Very strange starting problems - 240 DL

johnny volvo · Post by **johnny volvo** » 08 Oct 2010, 16:12

Calling all Volvo gods and goddesses! This one is driving me crazy. It's on my 1989 240 DL

A few months ago, I began to experience very occasional, intermittent starting issues: The car wouldn't crank at all, just as if the starter was dead. After a few tries, it would fire right up and start just fine for weeks. Then, it happened just a bit more frequently. Always, though, once it initially started, I wouldn't have any further problems for the rest of the day or week.

As I should have, I tried to identify any kind of pattern to the problem, but there was none. It happened in different weather conditions. I tried to notice things like, if I wiggled the key a certain way or if I played with certain connections, but there isn't an identifiable pattern, except that I noticed that sometimes, only sometimes, there was a slight hesitation when I turned the key to the "start" position. A split second would pass before the starter would crank. The other pattern was that, if I let the car sit for a few minutes, it would invariably start. Sometimes it was five minutes, sometimes three, rarely longer than ten. Keep in mind, the car is cold in all circumstances.

Last week, the car started up and off I went to the laundry, washed my clothes and, an hour and a half later, loaded up the car and turned the key. Nothing. Tried and tried, but still nothing. I sat for fifteen minutes and tried again and still nothing. Finally, after 30 minutes, I walked a few blocks to the part store, bought a new starter and walked back to the car. I tried to start it again and got nothing. Then I tried again and it started right up.

I did identify that the connector bolt for the positive cable on the starter was loose; it wiggled slightly. I felt that that might account for the intermittent nature of the problem. The next day, with no little amount of difficulty, I replaced the starter with the new one. It has been starting fine since.

Until today.

I started the car four times within an hour with no trouble. Then, I turned the key, the engine cranked, but didn't fire for about ten seconds. Unusual. I made another stop, came out of the store, turned the key and it cranked and cranked, but didn't fire. I tried again, with the same result. I know that there is a fuse in the circuit that had given me a similar symptom before, so I removed and checked it and reinstalled it. I tried starting again, but again it cranked and cranked without firing. Then, I tried again, but this time and ever since, the car will not crank at all. There are several times when I could hear the solenoid click and the tow driver said he saw a little spark at the starter connection when I turned the key. Now the car will not crank at all.

So, keeping in mind that I'm unemployed and living on a shoe string and have to solve this pretty much on my own, I'm looking for expert advice. Is it likely that the intermittent malfunction is in the ignition switch itself. Is there a relay I should be looking at? (I replaced a relay about a year ago that fires the fuel pumps on cranking.) My battery is new and working great. I rechecked connections on the starter and they are good. And I hate to go through the arduous replacement of the starter only to find that I still have that intermittent problem. It occurs to me that, if there is a connection problem, it would be between the ignition key and stab connector on the starter that receives the start signal.

Has anyone been through this problem? Any help would be greatly appreciated. Thanks.

Retired MVS Contributor · Post by **Retired MVS Contributor** » 08 Oct 2010, 16:56

Does this car have an automatic transmission?...If so, this condition could be caused by the neutral safety switch...Have you tried wiggling the shift lever while turning the key to start?...

If it is not the neutral safety switch, or if the car is a stick shift, then the next most likely culprit is the ignition switch...

johnny volvo · Post by **johnny volvo** » 08 Oct 2010, 22:42

Yes, Jerry, it is an automatic and I have fiddled with the shift a number of times. Tried starting in both park and neutral, but it never seemed to make the difference. From your reply, it seems like I should be looking at the ignition switch. Is there any way to test it before replacing?

Thanks for your help.

Retired MVS Contributor · Post by **Retired MVS Contributor** » 09 Oct 2010, 06:58

It could still be the neutral safety switch even if wiggling the lever does not start the car...

There are two wires on the starter solenoid, one is the heavy battery cable and the other is the small (push-on connector) one coming from the neutral safety sw'itch...Connect the positve lead from your voltmeter to this small wire and the voltmeter negative lead to engine ground...Turn the ignition key to "start" and you should see 12 volts...If you do see 12 volts, then the starter solenoid is bad...If you do not, then it is either the neutral safety switch or the ignition switch...

johnny volvo · Post by **johnny volvo** » 10 Oct 2010, 07:59

Jerry -

Thanks so much for your advice. I held onto the gearshift while turning the key and, sure enough, it started. The culprit is the neutral switch!

Now, if I may ask you to indulge me just a bit more: Is the neutral switch something that can be adjusted, or must it be replaced? Also, my manual shows the use of a special wrench to remove the switch. Is this something that is available in most good auto part stores? Any other advice or cautions about adjusting or replacing, please let me know at your leisure.

Again, many thanks for talking me through this.

Retired MVS Contributor · Post by **Retired MVS Contributor** » 10 Oct 2010, 12:36

It is MANY years since I changed a neutral safety switch in a 240 so I am working from a rapidly fading memory...

As I remember, you disconnect the wire to the neutral safety switch and connect an ohmeter between the neutral safety switch terminal and ground...With the transmission in neutral (engine not running, of course) you screw the switch in until the meter reads, then go 1/2 turn more...Then lock the nut...I don't remember a special tool, it seems to me it was just an ordinary open end wrench, but it had to be very thin so it would fit in between the switch case and the transmission...LIke an old fashioned tappet wrench...

Retired MVS Contributor · Post by **Retired MVS Contributor** » 10 Oct 2010, 12:48

I just went back and re-read your original post...The neutral safety switch would cause the no-crank condition, but it would not cause the cranking without firing up...It looks like you have more than one problem...

The cranking but failing to fire might be caused by a corroded fuel injection fuse...The fuel injection fuse in not in the door-post fuse panel, it is under the hood on the inside of the left fender, just behind the battery next to a couple of relays...It is a blade type fuse and becomes corroded...Removing it and cleaning it (and the inside of the connector) often clears up these "crank-but-no-start" problems...If it is too far gone, IPD sells replacement fuse holders...

Retired MVS Contributor · Post by **Retired MVS Contributor** » 10 Oct 2010, 15:05

I gave you wrong info...I'm getting on (80) and my memory was not for the neutral safety switch, I beleive it was for the overdrive solenoid...When you mentioned a special tool, I was thrown...

It bothered me and I dug out some old books, etc...The neutral safety switch in your car is in the center console on the left side of the shift lever...It is also the back-up light switch...It is a triangular shaped affair...I never had to adjust one of those and I don't know if it IS adjustable...I would expect so, but I don't know...

iaguilera · Post by **iaguilera** » 14 Sep 2022, 10:17

good day all, I am hoping someone may have an answer to my issue.
my son's 91 240, just recently started with a very strange issue, it starts just fine, but here is the kicker, once running seldomly it wants to start all over again briefly, now I have replaced the starter (NOT OEM) and have replaced the ignition switch with an IPD Volvo OEM, I hope someone may have an answer or point me in the direction to start.

imperialist69 · Post by **imperialist69** » 17 Nov 2022, 14:02

I just found this post and was curious. Did you ever fix your no start problem? And if you did, could you please post a response for future readers. As I'm not new on posting advice, I AM new on the ins and outs of the Volvo 240. But, in the short time I have been here ( 2 days), I have already noticed that these Beasts are rather simple in repair problems and getting back on the road. So, I have always found that whenever I post a problem on ANY forum, it is appropriate to always follow up on the final outcome as the poster. So, I would genuinely like to know how you solved your no start problem. Thank you, Bob S.