| VOLVO
RELAYS |
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FUEL INJECTION, FUEL PUMP,
OVERDRIVE
& OTHER
RELAYS
and CRANK POSITION SENSORS
| Volvo 240s and 740s
are well known for their reliability
and for going many miles longer than most other cars. But
many of their RELAYS
(Fuel Pump Relays, Radio Suppression Relays, etc)
are
widely known for failing sometime after around ten or more years of
service. I don't really think these relays were built that
poorly.... I think it might be the cars are so well
built, they simply outlast some of their electronic components. So, at least for Volvos, it appears these relays can be considered "wear items." If
one of these relays
fails away from home, it could be costly (high towing expenses, wild
mechanic's
diagnoses, etc.). |
|
Spare Fuel Pump
Relay: I have experienced a fuel
pump
relay failure
in FOUR of my Volvos over the
years (240s and 740s). After one particularly stupid $200
tow bill, I made it a point to replace the original Fuel
Pump
Relays in my older Volvos with NEW ones, and
I carry
a used old one as a spare in my glovebox just in case. If
you
have older or
original relays (10 years and up) in your Volvos, or
if you are experiencing
intermittent or temperature related fuel or electrical issues, maybe
it's time
for a replacement
before it leaves you stranded. I had a 1990 740
Turbo a number of years ago. When it was close to 8 or 10
years old, it began developing
intermittent stalling, but would eventually start
back up after a few minutes. After it
happened to my wife twice, she refused to drive the car. I
could not re-create it when searching or testing.
I figured it had to be
a relay or crank sensor, and THIS CAR HAS TWO RELAYS that are prone to
failure. So I replaced the Fuel
Pump Relay (3523608), Noise Suppression Relay (1323592) and Crank
Position Sensor (3547847), all at once. Sure enough, one
of those was the problem and the car was good after that.
Because this is so common in Volvos, I keep all
three of these items in stock here just in case any of you need
them. They fit '88 to '93
240's (except the 240 uses the 1323592 as the cooling fan
relay), '88 to '92 740's
and most '91 to
'95 940's. CAUTION Regarding
VOLVO COOLING FAN RELAY FIRES in late model 240s |
|
Here's
a Brickboard post
regarding a couple of Radio Suppression Relay replacements.... "Dave, thanks for posting this information on how relays can interfere with ignition. I had a gradually worsening stalling problem over the past year and a half. The mechanics could not trace it, since the stalling was never associated with a "check engine" light (good mechanics but not Volvo specialists). The symptoms usually were a failure to restart after a short stop, but it eventually worsened to stalling in traffic. I guess the engine heat would cause a bad solder joint to open up and block spark to the engine. I replaced the various relays you mentioned and I have not had any stalling since then. I wonder if a Volvo specialist would have diagnosed the problem earlier? In this case I took your suggestion to the mechanic, and he admitted it would not have occurred to him. Definitely bookmarking your site for future reference!" M.L. "Hi Dave. Well probably no surprise to you....the cars working fine now after three months of pulling my hair out, 2 tows and 8 trips to the mechanic. Your right...too few know of this fix... I'm mechanically inclined, yet can't believe I solved this one with your help with relays from Hungary... of all places...amazing. The car currently has 145K and is a honey. Your the best." B.L., Martha's Vineyard, MA "Hey Dave, Thank you so much. Your hypothesis that failing relays causing intermittent problems was spot on! I replaced the Overdrive Relay and it instantly fixed my phantom shifting/not shifting overdrive problems also, the car seems to auto shift at the appropriate times and RPM's more precisely, the way I remember it did. Then I replaced the Fuel Injection Relay and the intermittent stalls have disappeared - a major boost of confidence before Holiday travels! Holding off on the Noise Suppression Relay and Crank sensor for now because it's running so well! I did a lot of web crawling before I found your site and can confirm there are lots of 740 owners with the same issues - most seem to spend a bunch on Fuel Pumps and Mass Air Sensors and just about everything else, often without success. I'd encourage you to post on the various boards out there regarding Intermittent Stalling and Overdrive issues... $80 for the two relays I installed in a couple of minutes and a now in a world of Volvo goodness!" E.S., Blue Lake, CA |
