924 turbo starting problems
 

hi, can anyone help, i,ve just change the fusebox in a 924 turbo which was rusted, pluged everything back in one by one to make sure it went in same place , everything working (fuel pump, ignition parts etc) then engine loom plug came out of fusebox and now i have no pump or spark, i,ve tried a new control unit that sits under the heater in car ,but all that has done is make the fuel pump prime but the pump still doesn,t work when turning car over and no spark. any ideas.. many thanks Rik

I suggest you pick the brains at 924board.org

No offense to the fine people here but you will get much better 924 (turbo) troubleshooting and advice over there.

I would help but unfortunately I am not very good with the stock systems, especially the old wiring.

The two problems are likely connected; the pump relay requires a signal from the coil to run (safety measure). Check your wiring diagram; perhaps you have a break there. If you're not getting a spark either - yeah, I'd be concerned about either the DITC (ignition module you changed under the heater) or even your crank pickup sensor. You may just not be getting a signal. I've had problems with that connector rusting at the DITC connection.

If the car ran before, you might try using the old DITC box again.

Finally, I'd recommend working on getting spark and a reading at the tach (when you crank) before I'd worry about fuel.

HI, THANKS FOR REPLIES, I,VE CHECKED CONTROL UNIT AND COIL I SEEM TO HAVE POWER COMING IN AND OUT OF UNIT AND UP TO COIL , BUT NOT ALOT COMING OUT OF COIL (YOU CAN HOLD LEAD WITH YOUR HAND) AND THERE,S ONLY A VERY WEAK SPARK ,SO I,M GOING TO TRY ANOTHER COIL FIRST . AGAIN THANKS FOR THE HELP . IF ANYONE NEEDS ANY USED OR OLD STOCK NEW HARD TO FIND PARTS FOR 924 931 944 OR EARLY 911 I MIGHT HAVE WHAT YOUR LOOKING FOR , JUST EMAIL ME , RIK.......

HI, FOR ALL OF THAT HAVE READ ABOUT THIS PROBLEM CAR, I,VE TRIED A NEW COIL , BUT STILL NO LUCK,I HAVE TESTED CRANK SENSOR (SEEMS TO BE WORKING) , AS I,VE SAID BEFORE I,VE GOT FEED TO THE COIL AND I HAVE FEED COMING OUT AND TO THE FUEL RELAY BUT NOTHING WORKING. I,VE TRIED PUTTING THE OLD DITC UNIT BACK ON ,BUT STILL NOTHING (APART FROM NOW I HAVE SOME STRANGE NOISES COMING FROM THE DITC UNIT , AS IF I HAVEN,T GOT ENOUGH TO WORRY ABOUT). I,VE LOOKED AT THE WIRING BUT CAN,T SEE ANYTHING WRONG , EVERYTHING WAS FINE TILL THE PLUG FELL OUT . ANYMORE IDEAS? MANY THANKS RIK...

HI, WOULD ANYONE HAVE A WIRING DIAGRAM FOR THE DITC UNIT UNDER HEATER, IF ANYONE HAS COULD THEY PLEASE EMAIL ME A COPY . MANY THANKS RIK....

No, not the internals - they never released one.

I can't help but wonder, based on your observations of weak spark, if you either have a bad ground or bad ignition unit. By this I don't mean the DITC, but the actual spark trigger up on the LF fender, behind the headlight. Make sure the connections to this are clean, no corrosion. Make sure also that the ground to the frame rail is good - in fact, check and clean ALL your grounds. The other key ones relevant to this problem are:
engine bay on the firewall, back of the intake
inside the driver's compartment, upside-down on the firewall behind the fusebox (have to remove the fusebox to get to it)
fuel pump ground in the trunk between the taillights

Thoroughly remove all that corrosion.

Additionally, to get any questions about fuel delivery out of the way, you may wish to try jumpering the fuel pump relay (replace it with a jumper) so that you know you've got fuel.

Note that the fuel pump relay grounds through the boost cutout switch; this is a 1-wire electrical switch on the intake pipe between the turbo and the throttle body. It will open up if boost exceeds allowable/safe levels. It will fail open; you can try removing the (brown) wire and jumping it to ground to test if that is a problem, if fuel delivery is determined to be a problem (probably not in your case).

Hi 924racr, thanks for all your help , i,ve manage to find a wiring diagram of the ditc unit (not internal just the ins and outs and what goes where)the ingition unit was my next unit to test , i,ve cleaned all grounds behind fusebox and any i can find elsewhere , but unit on wing does have a bit of corrosion on it and looks like it,s been messed with alot as pins are not in good shape. i,ve also used a jumper wire on the relay and pump works fine. so i,ll get back to it and let you know , many thanks Rik.....

Great, best of luck! Do stop in on the 924board.org discussion board - plenty of guys in the UK there, though I'm not sure if any in Wales...

Cheers!
http://vaughanscott.com/Helmet/front.jpg

hi, checked and cleaned all grounds(this is where it gets strange)checked all connections and found that on transistor ignition unit on inner wing, that the green wire to coil on pin number 1 (which has been messed with and you can see where pin used to be and that it was corroded ,but pin on unit is clean) is in pin number 7 on plug, which on wiring diagram i,ve got says it,s not used.NOW,is the horror story over or are we just going for an ad break and we,ll be right back for more.now for all the questions , if this is wrong and just swap it over ,how did the owner get the 15miles to me and what damage has it done (this car also drove 15 miles with no rubber boot from air filter to mixture control unit with flap held open by two cable ties and no rubber boots on coil lead ) but back to now , can i just swap green cable over and not cause any damage. many thanks Rik....

Oh my! Well, I'd be concerned about that, for sure. I'll need to check my wiring diagrams when I get home, see what's up with that re-wiring. The other question might be do you still have the original part on there, or was a different ignition box swapped in from another year?

I'd be concerned also about what you describe with the mixture control unit; that may be masking a bad fuel distributor? Or maybe it's just horribly out of tune. If he's willing to jury-rig the thing with zipties, I wouldn't be surprised if he limped it over 15 miles just to get rid of it... did you drive it beforehand?

hi, looks like ign unit is original and has been cleaned before after someone else finding corrosion and put pin in wrong place, as where pin should be , there,s still some green still in it. i only drove car 20 feet in to garage(it was running rough). again thanks for all your help , cheers Rik.......