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FUEL INJECTION, FUEL PUMP
& OTHER
RELAYS
plus CRANK POSITION SENSORS
Volvo 240's and 740's
are well known for their reliability
and for 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 sometime after around ten or more years of
service. I don't really think 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 these relays can be considered "wear items."
If
one of these relays
fails away from home, it could be costly (high towing expenses, wild
mechanic's
diagnoses, etc.).
Even though these are VERY common
failures and widely known by anyone who works on
these cars
professionally, I have seen MANY mechanics insist a Volvo needs a new
fuel
pump, fuel injection computer, air mass meter or other expensive parts,
when in the
end it is discovered it was ONLY A SIMPLE INEXPENSIVE RELAY that you
can plug in yourself.
What about 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
Bosch main fuel pump might
have failed... Give it a quick rap with a heavy wrench, preferably when
cranking
the engine. If the pump is bad, often the jolt will make it come
to life and usualy it will keep running until you get 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. So I replaced the Fuel Pump Relay (3523608), 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. For this reason, I keep all three of these items in stock just in case any of you need them. They fit '88 to '93 240's and '88 to '92 740's and '91 to '95 940's.
Here's a Brickboard post
regarding a couple of Radio Suppression Relay replacements....
"I have had two cars
which had a problem with this relay. It is black,
usually on the passenger side by the anti-freeze expansion tank. The
part number is 1323592-1. My 740 had poor acceleration
and hard cold weather starting here in
Minnesota. The problem did not change with a L-engine out of a 1993 940
(non-turbo). Changing the relay made a huge
difference in both
acceleration and cold weather starting. The reason I put in an
L-engine
is because the old K-engine froze with a broken intake valve. I have
always wondered whether the relay, which supplies a ground to the fuel
injection, could have had high resistance contacts leading to the
injectors not injecting a rich enough mixture so the engine ran
lean? The second case of this relay going bad was fixed two
nights ago. My
1995 940 (non-turbo) with 69K
miles had poor acceleration and would
surge slightly while running steady. I thought the problem
could be related
to the years in storage even though I started it periodically and had a
full tank of gas with stabilizer. I changed the fuel filter,
cleaned the
IAC valve and throttle bottle, checked fuel pressure and volume, and I
could not
find anything wrong. Then I changed
the relay and again, it was like a
different car."
I have received a lot of
emails over the years asking how to test these
relays. Since I'm only an "amateur Volvo tech," the only test I know
for a relay is swapping it with another (try a used one if you have
one). 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 changing it
if you 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
These parts are available below if you need one. The first four items are requested fairly often, so I keep them in stock. The others relays are available, but I will have to order them. That adds about 2-3 days to an order.
 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. After adding to cart, please choose SHIPPING below (Click Here). |
 3523608 New Relay, Original
Volvo (made by Stribel), WHITE (LH-Jetronic Fuel Injection), Fits 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 After
adding to cart, please choose SHIPPING below (Click Here).
|
 1323592 Radio (Noise) Suppression Relay. Also used
as a Cooling Fan Relay on some. Fits '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: $38.00 ea. |
3547847 Crank Position Sensor. AKA: Crank Impulse Sender, Engine Speed Sensor OEM manufacturer Bougicord. For 240 89-93, 700 non-turbo 89-92, 700 Turbo 90-92, 900 ALL w/4cylinder. Located near top passenger side of transmission bell housing behind engine. ONE In Stock $46.00 ea. |
After adding to cart, please choose SHIPPING below (Click Here). |
9434225 Fuel PUMP Relay 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 Alternative for above "K" relay. Available spec order only $15.00
ea.
|
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. Genuine Volvo part (made by Stribel) Old PN 3523872 Available spec order $55.00 ea. After adding to cart, please choose SHIPPING below (Click here). |
