Another Carrera starting problem question

[WW911]

The subject of intermittant starting problems on a 3.2 Carrera has been discussed in length, but I don't remember seeing a reference to a clicking noise when the ignition key is turned to the on position. I have a 1989 Carrera and am having the starting problem with no predictable pattern. But the one thing that remains constant is when I turn the key to the on position, there is a very noticable clicking noise coming from the front, and I am assuming that it is the fuel pump.
The noise will continue as long as the key is kept in the on position, but when the key is turned off and then back to the on position, the noise disappears. Sometimes the car will start right up ( hot , cold, ...doesn't seem to matter). But at times it will take 3 or 4 times, almost catching on the next to the last try before it finally starts.
I have installed a new DME. Took it to the shop and had the following done:
Elec. diagnostic scope secondary pattern (?) Test coolant temp. sensor, air temp. sensor, throttle switch, air flow sensor and injector resistance. Pin test ECU control unit. Replace reference and speed sensor.
If the fuel pump is the problem, would the car still run as well as it does when it finally does start?
These fishing expeditions are getting expensive.....just replacing and diagnosing until the problem is found. Maybe this is how it has to be done. Or maybe just put up with the problem? After all, it does eventually start.
Thanks for any help

[geoz]

Should the fuel pump not rather be a whirring sound? Have you tried locating what makes the clicking sound?

[WW911]

Yes...fuel pump. Just now turned key to the on position and no rapid clicking this time. Puzzled.......

[steely]

This coolant statement caught my eye.(?) Is it air cooled?

Originally Posted by WW911

....Took it to the shop and had the following done:
Elec. diagnostic scope secondary pattern (?) Test coolant temp......

Were you under the car when the fuel pump clicked?
This is a WAG, but how is your battery and how are your grounds? I was just wondering since when you go to start, the DME/fuel relay under you seat clicks and applies power to the pump. The voltage could drop, open the relay, then with the load removed the voltage recovers, and the process repeats. (for a low V or bad ground).

But like geoz mentioned, I would verify it is the fuel pump first and/or locate the noise source.

hth

[WW911]

Yes..air cooled. Battery is 2 months old and I have been checking it daily to affirm that is not the problem. All is good there. And I recently checked the transmission ground and all seemed good there as well (could only unfasten one end, however, as the car was not up on a lift and could only easily remove the one). But no sign of corrosion there and the strap looked to be in good shape. I haven't verified the the relay under the seat clicks. Will do that tomorrow. And yes, I assumed ( maybe that's part of my problem) that it was the fuel pump clicking rapidly. I wasn't able to reach under and feel the pump as the engine cranked, but not sure what else in that area could be making that noise. Will be digging further tomorrow.

[kidrock]

I'm just guessing, but if you're hearing a "clicking" noise from the front when you engage the ignition, I'd bet a previous owner installed one of those Ford ignition relays up front in an attempt to solve your current starting issue. It may even be in the Smuggler's Box.

I'd try 2 things if your starter isn't engaging:

1) With the ignition off, put your tranny into 2nd gear, engage your clutch and roll your vehicle forward or backward for 1-3 feet then disengage your clutch. This will unstick your pinion if it is jammed or frozen on the flywheel teeth. See if your ignition will turn your motor over. If not,

2) get a small hammer or screwdriver and WITH THE CAR OUT OF GEAR, have a friend turn over the ignition while you GENTLY TAP on the solenoid of the starter. These cars are notorious for having old Bosch starters with crappy old solenoids that refuse to work.

Report back to us.

[steely]

If you want to check the fuel pump ground, look in the trunk, drivers side strut tower, to the left of the fuse box (G104 if you have a Bentley manual).

[WW911]

The problem isn't with the starter. It engages and engine spins with no problem. Checked it briefly this morning and felt the click on the dme relay, but no rapid clicking. Didn't start the car as was running late for work. Checked the ground in the pic and all is well there. Wish something would just go ahead and fail so I could fix it....

[Chuck.H]

On a carrera the fuel pump shouldn't run until the key is turned to the 'start' position IIRC... Can you hear the clicking with the front hood open, maybe it's one of the relays?

A quick test would be to check your fuel pressure at the fuel rail - even without a gauge, it should at least spray a little when you unscrew the nut.

Chuck.H
'89 TurboLookTarga, 332K miles

[WW911]

I think the repair shop checked the fuel pressure, but will confirm. When I heard the rapid clicking, the hood was open and it appeared to be coming from the very front and low.

[WW911]

My problem just got a little more interesting. In my haste to blame the fuel pump, the rapid clicking noise appeared to be coming from that area. But after closer examination, the sound was echoing from the DME relay toward the front of the car. I had removed all the carpeting and the sound was channeled forward (I know, sounds strange ) I put my hand on the relay and turned the key on and it was vibrating and rapidly clicking. Turned the key off and back on and the noise was gone . Car started on second try. So I did what anybody else would do......put in a new DME relay. The first time I fired up the car it was textbook..perfect . But the next time, the same thing.....the rapid clicking and vibration ................ anyone else experience this ?

[WW911]

It's been a while, but have starting issue update.....repair shop installed new ( actually re-built)
ECU and have had no problems since. Wish I had tried this a long time ago..