Web www.davebarton.com

Volvo 240's and 740's are well known for reliability and 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 after around ten or more years of service.  I prefer to see it this way... the cars are so well built, they simply outlast some of the electronic gizmos they came with.  So, at least for these cars, a relay is a wear item. 

If one of these relays fails away from home, it could be costly (towing expenses, wild mechanic's diagnosis, etc.).  Even though it's a VERY common failure after a number of years and widely known by anyone who works on these cars professionally, I have seen MANY mechanics insist the car needs a new fuel pump, fuel injection computer, or other expensive parts, when in the end it is ONLY A SIMPLE INEXPENSIVE RELAY. 

The main fuel pump in a Volvo is really well built and rarely fails (Bosch makes great fuel pumps).  A good survival trick if you think a Bosch main fuel pump might have failed... give it a quick rap with a heavy wrench, preferably when cranking the engine.  If it's a bad fuel pump, 95% of the time it'll come to life and keep running to get you home.  If it's a bad relay, you might be stuck.

I have had a fuel pump relay failure in FOUR of my Volvos over the years (240's and 740's).  After one $200 tow bill,  I have since replaced the original Fuel Pump Relays in any of my older Volvos with NEW ones, and I carry the old one as a spare in my glovebox just in case.  If you have older or original relays (10 years and up) in your Volvo or 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.  It was my wife's car.  It began developing intermittent stalling, but would eventually start back up after a few minutes.  It only happened a few times and I could not re-create it when searching for the problem or testing.  After it happened twice, she refused to drive the car.  I knew it had to be a relay or crank sensor, and THIS CAR HAS TWO RELAYS that are prone to failure.  I replaced the Fuel Pump Relay (3523608), Noise Suppression Relay (1323592) and Crank Position Sensor (3547847), all at once.  Sure enough, one of them was it and the car never again had a problem.   For this reason, I keep all three of these in stock just in case anyone needs them.  They fit '88 to '93 240's and '88 to '92 740's and '91 to '95 940's.

I have received a lot of emails over the years asking how to test these relays. The only test I know for relays is swapping with another (try a used one if you have it).  As for the Crank Position Sensor (240's: '89 to '93, 740's: '89 to '92, 940's: all 4-cylinder models), I hear of them going out often enough in later 240/740 models that I would consider just changing it if you even suspect it's original.  It will be MUCH HARDER TO CHANGE if it fails on some back-country road.  I don't know how they are tested or what to expect if one is tested.  The Crank Position Sensor may also be known as an Engine Speed Sensor or Crank Impulse Sender. 
Here is a good Brickboard post on these sensors http://www.brickboard.com/RWD/index.htm?id=807903

Here is some excellent info on Volvo fuel pump relays:
http://brickboard.com/FAQ/700-900/ElectricalCircuitsRelays.htm#Hot_Fuel_Pump_Relay

3523639  New Relay, TK (aftermarket, Made in Germany),
Fuel Pump, GREEN (K-Jetronic), 
240 DL 78-82 w/K-Jet,
240 Turbo 81-85,
260 78-82,
760 (non-turbo, V6) 83-86.
  ONE In Stock                    
  $45.00 ea.  

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   3523608  New Relay, Original Volvo (Stribel),
  WHITE (LH-Jetronic Fuel Injection),
  240 DL/GL 85-93 all,
  740 85-92 all, 
  760 87-90,
  780 87-91,
  940 91-94.
  Location of 700-900 relays: http://www.brickboard.com/FAQ/700-900/ElectricalCircuitsRelays.htm#RelayLocations

  I keep these in stock
  $38.00 ea.

1323592 Radio (Noise) Suppression Relay
Also used as Cooling Fan Relay on some.
'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.
This Radio Suppression Relay and the Cooling Fan Relay used in the same year are
interchangable and can even be swapped during an emergency.  If the Radio Suppression
Relay starts going bad, you will likely 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: $36.00 ea.

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3545803 Fuel Injection Relay

for 850 '93-'97,  850 GLT '95-'97, 850R '97,
850 T5 '97, 850 T5R '95. 
Original Volvo Part (made by Stribel). 
Available spec order only
$35.00 ea.

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9434225 Fuel PUMP Relay

for 850 '93-'97, 850 Turbo '94-'96,  850 GLT '97, 850R '96-'97,
850 T5 '97, 850 T5R '95, C70 '98-'04, S70 &V70 '98-'00.
Original Volvo Part (made by Stribel). 
Available spec order only
$55.00 ea.

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  1324749, AKA 0332-015-006  (superceded from 0332-204-126) 
  New Relay, Original Volvo (Bosch)  "K" relay. Fuel pump relay for
  '83-'84 240 DL/GL w/LH-Jet  (2 required for 240 fuel injection). 
  Also other applications in 240 and 740 series.
  Headlight relay for 240 '86-'93,  740 '85-'92, 780 '87-'91, 940 '91-95.
  Oxygen Sensor relay for 240 '77-'81, 260 '80-'81
  Available spec order only

  $25.00 ea.

0332-209-158    New Relay, Bosch,
  Fuel pump relay for
  '83-'84 240 DL/GL w/LH-Jet (2 required for 240 fuel injection).
  Also other applications in 240 and 740 series.
  Headlight relay for 240 '86-'93,  740 '85-'92, 780 '87-'91, 940 '91-95.
  Oxygen Sensor relay for 240 '77-'81, 260 '80-'81
   Less expensive substitute for above
   "K" relay.
   Available spec order only

     $15.00 ea.

1363449 Air Conditioning Relay

for 240/260 all '81-'93,
740/760 all '83 to '92,
780 all '86 to '91, Genuine Volvo part (made by Stribel). 
Available spec order only
$40.00 ea.

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9442468  Turn Signal Flasher Relay
Fits 240 DL, GL '85-93, 240 Turbo '81-84
260 '76-'82,  740 '85-92,  760 '84-'87,
760 GLE '88-'90, 760 Turbo '85-'90,  780 all,
850 '94, 940 '91-'95, 960 '92-'97.

$25.00 ea.

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for 740 92 & up, 940,960 92 & up, 850 all, 
Genuine Volvo part (made by Stribel). 
Old PN 3523872 superceded to 9442933.
Available spec order only
$55.00 ea.