Relay issues POS 2000 Kia SUV

[WarWagon]

Working on a POS 2000 Kia SUV. Engine starts like 2 or 3 times out of 5 tries. Just grinds the starter other times.

Cleaned all grounds. Battery good. Cranking and static vibration test administration on ECM / fuel pump relay area will cause it to fire off while cranking.

Here is where it gets weird. And why the grounds were cleaned... You would think the relays went bad and this is correct.

Drop in two new relays. (Korea made O'Reilly part.) Will NOT start at all. ECM and fuel pump relays are the same part number. Look identical and OEM relays have same P/N on them.

Swap in old relays - same random start issue. Vibration test making it start while cranking...

Return 'defective' new relays. Get two more.

Same issue - no start with new fuel pump and new ECM relay. Static vibration test administration will not cause it to start. BFH test version did not help.

Blow an afternoon cleaning grounds, cables, checking fuses etc.

Disassemble old relays. It gets weirder!!!

Manually move armature to make contact. Fuel pump relay gives off a blue spark, but, no fuel pump running most times.

Swap in ECM relay and manually move armature spark then fuel pump runs every time.

New relay in fuel pump spot and old relay that passed above test in ECM spot - starts every time.

New relay in ECM spot - Will not start. :mad2: Tried both new relays including the one that will run the fuel pump. Runs fuel pump after being in ECM spot.

Starts every time with new fuel pump relay and old ECM relay. :skep:

Why does the new relay work for the fuel pump but not for the ECM? :werd:

Suggest we throw it in back of pickup and get scrap metal value for it... After all the $24 cost *2 for relays is totaling the vehicle! :hihi:

 

[3500GMC]

Might get out the DVM and do some continuity checks comparing the two relays.

Still vaguely resembles a ground issue too.

I know new/spare ECMs don't grow on trees but that might be worth a try.

Your 'static vibration test' is sometimes referred to as a 'technical tap' around my garage..

 

[WarWagon]

I ohm'd out the relays and the fuel pump working with the new ones indicate they do work.

All I can figure is low voltage not pulling them in, yet, the old one working has me scratching my head.

 

[THEFERMANATOR]

I fought one like this before, and it ended up being the ground where it hooks up to the trans was dirty. If you think GM used some screwy ground set-ups, step back and follow the KIA's ground system.