer when it got squirrely?
> The (Penn?) Sylvannia silver star 9004 / HB1
Look here for some first class info from Brickboarder Ron Kwas:
http://www.sw-em.com/techarticles.htm
http://www.sw-em.com/Wiring%20Notes.htm#the_lowly_250_push_on_terminal
http://www.sw-em.com/Deoxit_D5_Additional.htm#my_recommendations
http://www.sw-em.com/voltage_drop_in_headlights_power_in_hex_connector.htm
Then ditch the halogens for better LED headlights
>I doubt there is something generating RF powerful enough in your 900.
Cars make lot's of RFI, plus RFI can come from external strong sources.
Here's an article about cleaning up noise so you can hear things better with a HF or VHF radio in a car, boat, or plane.
https://www.rfcafe.com/references/popular-electronics/eliminate-mobile-radio-noise-popular-electronics-june-1966.htm
This same noise can corrupt geriatric computers.
>Spare ECUs or newer versions of ECUs your model can use helps as well as spare relays. I have a half dozen white fuel injection and other relays, merely reflow the solder, and add moar solder so welds do not crack again!
Relays crap out with use and age. Solder isn't everything. If the solder melted, it's likely because the circuit has too much current. I'm not sure
if it's a fuel pump that starts drawing more current or if its loose main relay
socket pins that are the reason for too much current.
How much additional current flow for loose arcing relay socket pins?
(That cause the fuse block to crispy critter.)
The last poster that was blowing 30 amp fuses in 940 Fuse 1 couldn't bother to
measure current and/or look for loose pins and report back.
You should see 10.5 amps at fuse 1, blowing a 30 amp fuse there is crazy.
Especially as it's fused at 25 amps.
Proactive:
A simple way to check Fuel pump health is by measuring current at Fuse 1.
If its 10.5 Amps relax, if it's more then fix it,
if its 20 amps call the fire department.
>Easy to replace in the 700/900 engine bar! Sort of terrible in the 240 engine bay. The factory shop manual says 'pull the gear box' to replace this thing on 240.
You lost me.... engine bar?
Happy new year, Keep well! Bill
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