That's weird... CIS issue

For the first time this calendar year, my 85 QV is back on her wheels, recovering from a engine-out 30K service-plus-whatever-else-was-convenient-to-do-while-I-was-in-there. Mechanically, everything is back together, and fluids are topped-off, but I haven't not yet attempted to start the engine. For the second time this week, I turned the key to test the electrical system (lights, stereo, and such)--this time, something weird happened: the CIS system powered up. I heard the frequency valve buzzing and the fuel pump pressurizing. Those shouldn't come on until the ignition circuit is engaged--and it definitely didn't happen a few days ago when I first connected the battery and applied power. Since then, the only thing I did to the car was swap out a cracked thermostat housing. (A story for another day.)

As I recall correctly, there is a trick with BOSCH CIS systems where you deliberately trigger this condition (in order to prime the engine) by pulling the blue-green plug on the back of the injector manifold. The blue-green plug was still connected. I re-seated it, with no change. Also swapped out the fuel pump relay with known good spare. No fuses are blown. Strange. I will have to dig into my CIS book and troubleshoot more in the morning, but if any brilliant minds here have a suggestion...

 

Steve! Exactly the guy I was hoping would see my post! Thanks for the tips. I'm pretty sure I have BOSCH 101 in my spare box; I'll give that a shot in the morning. I'm betting that the problem lies further aft though. Didn't realize the safety/kill switch worked on the basis of zero-lift on the air metering plate, but that makes a lot of sense when I think about it. The plate looked good when I put the air filter and lid back on it today (after changing out the thermostat housing) but I didn't actually check it again for correct position and freedom of movement since installing it last weekend. It's possible I bumped it out of alignment while working on other things.

I'll let you know how it goes. This has been an interesting journey so far.

 

UPDATE: Easy fix. The air metering plate was ever so slightly gapped... a scrap of shop-towel caught on the rim. (Perils of having the part in a box for over 9 months.) That was enough to break the circuit so the pump relay did not get the "engine is off, don't turn the fuel pump" signal. So, assuming the motor was running, it powered the pump (and the frequency valve).

Alas, the now I have a different CIS problem. I think I will start a new thread on that one however...