Join Date: Aug 2003
Location: Sterling Heights Michigan
Hi Kevin first of all let me apologize for the late reply to your prompt response.
My name is Pete Castiglione, I purchased my first alfa in 1973 when I was only 19 years old, a 1969 GTV 1750 and I still own that car.
I have also owned a 1976 Alfetta GT, and a 1987 Milano, Iím down to only the 69GTV a 1979 Alfetta Sport Sedan and the 1989 Milano Verde.
June of 2014, with the Verde having only 27826 miles I detected a small amount of play and noise from the water pump and decided to replace the water pump, timing belt and the hydraulic tensioner with the fixed Zat tensioner. While doing all of that work I decided to paint the valve covers, plenum chamber and little bit of detailing while I was at it.
A new job coupled with long work hours, I did not finish the car until this year in April.
At the first start attempt the car didnít start because I had forgotten to connect the harness on the side of the distributor, once connected the car started and ran until reaching operating temperature than I realized that I had forgotten to hook up the wires to the radiator fan temperature sensor, I shut the car off, connected the radiator sensor wires and tried to restart and that is when the start and stall symptoms surfaced.
The only modification to the car are as follows:
1. Complete SS exhaust system including removal of cat conv. and oxygen sensor
2. Modified relay per Fred di Matteo to have cooling fan come on after driving and parking car.
3. Added starter relay based on your excellent write up on this subject.
The above modifications where done and the car ran more than one year prior to this start/stall condition
My troubleshooting went as follows:
When the car didn't start, I decided to remove all old gas (drained tank completely) and replaced the gas with 5 gallons of fresh premium gas and a new gas filter.
Still no start, checked fuel pressure using a borrowed gage from O'Reilly Auto Parts, which read ď0Ē pressure so I decided to replace the fuel pump, still no start with new Bosch pump. I became suspicious of the fuel pressure gage and tried the fuel pressure gage on a working car only to discover that the gage was not working, ok so I have a new fuel pump and a new fuel filter. Now Iím getting impatient and focused on the combi relay, purchased a new one installed it and still start and stall.
Red all of Gordon troubleshooting guide (maybe should have done that first), purchased silicon hose kit from him (not all installed yet) still start and stalling condition. Have checked and verified resistance on all sensors, all within specs.
Checked all grounds and all seem good, purchased an additional dual relay in case I got a bad one and a DOA on the first one, still start and stall. Cleaned all connectors with contact cleaner DeoxIT D5 from Radio Shack, still a start and stall condition. Ignition switch checked and working as designed.
The one strange puzzle is that throughout the starting and stalling routine after turning the key off and removing the key, the fuel pump remains on forcing me to remove the fuel pump fuse in order to turn the pump off. Once the fuel pump fuse is replaced the pump does not run but will remain running after another start attempt.
When the key is removed nothing else seems to be running. The car starts immediately because the cold start injector checks ok and seems to work as it should, but the car does not stay running.
I have not checked if the injectors are getting firing signals, I have yet to try running the pump directly from the battery and verify fuel pressure. What can cause the pump to stay on after a non start condition?
Any suggestions would be appreciated.