Starter Relay clicking when warm

[Martyn]

Hi,

Car starts fine and when engine cold, there isnt a problem. But as engine temperature rises the starter relay starts clicking. When I rev the engine the clicking stops. When driving and the engine is fully warmed, 90C, the engine cuts out at low revs, e.g., changing down from 2nd to 1st.

The idling revs looks OK at just below 1000.

Prior to this I changed the water pump, thermostat, hoses and two sensors (temp and temp switch), and flushed system. I removed the AFM and intake hose for easier access to water pump, hoses etc.

Any help much appreciated.

Martyn

[18Fiatsandcounting]

I'm not sure I know which relay you mean? Do you mean the starter solenoid, which is mounted on top of the starter motor? Or something else?

Could the clicking be something hitting on the alternator belt or the timing belt? A loose metal part or the like?

-Bryan

[Martyn]

Hi Bryan,

My fault, I am referring to the dual relay that powers the fuel pump.

Martyn

[18Fiatsandcounting]

Ahhh, the famous dual relay, also called the double relay. It powers both the electric fuel pump and fuel injection system in 1980 and newer spiders. I don't have much direct experience with them, although I just happened to take one apart yesterday just to see how it's wired internally. Two relays, 3 simple diodes, and 1 resistor.

I have heard that the relay contacts in these can get corroded, which makes it click on and off. I think the standard approach is just to replace the dual relay, but I wouldn't do that unless you are sure that the relay is the problem. Try retightening all the connections first, and checking all the wires for any issues.

-Bryan

[Martyn]

Hi Bryan,

I have had trouble in the past with the relay and they are increasingly difficult to get hold of, so I'm hoping it isn't the problem.

There is a clear pattern though to the clicking and I think the relay is responding to signals possibly from the AFM (this is from other posts I've read). 1. when the engine is cold - no clicking, 2. when its warm - clicking, but rev up and clicking stops, 3. engine cuts out at low revs when change gear (I think because no power to fuel pump) - this occurs when engine fully warm (90C).

Martyn

[18Fiatsandcounting]

Check the adjustment of the Throttle Position Sensor (TPS). It's that little black box forward of the throttle shaft, with a 3-wire connector. The TPS sends one signal to the ECU when the throttle is in the idle position and another signal when the throttle is fully opened. If it's out of adjustment, it might be causing the issue.

With the engine off, you should be able to hear the TPS click very softly if you open the throttle just a bit. If you hear that, that means the actuator for the TPS is working, but the switch itself might still be bad. To adjust, loosen the two set screws (but don't remove them) and turn the body of the TPS until it clicks just as you open the throttle very slightly by hand. Then retighten the screws.

-Bryan

[Martyn]

Hi Bryan,

Thats an interesting suggestion and one I will follow up.

Unfortunately, the car is "in hibernation" for the next 90 days! The car is in Spain, but I can only stay in the country for 90 days and then cant return for another 90 days. This is due to a small majority of my fellow UK countrymen and women in 2016 thinking it a good idea to leave the EU. This means I have lost my freedom of movement across Europe amongst other things. So my time is up here and have to leave.

Nevertheless, I will tackle the issue in December/January time and in the meantime all the best and thanks for helping.

Regards

Martyn