No start issue! Please help. 1992 240 wagon

benhogan · Post by **benhogan** » 26 Oct 2009, 07:55

I just picked up a 92 240 wagon for $150 non-running.

I tried to bring it back to life today with no success.
Here's what I know:
-there's good gas in the car
-there's spark from the coil to the distributor to the plugs
-the air filter is not clogged

I opened the gas cap and tried to listen to the pump (car on "on"). No sound.

So as of right now, I am thinking it might be the fuel pump.

According to the Haynes manual, the fuel pump is attached to the block? According to the parts stores online, the fuel pump is in the tank. I believe it is in the tank.

I would like to check the pump relay first. Can anyone tell me where the fuel pump relay is? I have another 240 I can borrow the relay from to check this.

Lastly, if switching the relay does not work, is there another way to isolate the problem? Please help. All suggestions are welcome.

Post by **billofdurham** » 26 Oct 2009, 13:28

Welcome to Matthew's Volvo Site.

This shows most of the relays on the '92 240. If the 'donor' car is an earlier model the fuel pump relay may be elsewhere.

'92 240 relays.pdf: (808.04 KiB) Downloaded 173 times

You have two fuel pumps, one in the tank which is a primer pump for the main pump which is in a cradle underneath the car in the area of the right hand rear door. The in-tank pump should be audible when you take off the fuel cap, but it is momentary if the engine isn't running. The best way to hear either pump is to have an assistant turn on the ignition whilst you are in a position to listen. Fuse #4 ,8 amps, covers the in-tank pump and fuse #6, 16 amps, covers the main pump.

According to the Haynes manual, the fuel pump is attached to the block?

That was the location for the earlier engines when the pump was mechanically operated.

Try switching the relay, which is a common problem, and if that doesn't work post back for more.

Bill.

benhogan · Post by **benhogan** » 27 Oct 2009, 06:07

Bill,

The donor car is a 91 240 wagon. Could you tell me the location of the fuel pump relay? Thanks!

Ben

Post by **billofdurham** » 27 Oct 2009, 10:55

It is in the same place as the '92. The relay was moved to this position after the 1988 model.

Bill.

benhogan · Post by **benhogan** » 27 Oct 2009, 11:15

billofdurham wrote:It is in the same place as the '92. The relay was moved to this position after the 1988 model.

Bill.

bill,
from the diagram, looks like the fuel pump relay is located in the same place as the shift indicator control unit.

can you tell me which one to pull or is it labeled somehow? i really appreciate your help by the way. the car should be running soon with all your help.

ben

Post by **billofdurham** » 27 Oct 2009, 12:10

Going from a decidedly dodgy memory the fuel pump relay is to the left of the shift indicator relay.

Bill.

benhogan · Post by **benhogan** » 28 Oct 2009, 06:04

Bill,
The location of the fuel pump relay was on the passenger side. It must be different for the US models somehow.

I switched the 'known good' relay into the 'no start' car. It still did not start. I did not have time to check the fuse.

If the fuses turn out OK everything is pointing to the actual fuel pump.

Any chance you have the procedure for changing the fuel pumps (both).

There is no humming sound coming from inside the fuel tank. I will change that pump first, if that does not help, I will change the one under the car.

Help!

Post by **billofdurham** » 28 Oct 2009, 13:22

The information I was working from was for the US models. The fuel system relay is listed as being behind the right side of the dash but the fuel pump relay is as the illustration. This is supposed to be from an official Volvo publication but I have found several errors and this may be another.

The in-tank pump is fairly easy to do as you can access it through an inspection hole in the floor in the luggage compartment.

Disconnect the battery negative lead, after making sure you have the radio code.
Remove the inspection cover to expose the top of the pump/sender unit.
Disconnect the wires.
Disconnect the rubber pipes. If these look as though they need renewing they are a non-standard 1/2". Most parts shops only stock 3/8" pipe.
The large knurled nut will come loose by gentle tapping. Use a piece of wood against the nut and tap that with a small hammer. Once it starts to move it can be turned by hand.
Lift the pump/sender unit out carefully. You will find that you will have to tilt it as there is an obstruction in the tank which stops it coming straight out.
Replacement is, as they say, a reverse of removal. Again, be wary of the obstruction. Use a new rubber sealing ring under the top of the unit. When re-tightening the knurled nut don't over-tighten as it will distort. Hand tight and a little more is sufficient.

The main pump is in a cradle under the car along with the main filter. The cradle is held on by 3 x 13mm bolts. Drop the cradle to make things easier. Normally before removing the pipes you would release the fuel pressure but, as the engine hasn't been running, this should be negligible. You may still have some fuel seepage when you remove the pipes. Again, the rubber pipes are 1/2".

If you remove the in-tank pump, bench test it to see if it works. If it does, replace the sock filter before putting the pump back in the tank. This was a service item at one time but Volvo took it off the list. If it disintegrates it will cause all sorts of problems.

NOt much else to say except good luck.

Bill.

johnny volvo · Post by **johnny volvo** » 05 Nov 2009, 00:35

Hi. I own a 1989 240DL and recently went through hell with a similar starting problem. The car would crank and crank until the battery died, but never fire. I replaced the coil and the wire and the fuel pump relay and the engine control module. It also had a new battery and new alternator. But, the problem continued. That's when I found the culprit. There is a fuse-holder on the fire wall, just to the rear of the battery. There may be a few relays there as well. The fuse was fine, but the fuse holder was the problem. I removed the fuse, cleaned it, added some bulb grease and made sure the blades were making contact. The car started right up and ran fine.

Good luck!