| VOLVO
RELAYS and Related Parts W O R L D W I D E S H I P P I N G |
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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 years and miles longer than most other cars.
But
some of their CRITICAL
RELAYS are known for failing sometime after around 10 to 20
years of
service. I don't really know if 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 there are some relays that can be considered "wear items." If
one of these critical relays
fails away from home, it could be costly (high towing expenses, wild
mechanic's
diagnoses, etc.). |
|
Should You Carry a
Spare Fuel
Pump
Relay?: I had a 1990 740
Turbo a number of years ago. When it was close to 10
years old, it began to develop
intermittent stalling while driving, but it would eventually start
back up after a few minutes of rest. 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 commonly
prone to
failure. So I replaced the Fuel
Pump Relay (3523608), Radio 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. CAUTION Regarding
Potential COOLING FAN RELAY FIRES in late model 240s |
|
Here's
a Brickboard post
regarding a couple of Radio Suppression Relay replacements.... "I purchased a RADIO NOISE SUPPRESSION RELAY for my 87 740 Turbo wagon a couple of months ago, and thought I'd drop you a note to tell you that the car has been running great, I've been driving it every day for about the last month, with NO STARTING ISSUES!!! It was having intermittent starting issues, would be fine for a few days, then leave me stranded. I had replaced both fuel pumps and the fuel injection relay. It would start with a shot of starting fluid, then be okay for a few more days. I would have never thought that a radio noise relay would have an effect on my fuel injectors, but thanks to your site and all the information on it, I was steered in the right direction. You saved me from scrapping out a car that i truly enjoy to drive." C.W. "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 car is working fine now after three months of pulling my hair out, 2 tows and 8 trips to the mechanic. You're 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 "I had a great outcome with the C70 – I called my mechanic and asked him if he could replace the Fuel Pump Relay in the car. He said it could be a number of things, but I told him I wanted to start with that first since it was a cheaper resolution and after researching it on your site, I felt pretty sure that was the problem. Before, the car did the same thing when he tested it in the late day / HOT sun after sitting most of the day. Car started up and died after a minute as if it were out of gas. Then he changed the relay and I’m back up and running!! He charged me for his time and the relay – out the door for $100. I think he should have paid me for finding the problem out for him. (ha ha). Thanks again. Even though it was a C70 and not the other model Volvos – the answer was the same. I'll keep one of those in the glove compartment for sure! Your site helped a ton!! M.G. |
|
TESTING VOLVO
RELAYS Here is some
excellent
info on Volvo fuel pump
relays: |
| VOLVO
240 HEADLIGHT RELAYS Some 240s ('86-'93 only) are equipped with
2
different relays that control
the headlights (earlier 240s have only the one step relay).
 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 (or stepping) between low and high beams.
It's
controlled by the stalk on your steering column. It has been known to
fail when upwards of 10 to 20 years old, although some will last 30
years or longer without problems. FAILURE SYMPTOMS: You'll know it has failed if you can no longer switch between low and high beams (you can hear the audible 'click' if it's working). Also, if your headlights go OFF when in low or high beam mode (only low beams work or only high beams work), then it is most likely this relay. 2. Main Headlight Relay, '86-'93 240 only, Volvo PN 1324749 (or 1235013) (click here to see it), 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. In the '86-'87 240, it should be found behind the brake pedal area (see relay diagrams above). For the '88 or '89 to '93 240, it will be behind the center dash area, just below the accessory gauge locations (exact year of this change is not certain to me, but probably '88 or '89). This relay fails far less often than the above step relay. FAILURE SYMPTOMS: Headlights turn off on their own after a short time (and your fuses are good). Headlights may come back on after switching them off, then on again... or you might need to wait a while and try again (cooling off period). Or, headlights may not come on at all when the switch is turned, but your high beams will flash correctly when the steering column stalk is pulled back. |
FAILURE
OF VOLVO BULB FAILURE RELAYS The Bulb Failure
Relay is a device that alerts the driver of a failed low-beam
headlamp,
tail lamp or brake lamp by
sensing the balance of current draw between the left and right side
lighting circuits. When that dash light comes on, it means the
relay recognizes that one side is drawing more current that the
other. This usually means there is a bulb out, but occasionally,
it can be triggered by incorrect or mismatched bulbs, or even sometimes
when one side has a newer bulb than the other.The red relay pictured at left is PN 1362370, which fits the 1986-93 240, 1986 and later 740, 780, and 1991-94 940. Other variations for 200/700/900 Volvos include a yellow one, PN 1362278 (1978-85 240 and 740 through 1985), another yellow one, PN 3545704 (1988-90 760, 1991-94 940 SE and 960), and a blue one, PN 9128814 (same 1988-90 760, 1991-94 940 SE and 960). The failure of these relays is becoming more frequent in older Volvos. FAILURE SYMPTOMS: The symptoms of failure can be headlights or tailights (or often just one side) that will not work even after verifying that fuses, switches, headlight relays and wiring are all in good order. |
