2007 Phazer Fuel Pump Won't Prime + Code 81 Grip Heaters

[Mooseman]

Apart from what has already been discussed, check the ground block even though your 09 shouldn't be affected by the issues on the 07. Did you check if the pump works powering it directly from the battery? Check to see if the ECU is sending the signal (+ or -, can't remember which) to activate the pump relay. Are you also getting the same issues with the hand warmers? Do you have the updated red pump relay?

 

[Schicks]

Apart from what has already been discussed, check the ground block even though your 09 shouldn't be affected by the issues on the 07. Did you check if the pump works powering it directly from the battery? Check to see if the ECU is sending the signal (+ or -, can't remember which) to activate the pump relay. Are you also getting the same issues with the hand warmers? Do you have the updated red pump relay?

1. The fuel pump works when I connect it directly to the battery.
2. I unplugged the plug from the fuel pump and checked voltage there when I turn the key on. I measure 12.5 volts. This is a little weird because the battery measures 13.1 volts. So I'm losing about 0.6 volts through the system. Not sure if that is a big deal.
3. My sled is also throwing the code 81 for the hot grips when I turn the key on.
4. I'm not sure about the color of the fuel pump relay. I'll have to check that tonight. I purchased the sled new and have never changed it.

 

[Mooseman]

2. I unplugged the plug from the fuel pump and checked voltage there when I turn the key on. I measure 12.5 volts. This is a little weird because the battery measures 13.1 volts. So I'm losing about 0.6 volts through the system. Not sure if that is a big deal.

Could be a defective relay. What temperature are you trying to start it in? If it's below -15c, it could be the relay. A voltage drop could indicate a bad contact in the relay and it might not be able to handle an actual load. Try putting a headlight bulb on it and see if that voltage drops even more.

If you get to the fuel pump relay, try removing it and jumping the socket to see if the pump will work. I don't have the manual in front of me so I can't tell you which relay it is or the wire colours.

 

[Schicks]

Solved the issue. It was a ground issue in the grounding block near the fan. The ground wire coming into this plug had been arcing and had a lot of carbon build up. The plastic from the plug housing had even melted to the terminal.

 

[ZekeRydes]

Right on! Schicks, what did you do--replace that grounding block, or just pull everything apart, clean it, and put back together?