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Yes, I'm still mystified why this has cropped up, when the car was previously reliable for many years. I sawed open all my failed relays and they are all going in the same way. There is a small length of braided copper wire connecting the #30 post to the moving arm of the electromagnet connection. That wire was melting in half. But even after it melted, the melted off ends could apparently still touch the metal frame of the electromagnet, allowing it to continue working intermittently. Why these are overloading without blowing the fuse is the mystery. Nothing on this circuit but the ECU. So does that mean I have some sort of ground short in the ECU that's pulling too much power - enough to overload the relay but not enough to blow the fuse? And what's the point of having a fuse if the components it's supposedly protecting burn out before the fuse goes?
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