|
TESTING VOLVO
RELAYS Here is some
excellent
info on Volvo fuel pump
relays: |
| VOLVO
240 HEADLIGHT RELAYS Some 240s ('86-'93) are equipped with 2 different relays that control the headlights. 1. High/Low Beam Step Relay, all year 240s, Volvo PN 1307991 (click here). This is the best known headlight relay, because it sits under the hood in plain sight. There are two versions of this relay. Click here to see this info. This relay controls the switching between low and high beams. It's controlled by the stalk on your steering column. It is known for failing when upwards of 10 to 20 years old. You'll know it has failed if you can no longer switch between low and high beams (you can hear the audible 'click'), or your headlights go OFF when in low or high beam. 2. Main Headlight Relay, '86-'93 240s, Volvo PN 1324749 (or 1235013) (click here), Bosch PN 0332015001, 0332015011, 0332015012, 0332015016. This relay is more of a mystery to many 240 owners, because it's tucked away out of sight, under the dash, behind the brake pedal area (for '86-'87, see relay diagrams above) or for later 240s up to '93, it will be behind the center dash, just below the accessory gauge locations (exact year of this change is unknown to me so far). This relay fails less often than the above step relay. The symptoms of a main relay failure are a bit different also. Symptoms may include the following: Headlights turn off on their own after a short time and your fuses are good. They may come back on after switching them off, then on again... or you might need to wait a while and try again. Headlights may not come on at all when switch is turned, but will come on in high beam when steering column stalk is pulled back. |
| COULD IT BE
SOMETHING OTHER THAN A RELAY? What about Volvo fuel pumps? The main fuel pump in a Volvo is really well built and rarely fails (Bosch simply makes great fuel pumps). A good survival trick if you think a main fuel pump might be bad... give it a quick rap with a wrench when cranking the engine (when power is going to the pump). If the pump is bad, often the jolt will make it come to life and it may stay running until you shut it off. This trick can get you back on the road and get you home in an emergency. If it's a bad relay, this will NOT work. TESTING YOUR FUEL PUMP How to "JUMP" the fuel pump at a Volvo 240 fuse panel: The fastest method to make the main fuel pump run (bypassing the Fuel Pump Relay) is by jumping two circuits at the fuse panel (left side driver's kick panel). ![]() You can make a jumper from a wire with stripped ends or even a straightened paperclip. Jump the circuits on the right side of the fuses for best results (see photo). For a 1979-84 240, jump fuse circuit #5 to #7. For a 1985-93 240, jump fuse circuit #4 to #6. If the main fuel pump doesn't begin running when jumped (you will definitely hear it if it does), you either have a faulty fuel pump or faulty wiring to the pump (bad wiring is really common). This test of course assumes your battery is good. If one of the fuses blows during this test, the pump circuit wiring is shorting to ground somewhere between the fuse panel and the pump. More detailed info can be found at http://cleanflametrap.com/transferPump.htm. IN-TANK PUMP (PRE-PUMP) ISSUES Applies to all 240/260 and many 700 models ![]() This
is a VERY common problem in Volvos reaching the age of 15 years
and
older. Often the actual in-tank pump is NOT broken, but the RUBBER FUEL HOSE
that goes from
the pre-pump to the metal feed tube in the tank decomposes and falls
apart after many years
of being submerged in fuel. When this hose ruptures, the in-tank
pump can no longer push fuel. The main pump under the car will try to
make up the
difference, but it can't keep up, especially when your tank is half
full or less, when your fuel level is at or below that
hose rupture. A
GOOD TEST: If the symptoms go away after filling the tank up,
then this
is your problem. Opening the top of the tank (in the trunk or cargo
area)
and replacing that small hose is the
cure. A simple piece of 5/16 inch fuel
injection hose about 3
inches long works fine. And replace the cheesy hose clamps
with
nice new ones while you're at it. You
might be shocked to find out how many people have been advised by
service technicians
that they need new fuel pumps when only a short piece of fuel
injection hose was needed.
