1990 240 fuel relay no start Topic is solved

kylelarsen143 · Post by **kylelarsen143** » 30 Jan 2023, 11:12

Hello,

I am a novice Volvo owner trying to uncover a gremlin in my wagon. I have had a recurring issue with my relay not feeding my fuel pump from time to time. On occasion if I leave the key in position 2 for a while, it will eventually go brrr. After this happened a few times I stopped by Auto Zone and got a compatible cheapo spare, and when the issue came up again I swapped and had it running on the first crank. After dozens and dozens of normal starts the issue came up again on the replacement, so I swapped to the original and lo and behold, fuel pump is active and feeding normally. At this point last wednesday i decided to order a proper OEM stribel so that i could put this problem in my past. However while i was idling this morning after three normal starts, it died (thankfully in my driveway!). no start with either old relay, but i figured since i was due to receive my stribel this morning i would be fine. Unfortunately, that has turned out not to be the case, i am still in a no start after putting in the stribel.

Earlier in the week i also noticed my diagnostic computer threw the codes for ECT (has been replaced), knock sensor, and rich fuel at speed and idle (could smell gas at stop lights), although it was only idling rough while cold. i jumped the fuses at four and six, and i hear both pumps kick on (also they were recently replaced, very low mileage on them), but i couldn't get it to start while manually bypassing the relay which has worked in the past as a last resort. I have also checked the 25 amp fuse under the bonnet which had been moved to a safer spot to avoid corrosion and replaced less than a thousand miles ago, and it seems good as well. the fuse panel has been cleaned, and i tried swapping and readjusting the offending cermaic fuses just to make sure it wasn't something so basic.

Having gotten to the end of my rope, i am reaching out to the boundless enthusiasm and solomonic wisdom of our community here in search of a solution as i am in a tight bind, and thanking all of you knowledgeable volvo black belts in advance.

-kyle

Post by **June** » 30 Jan 2023, 11:18

Have you checked the ground for the relay? June

Post by **volvolugnut** » 30 Jan 2023, 11:25

These fuel pump relays (even Volvo OEM) are prone to bad solder connections internally. If you have any soldering skills at all, open the relay and reflow each of the solder joints. Just heat the joints with a soldering iron until the solder melts and reflows around the joint to restore electrical contact.
volvolugnut

kylelarsen143 · Post by **kylelarsen143** » 30 Jan 2023, 11:58

thanks for the quick reply. currently i am 800 miles from my garage (death in the family... when life rains stress it pours). the stribel was used by matthew at blkvlv as a tester a few times, i think it's good but i have no way to solder (or skills for that matter). there is a specialty volvo shop i could get it to that is willing to take look for me, but it would cost a fortune to tow because its 100 miles away. even if i cant crack this nut myself, i am wondering why feeding the rail by jumping the fuses didn't work as it has in the past. my procedure was to use a paper clip and connect the left sides of fuses 4 & 6 until there was a spark and i could hear the pump and then moving into position three from position two in the ignition. i try to be quick about it, as i assume there is a danger of flooding the engine with too much fuel. honestly i would be happy just to get it running one time to make my appointment with the shop.

kylelarsen143 · Post by **kylelarsen143** » 30 Jan 2023, 12:08

June I have not checked the ground, how would i go about that?

kylelarsen143 · Post by **kylelarsen143** » 30 Jan 2023, 16:23

update- still no juice through the FPR, so i threw caution to the wind and jumped the fuses so i could drive around the block. left it to idle a few times and had a stall on one. swapped relays after the stall, still nothing, and the relay was very very warm to the touch. any ideas?

Post by **June** » 30 Jan 2023, 17:25

You need a wiring schematic for the fuel pumps. Possibly follow/check wiring/grounds back to the computer. If this was a same Era Buick, the ECM would control the ground for the fuel pump relay. Then in case of failure the oil pressure sensor provides a backup circuit. I assume Volvo also uses the computer to control the ground to the fuel pump relay. Since these cars won't run when the relay dies, I assume no backup circuit exists. These cars are famous for ignition switch failure, especially if you have a heavy Keychain. June

Post by **volvolugnut** » 30 Jan 2023, 18:06

There used to be lots of Haynes paper manuals around for these 240 Volvos. Bentley printed a very good manual for 240s from 1983 to 1993. It included detailed electrical schematics.
volvolugnut

Post by **volvolugnut** » 30 Jan 2023, 18:13

There used to be lots of Haynes paper manuals around for these 240 Volvos. Bentley printed a very good manual for 240s from 1983 to 1993. It included detailed electrical schematics. It says ground for fuel pump relay is at left side of transmission tunnel next to gear shift. It is also the ground for headlight relay, horn, dash panel, radio and others.
volvolugnut

kylelarsen143 · Post by **kylelarsen143** » 30 Jan 2023, 19:15

thanks again, will give it a try in the morning light. sorry to ask such a basic question, but i have not done this procedure. does gaining access involve removing the square dash panel in order to peel back the upholstery where i will find the ground?