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How is the top of the fuse box/relay panel removed?
The fuel pump fuse takes a lot of current (especially if you have an 044 fitted), the fuse contacts can overheat and make a poor contact. In mine the fuse actually melted, the contacts overheated and went slack so the pump wouldn’t run.
I cleaned the contacts in the fuse box, nipped them up a bit to be tight on the fuse again, then relayed the pump straight from the battery so the fuse box is only switching the relay, no problems since.
Thanks Newsh, that's exactly what I am doing now. When I bought the car there was a jumper direct to the fuel pump. I found an old alarm that was cutting the signal, the fuse had blown and the contacts are slightly melted! I seem to be getting somewhere now. Just need to replace the wires at the fuel pump end and wire in the relay and it should all work well. Removing the pins from the fuel tank connector is the latest headache!
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