DamirGTI 325 Posted January 1, 2008 (edited) Hi ! Last night on my trip to NY party I've almost catch on fire by the Tachy relay while driving I've first notice some strange smell inside the car , however as I've been smoking i was thinking that maybe i bought some bad stinky cigarette paper or something .... few seconds later the afoul smell begin more intense , white smoke rise out from the bonnet and the engine shut down shortly after leaving me in the middle of the motorway with strange WTF look on my face - So i push the car off the road , carefully lift up the bonnet and the engine bay was all steamy from disgusting white smoke on molten plastics and fire coming out from the black relay box ok. i turn off the fire (I've burnt two fingers while doing that ..) and examine the wiring/relays - this is what I've found : http://s27.photobucket.com/albums/c151/Pie...;current=R1.jpg http://s27.photobucket.com/albums/c151/Pie...;current=R3.jpg http://s27.photobucket.com/albums/c151/Pie...;current=R5.jpg http://s27.photobucket.com/albums/c151/Pie...;current=R6.jpg http://s27.photobucket.com/albums/c151/Pie...;current=R7.jpg http://s27.photobucket.com/albums/c151/Pie...;current=R8.jpg Anyway I've manage to repair this as i always have some spare parts and tools in my car , so I've had one spare Tachi relay - i fix up this burnt wire , fit back the spare relay and continue my journey without and further problems .. The earth wire burned out (the green/yellow M wire..) , but i don't understand why ? anyone had similar problem with burning Tachy relays ? Also i have spare Tachy relay connector : http://s27.photobucket.com/albums/c151/Pie...;current=R9.jpg ... and i was wandering what is the best way to repair/fix this molten connector ? was thinking to cut out this burnt connector and solder this spare connector together with wiring , but theres too much wires and im afraid that the wires might get in touch if the insulation tape fall off (im still stinking on this burnt plastic odor :glare: afoul smell i just can't get rid of it as like I've been on barbecue party all evening ...) Thanks ! - Happy New Year Damir Edited January 1, 2008 by DamirGTI Share this post Link to post Share on other sites
ALEX 98 1 Cars Posted January 2, 2008 Never seen that before. I have seen a few with a little bit of scorching around the connections but never that bad! I'd fit the new one with solder and use heat shrink rather than tape. Share this post Link to post Share on other sites
GLPoomobile 958 Posted January 2, 2008 Also i have spare Tachy relay connector :http://s27.photobucket.com/albums/c151/Pie...;current=R9.jpg ... and i was wandering what is the best way to repair/fix this molten connector ? was thinking to cut out this burnt connector and solder this spare connector together with wiring , but theres too much wires and im afraid that the wires might get in touch if the insulation tape fall off (im still stinking on this burnt plastic odor afoul smell i just can't get rid of it as like I've been on barbecue party all evening ...) Thanks ! - Happy New Year Damir The proper way would be to remove the terminals from the holder (using a suitable tool) and crimp new terminals to your existing wiring (trimmed back) and then refit in to the spare holder. If you just want to splice it in by connecting the old wires to the wiring hanging out of the spare holder, then the most simple solution (while remaining relatively safe) would be to solder the wires together and protect each wire with heatshrink, which you can then cover with insulating tape if you want to be REALLY careful Or you could use these In line solder splice (bottom of page). Share this post Link to post Share on other sites
DamirGTI 325 Posted January 2, 2008 (edited) Hi ! Ok thanks i'll try something later , me thinks that the first solution is best - just replace the connector without cutting existing wires from this burnt connector Just one more question do this tachy relays gets hot when they're "working" ? Cheers ! Damir Edited January 2, 2008 by DamirGTI Share this post Link to post Share on other sites
ALEX 98 1 Cars Posted January 2, 2008 Or you could use these In line solder splice (bottom of page). Wow expensive The stuff I used for the stereo in my Astra was only £1 a metre. Share this post Link to post Share on other sites
Roman 0 Posted January 2, 2008 Hi ! Ok thanks i'll try something later , me thinks that the first solution is best - just replace the connector without cutting existing wires from this burnt connector Just one more question do this tachy relays gets hot when they're "working" ? Cheers ! Damir hello i think this fire cause a dry yoint on you tachy(somevhere inside plate) this is common problem because over this contact feed fuel pump and vhen operate current is aprox6-8A and is posible to melt plastic cover and them.. blow . vhen you put another tachi relay open first and look for any dry joint,s... happy new year from ljubljana... Share this post Link to post Share on other sites
DamirGTI 325 Posted January 2, 2008 Hello ! Yes it might be that as the earth and the main positive wire (thick brown wire No. 20 ..) are close , next to each other , so must be that the dry joint was starting to melt/fall off the earth (or the positive ..) wire and made an short cut in between the wires .... - and + = nasty stuff (sretna nova kolega !) Cheers ! Damir Share this post Link to post Share on other sites
mickie 3 Posted January 2, 2008 wow, thats really bad, could have set the 205 a light Share this post Link to post Share on other sites
Guest jpward99 Posted January 2, 2008 Ouch! Lucky to catch it though. The fuel pump relay on some old Fords (Bosch injected Capri, Granada, Sierra) used to do the same, my 2.8 XR4 suffers from fuel pump relays going so I carry a spare in it too. I have had one heat up to the point of melting the casing before but not catch fire (probably wasn't far from it). I just replaced the relay without any further problems. We should all probably take this as a reminder to inspect the Tachy now and then for any signs of scorching, melting etc. Share this post Link to post Share on other sites