| 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 tap with a wrench. For best results, if possible, tap the pump when cranking the engine (while power is going to the pump). If the pump is bad, often the tap 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 fuel pump relay, this will NOT work as there will be no power going to your pump. If this is the case, you might try the below relay bypass "jump" trick to get power going to the pump. TESTING YOUR FUEL PUMP How to "JUMP" the fuel pump circuit at your 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 should definitely hear it humming), you either have a faulty fuel pump or faulty wiring to the pump (bad wiring is really common under an old 240, near the pump). 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. GETTING YOUR 240 HOME WITH A FUEL PUMP RELAY EMERGENCY If you find the above jump test makes your fuel pump run and you don't have a spare relay with you (or if your spare doesn't work either), here's a trick that will get you home. The simple trick of course is to jeep the jump wire (or paper clip) in place while driving. Your pump will run continuously. This won't hurt it as long as you have fuel in the tank. Keep in mind that when you turn off the car, your pump will continue running until you disconnect the jumper. Trying to secure a jumper wire (or paperclip) to the fuse panel is very difficult. There is another way. Find your fuel pump relay and unplug it. Look at the plug. There will be a RED wire going into one pin in the plug. That is the power from the battery. Also find the YELLOW/RED wires (usually two of them going into ONE pin). These go to the fuel pumps. Jumping or connecting these two pins in the plug will be the same as jumping the two fuses shown above and it will be much easier to stick a paperclip into the plug pins. 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 inside 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 out. 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 those 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. More
detailed info can be found at http://cleanflametrap.com/transferPump.htm.
Non-Turbo 240? - Remember to check the LH Fuse for corrosion On 1983 and later 240 non-turbos, the LH fuel injection system uses a 25 amp fuse located under your hood on the left side fender. It is not in any type of sealed fuse holder, so the elements will cause corrosion to invade the connector after a number of years. Often pulling out and re-inserting the fuse will cure this issue temporarily. For a long-term fix, clean the contacts with a wire brush, or even better, replace that fuse holder with a water-tight one, like the one found here: Volvo Harness Parts Page |
AVAILABLE RELAYS
These parts are available below if you need one. Some are requested fairly often, so I keep them in stock.
The other relays may be available, but I may have to order them. That can add about 2-3 days to an order.
 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). FUEL PUMP RELAY MOD CLICK HERE |
 3523608
Fuel Pump/Injection Relay. New
Relay, Original
Volvo (made by Stribel).Same as previous Volvo PN 1347603. Also known as a Fuel Pump Relay or Main Fuel System Relay. WHITE in color. Fits 240 DL/GL 85-93 all (LH-Jetronic), 740 85-92 all, 760 87 6-cyl (see green relay below for 760 88-90 6-cyl), 780 87-91 all (4 turbo and 6 cyl), 940 non-turbo 91-93, 940 Turbo 91-95 (see green relay below for 940 SE and 960 6-cyl 91-93). Location of most 700-900 relays: http://www.davebarton.com/pdf/700-900relaylocations.pdf >>WARNING: Some 760 and 900 models take the green relay or blue relay below.<< In
Stock After
adding to cart, please choose SHIPPING below (Click Here).
COOL FUEL PUMP RELAY MOD CLICK HERE |
 1362914
Fuel Injection Relay. GREEN with White base (LH-Jetronic), 760 1988-90 (6 cyl only), 960 6 cyl and 940SE 1991-93. Locations of most 700-900 relays (pdf): http://www.davebarton.com/pdf/700-900relaylocations.pdf NOTE: If you have a '93 or later 940/960 and this relay is not present, then the below blue relay may be your fuel pump relay. OUT
OF STOCK/NLA |
 9130270 Fuel
Pump Relay. Also PN's 9128124, 9162250, and latest is 9494787.Original Volvo part made by Hella. Usually BLUE with a white base. 1994-95 940 non-turbo. 1994 960 6-cylinder. This relay is not in the usual fuel pump relay location shown by diagrams I have listed above. Instead, it will usually be found in the front row, second from the right, in the fuse/relay board. If there is a second identical one to the right of it, that should be the high beam relay. Also designated as a Heater/Fog relay for 1993 and later 850. OUT OF STOCK/NLA through my sources, however any SPDT relay listed below (such asVolvo PN 1259926) can be substituted and will work perfectly. Dealer list: $20.00  |
 1323592 Noise
Suppression Relay. Also used
as a Cooling Fan Relay on some models, and some have TWO (one for noise
suppression and one for cooling fan). Fits '87-'92 700, '91-'95 940 & 940 Turbo. Also used as a cooling fan relay on many '88-'93 240s. Genuine Volvo part (made by Stribel). (The failure of this relay used as a Noise Suppression Relay will cause a No-Start or Intermittent Start condition) This relay is mounted under the hood, often at the right shock tower or near the coolant reservoir. For B230FT (turbo) engines this relay is often mounted near the left shock tower. On some models you will find TWO of these. In these cases one will function as a Noise Suppression Relay and the other a Cooling Fan Relay. They are interchangable and can even be swapped during an emergency if the radio suppression relay fails. If the Noise Suppression Relay starts going bad, you may get intermittent starting problems (and/or intermittant running) since the electrical pulse to the fuel injectors will be interrupted. If the engine turns over OK, but it won't fire, then this could be the problem. Locations of 700-900 relays (pdf): http://www.davebarton.com/pdf/700-900relaylocations.pdf I keep these in stock Dealer list: $55.00 Your Price: $42.00 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 of transmission bell housing behind cylinder head. In Stock $46.00 ea. |
Click on Photo for Larger Image After adding to cart, please choose SHIPPING below (Click Here).