|
3523639 Fuel Injection Relay. Also known as a Fuel Pump Relay. GREEN (K-Jetronic), 240 DL 78-82 w/K-Jet, 240 Turbo 81-85, 260 78-82, 760 (non-turbo, V6) 83-86. Limited availability. Special order. $0.00 please email for price. After adding to cart, please choose SHIPPING below (Click Here). |
3523608 Fuel Injection Relay. New
Relay, Original
Volvo (made by Stribel).Also known as a Fuel Pump Relay. WHITE in color (LH-Jetronic), Fits 240 DL/GL 85-93 all, 740 85-92 all, 760 87 only, 780 87-91 all (4 and 6 cyl), 940/940 Turbo 91-95. Location of 700-900 relays: http://www.brickboard.com/FAQ/700-900/ElectricalCircuitsRelays.htm#RelayLocations PAY ATTENTION: Some 760 and 900 models take the green relay below. I keep
these in stock After
adding to cart, please choose SHIPPING below (Click Here).
|
1362914 Fuel Injection Relay. GREEN with White base (LH-Jetronic), 760 88-90 (6 cyl), 960/940SE 91-93. Location of 700-900 relays: http://www.brickboard.com/FAQ/700-900/ElectricalCircuitsRelays.htm#RelayLocations One in stock After
adding to cart, please choose SHIPPING below (Click Here).
|
Fits '88-'93 240, '88-'92 700, '91-'95 940 & 940 Turbo. Genuine Volvo part (made by Stribel). (The failure of this relay will cause a No-Start condition) This relay is likely mounted under the hood at the right shock tower or near the coolant reservoir. For B230FT (turbo) engines this relay is likely mounted near the left shock tower. On some models you will find TWO of these. In these cases they function as a Radio Suppression Relay and a Cooling Fan Relay. They are interchangable and can even be swapped during an emergency if one fails. If the Radio Suppression Relay starts going bad, you may get intermittent starting problems (and/or intermittant running) since the electrical pulse to the injectors will be interrupted. If the engine turns over OK, but it won't fire, then this could be the problem. Follow this link for a good discussion on these relays: http://www.brickboard.com/RWD/?id=732937 I keep these in stock Dealer list: $55.00 Your Price: $38.00 ea. |
3547847 Crank Position Sensor. AKA: Crank Impulse Sender, Engine Speed Sensor. OEM manufacturer Bougicord. For 240 1989-93, 700 non-turbo 1989-92, 700 Turbo 1990-92, 900 ALL w/4cylinder. Located near top passenger side of transmission bell housing behind engine. In Stock $46.00 ea. |
1307793
Overdrive Relay (the ORANGE
one)For 240 1981-1984 with AUTOMATIC transmission Limited availability, please email.$XX.00 ea. Order Quantity: After adding to cart, please choose SHIPPING below (Click Here). |
1259750
Overdrive Relay (the BLUE
one)For below models with MANUAL transmission 240 1981-1984, 240 Diesel 1981-1984, 240 Turbo 1981-1984, 260 1981-1982, 260 Diesel 1981, 760 1984. Limited availability, please email.$XX.00 ea. Order Quantity: After adding to cart, please choose SHIPPING below (Click Here). |
3523805
Overdrive Relay (the RED
one)For below models with MANUAL transmission 240 1985-1993, 240 Turbo 1985, 740 1985-1991, 740 GL 1989, 740 GLE 1989-1990, 740 Turbo 1985-1991, 760 1985-1986, 760 GLE 1988, 760 Turbo 1985-1990. Limited availability, please email.$XX.00 ea. Order Quantity: After adding to cart, please choose SHIPPING below (Click Here). |
Order Quantity: After adding to cart, please choose SHIPPING below (Click Here). |
After adding to cart, please choose SHIPPING below (Click Here). |
After adding to cart, please choose SHIPPING below (Click Here). |
Available spec order only $25.00 ea. After adding to cart, please choose SHIPPING below (Click here). |
9442933 Cooling Fan Relay (2 speed), for 740 92 and newer, 940/960 92 and newer, 850 all. Genuine Volvo part (made by Stribel) Old PN 3523872 ONE In Stock $55.00 ea. After adding to cart, please choose SHIPPING below (Click here). |
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