240 fuel pump relay

[Clifford Pope]

Clean the fuse contacts by forming a bit of fine emery paper into a shallow cone that matches the shape of the fuse and twist this against the springy terminals in the fuse box. You can clean up the ends of the fuse with emery paper, or just fit a new fuse.
When you fit the fuse, press the terminals together to squeeze the fuse while twiddling it a bit to lightly grind the ends into proper contact with the terminals.

If that doesn't work or is unreliable, fit a temporary bridging wire between terminals 4 an 6. This will start the fuel pump, by-passing the relay. You can drive the car like that, but the pump will keep running when you turn off the ignition. That establishes that the problem is with the relay. As you probably know it is white and tucked up behind the glove compartment in a clip. Either replace it, or you can open it up and re-solder the connections inside.

[morwenna240]

I took out relay, took off cover, tapped both sets of points a few times, reconnected, an engine fired straight up. I did make up the little jump lead for fuses 4 an 6, but didn’t need; will keep in glove box. Scrolling back in threads, in 2011 you said about the above, Clifford, then someone said “ this will only power up the tank pump, an you have a 50/50 chance of getting home”. Tsk. Anyway, thanks to all here present, an I’ll get a new relay to go with jump wire in glove box. Onwards, til next time!

[Jungle_Jim]

I have been experimenting with refurbishing white Fuel Pump Relays and so far it's working.... though I keep a few spares in the car. There's not much to them, only 2 solenoid relays, one has a diode, the other doesn't (apparently the green ones have much more circuitry).

Of course a brand-new pattern-part Fuel Pump Relay is probably no doubt a safe bet to get up-and-running, but refurbing the white relays is definitely worthwhile...

Re-solder all the joints - even if the the multimeter is showing continuity. Remove old solder and give it plenty of new solder. And optionally put a coat of clear lacquer or PCB coating on the bottom to protect the solder joints from corrosion after.

Check the resistance across both solenoid coils. They should be around 90 ohms ish give or take. If either coil is an open circuit, after re-soldering the joints onto the board, then that coil may be broken and is probably un-repairable.

Giving the relay contacts a squirt with contact cleaner could help. And perhaps use a very fine abrasive on the contacts if they are pitted or burnt.

The genuine ones - which - far-as-I-know - are usually German-made Stribel brand - apparently aren't available new any more, and most of the new ones for sale are cheaper pattern parts. Like a lot of original Volvo parts vs currently available supplies - the Stibel relays look like much better quality inside, but genuine or not, they are all worth refurbing if they've stopped working.

Either way - having a spare fuel pump relay is a no-brainer.

[morwenna240]

I opened up mine, it all looked very clean, no corrosion, solder shiny. I waggled the points a few times, refiitted, engine ran.
Incidentally, Simon has new, genuine Volvo ones, albeit £72, as opposed to 30 for his pattern ones.

[Jungle_Jim]

Originally Posted by morwenna240

Incidentally, Simon has new, genuine Volvo ones, albeit £72, as opposed to 30 for his pattern ones.

Who is Simon? is that Brookhouse?

[Chris1Roll]

Morwenna's Torslanda will be an LH-fuel injected car I believe?
The White relays for that are still available from Volvo.

The green fuel pump relays for the K-Jet cars are not available from Volvo any more, only pattern ones which are not as reliable by all accounts.
Theres another project for someone - recreate the same function using some high-quality relays and components.

[morwenna240]

Originally Posted by Chris1Roll

Morwenna's Torslanda will be an LH-fuel injected car I believe?
The White relays for that are still available from Volvo.

The green fuel pump relays for the K-Jet cars are not available from Volvo any more, only pattern ones which are not as reliable by all accounts.
Theres another project for someone - recreate the same function using some high-quality relays and components.

It is. ‘92 Torslanda.

[morwenna240]

Originally Posted by Jungle_Jim

Who is Simon? is that Brookhouse?

Yes, Brookhouse.