|
 Volvo PN 1324749
(replacement for Volvo PN 1235893)Bosch PN 0332-015-006 (superceded from 0332-204-126) Also replacement for Volvo PN 1259925 (Bosch 0332-019-151) and Bosch 0332-015-012 headlight relays. New metal case relay, Original Volvo "K" relay. This relay is used in a number of different places in your Volvo. 1. Headlight relay for 740 1985-92, 780 1987-91, 940 1991-95 (2 used in this car). 2. Headlight relay (in dash or behind brake pedal) for 86-93 240 (1 is used). 3. Oxygen Sensor relay for 240 1977-81, 260 1980-81. 4. Power window relay, 240 1978-93, 260 1978-81. 5. Multi-purpose relay for 240 1975-93. Locations of 700-900 relays (pdf): http://www.davebarton.com/pdf/700-900relaylocations.pdf This relay is an SPST type (Single Pole, Single Throw) and you will see a diagram on it similar to this one here. This type relay will usually have 5 pins, with the center pin marked 87b (or sometimes just 87). With this type of relay, pins 87and 87b are both given power at the same time.  Limited supply -
1 in Stock $27.00
ea. or buy 2 or more for $22.00 ea. (limited offer while supply lasts)
|
 Volvo PN 1324749
(0332-15-006 Tyco)Compatible replacement for above metal case "K" Relay. Made by Tyco (formerly Bosch), same as Bosch PN 0332-015-006 (superceded from 0332-204-126) Replacement for Volvo PN 1235893, 1259925 (Bosch 0332-019-151 and 0332-015-012 headlight relays. This relay is used in a number of different places in your Volvo. 1. Headlight relay for 740 1985-92, 780 1987-91, 940 1991-95 (2 used in this car). 2. Headlight relay (in dash or behind brake pedal) for 86-93 240 (1 is used). 3. Oxygen Sensor relay for 240 1977-81, 260 1980-81. 4. Power window relay, 240 1978-93, 260 1978-81. 5. Multi-purpose relay for 240 1975-93. Locations of 700-900 relays (pdf): http://www.davebarton.com/pdf/700-900relaylocations.pdf This relay is an SPST type (Single Pole, Single Throw) and you will see a diagram stamped on the relay similar to this one. This type relay will usually have 5 pins, with the center pin marked 87b (or sometimes just 87). With this type of relay, pins 87and 87b are both given power at the same time. IN STOCK $12.00
ea. or buy 2 or more for $10.00 ea.
