1989 240DL, LH-Jetronic, Is there a fuel relay? Where?

I cannot start my 240DL. Initially, I was told my gas tank was full of garbage and I should replace it. After taking the tank down, I found the fuel strainer to be broken, which I'm sure allowed alot of garbage into the fuel system. I replaced the strainer, and installed a new tank.

Then, I replaced the fuel filter. Both fuel pumps, in-tank and main, were tested and are OK.

Now, it appears I'm getting to electrical spark to my main fuel pump. The car is still not starting. All fuel system-related fuses are OK and clean.

Is there a fuel relay switch? Where is it? I can't find it?

Any other suggestions are welcome!

Barry (Chicago, USA)

[Clifford Pope]

If yours is like mine (1993) it will be tucked up near the windscreen on the left hand side. Remove the felted lining and it should be clipped high up onto a metal rail. It is about 2" by 1" by 1 1/2" or thereabouts, either white or green.

Try bypassing it first. Connect a link from fuse 4 to fuse 6. This should cause the pump to run, even with the ignition off. You can hear it humming from inside the car. You can start the car like this. If this works, then I think it means the fault must be in the relay, when you find it! Try Brickboard.com. There have been dozens of threads on fuel pumps and relays, and how to troubleshoot them.

Good luck. The fuel system is a pain, it's the only thing I really hate about the 240!

You may like to check out my page:
http://volvoadventures.com/howtodofuelpumprelay.html

We have replaced fuel pump releay switch and we still cannot get fuel to injectors.

Originally Posted by BarryD

I cannot start my 240DL. Initially, I was told my gas tank was full of garbage and I should replace it. After taking the tank down, I found the fuel strainer to be broken, which I'm sure allowed alot of garbage into the fuel system. I replaced the strainer, and installed a new tank.

Then, I replaced the fuel filter. Both fuel pumps, in-tank and main, were tested and are OK.

Now, it appears I'm getting to electrical spark to my main fuel pump. The car is still not starting. All fuel system-related fuses are OK and clean.

Is there a fuel relay switch? Where is it? I can't find it?

Any other suggestions are welcome!

Barry (Chicago, USA)

[Peter D]

Under the carpet under the rear seat locate the fuel pump connector and disconnect it now use a amp meter and measure the current by linking one connection with a peice of wire and the meter leads to bridge the other. Now lint fuses 4 and 6 small crock clips and measre the pump curren from memory it's 4 to 5 amps. If it is all running then to be sure the turbine type blades have not busted off, disconnect the short rubber fuel return pipe by the manifold and use a length of pipe into a claean empty oil container ideally with measurement down the side. Again link the fused for 10 seconds and you shoul have pumped a ltr of fuel. If OK then it sounds like you are missing the injector pulse If you can borrow a Noid light. The install it inline with number one injector and turn the engine over there should be a small flash from the light. If you have a scope you can carefully place two thin wires into the female part of the connector and gentle replace it ( Thin wire like a stand fron a peice of flexi bell wire. ) Connect a scope and crank. One wire will be at 12v all the time the ignition is on and the other will be high but pulsing down to very close to zero ( Chassis ) for 2.4/2.5 milliseconds. If there is no pulse but you have a spark at the plugs then there is a broken wire somewhre of the Fuelling ECU if suspect ( Rare ) Regards Peter