|
  Volvo
PN 1259926 (0332-209-151 Bosch)The metal case relay on the left in No Longer Available. The Bosch relay on the right is the permanent replacement, although now it is getting scarce. Bosch PN 0332-209-151, same as PN 0332-204-101, 0332-204-126. Suitable replacement for Volvo PN 1324492, 1259926, 1308806, 1504952 (Bosch 0332-209-158, 0332-204-102 and 0332-204-110) fuel injection and heater fan relay. Original Bosch relay. This relay is used in a number of different places in your Volvo. 1. Fuel injection/fuel pump relay for 1983-84 240 DL/GL (2 used for this application). 2. Central locking relay for 240/260 all years (2 used). 3. Central locking relay for all '84 and newer 740/760/780 (2 used). 4. Fuel Injection relay for 240/260 all years. 5. Lamda, ignition and oil level relay for 240/260. 6. Seat heater relay for 700 all years. 7. Miscellaneous relay in 900 series. Locations of 700-900 relays (pdf): http://www.davebarton.com/pdf/700-900relaylocations.pdf This relay is an SPDT type (Single Pole, Double Throw) and you will see a diagram stamped on the relay similar to this one. This type relay will always have 5 pins, with the center pin marked 87a. With this type of relay, pin 87a is given power when the relay is off and power is switched to pin 87 when relay is activated. Limited
Availability -- 1 in Stock $16.00
ea. or buy 2 or more for $16.00 ea. (limited supply, takes a few days
extra to get)
|
 Volvo
PN 1259926 (0332-204-101 Tyco)NEW Compatible replacement for above Bosch metal or plastic case relay. Made by Tyco (formerly Bosch), same as Bosch PN 0332-204-101, 0332-204-126, 0332-209-151 Suitable replacement for Volvo PN 1324492, 1259926, 1308806, 1504952 (Bosch 0332-209-158, 0332-204-102 and 0332-204-110) fuel injection and heater fan relay. 1. Fuel injection/fuel pump relay for 1983-84 240 DL/GL (2 used for this application). 2. Central locking relay for 240/260 all years (2 used). 3. Central locking relay for all '84 and newer 740/760/780 (2 used). 4. Fuel Injection relay for 240/260 all years. 5. Lamda, ignition and oil level relay for 240/260. 6. Seat heater relay for 700 all years. 7. Miscellaneous relay in 900 series. Locations of 700-900 relays (pdf): http://www.davebarton.com/pdf/700-900relaylocations.pdf This relay is an SPDT type (Single Pole, Double Throw) and you will see a diagram stamped on the relay similar to this one. This type relay will always have 5 pins, with the center pin marked 87a. With this type of relay, pin 87a is given power when relay is off and power is switched to pin 87 when relay is activated. IN STOCK
$12.00
ea. or buy 2 or more for $10.00 ea.
|
 5-Pin
Replacement RELAY SOCKET (Suitable
for all above 5-pin relays).Click here for tips on removing wire connector inserts from these sockets. IN STOCK $2.00
ea. or buy 2 or more for $1.50 ea.
|
|
 Volvo
PN 1362900 Headlight Relay. Found in relay locations A and E in diagrams for the 1988-90 760 and 1991-92 960/940SE. OUT OF STOCK/NLA |
OVERDRIVE RELAYS
 3523804
Overdrive Relay (White)Genuine VOLVO part, made in Germany by Hella Below models with AUTOMATIC transmission: 240 1985-1993, 240 Diesel 1985, 240 Turbo 1985, 740 1985-1992, 740 Diesel 1986, 740 GL 1989, 740 GLE 1989-1990, 740 Turbo 1985-1992, 760 1983-1987, 760 Diesel 1984-1985, 760 GLE 1988-1990, 760 Turbo 1984-1990, 780 1987-1991, 780 Turbo 1986-1990, 940 1991-1995, 940 Turbo 1991-1995. Locations of 700-900 relays (pdf): http://www.davebarton.com/pdf/700-900relaylocations.pdf One in Stock $69.00 ea. |
 1307793
Overdrive Relay (the ORANGE
one)Original Volvo part made by Hella. For 240 1981-1984 with AUTOMATIC transmission Limited availability, please email.$XX.00 ea. |
| 1259750
Overdrive Relay (the BLUE
one) Original Volvo part made by Hella. 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.$XX.00 ea. |
| 3523805
Overdrive Relay (the RED
one) Original Volvo part made by Hella. For below models with MANUAL transmission 240 1985-1993, 240 Turbo 1985, 740 1985-1991, 740 GL 1989, 740 GLE 1989-1990, 740 Turbo 1985-1991, 760 1985-1986, 760 GLE 1988, 760 Turbo 1985-1990. Currently Unavailable$XX.00 ea. |
|
3545803 Fuel Injection Relay
After adding to cart, please choose SHIPPING below (Click Here). |
9434225 Fuel PUMP Relay
After adding to cart, please choose SHIPPING below (Click Here). |
1363449 Air Conditioning Relay
Available spec order only $25.00 ea. After adding to cart, please choose SHIPPING below (Click here). |
9442468 Turn Signal Flasher Relay
9442933 Cooling Fan Relay (2 speed), for 740 92 and newer, 940/960 92 and newer, 850 all. Also used for the air pump relay on a number of late model Volvos. Genuine Volvo part (made by Stribel) Old PN 3523872 OUT OF STOCK / Not Available $65.00 ea. After adding to cart, please choose SHIPPING below (Click here). |
|
240 Headlight Step Relay:
Installation
info - EARLY versus LATE types.
This is a Specific Problem & Solution for 1990-93 240 Volvo 240s remained about as consistent as any car could be for their 18 year production. One change in the headlamp relay has been discovered and this small article will explain the solution.
|
Here is how the wire colors go for the headlight relay sockets. | NEED FASTER SHIPPING? USPS Express Mail is now available for faster shipping in the USA. It will arrive in ONE DAY for most US locations. For International Express Mail, please email Dave. |
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Please remember that if your order becomes LOST in the mail, I will not be responsible to send you another order for free.
It is VERY rare that a mail loss occurs with my orders (less than 1%), but the possibility exists.
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