Volvo RWD 200 Forum

INDEX FOR 10/2025(CURRENT) INDEX FOR 9/2003 200 INDEX

[<<]  [>>]


THREADED THREADED EXPANDED FLAT PRINT ALL
MESSAGES IN THIS THREAD




  REPLY TO THIS MESSAGE    PRINT   SAVE 

system relay problem 200 1984

solved a no start problem by removing the system relay and jumping terminal 30 to terminal 87 on the connection plug. had tried a new relay with no success. only way to get fuel pumps to run is to jump terminals on system relay. have installed a switch so can disconnect jumper when ignition switch is turned off. will this cause problems? anyone suggest a proper fix? car runs fine with jumper in place. thanks for any suggestions - i'm stumped.








  •   REPLY TO THIS MESSAGE    PRINT   SAVE 

    Re: system relay problem 200 1984

    Maybe you read my post a couple days ago of a similar problem on the same car.

    the black relay clicks on/off with the key turned to "run". But the white, cube relay won't click reliably when key turned to "start". Only with this relay clicking, can I hear the main fuel pump, and get it started.

    Someone suggested cleaning the ignition siwtch.

    Did that, broke that.

    Getting a replacement Thusrday.








    •   REPLY TO THIS MESSAGE    PRINT   SAVE 

      Re: system relay problem 200 1984

      I had same problem with intermittent clicking. Could get it to run by turning key on and off several times. Finally wouldn't start no matter how many times I tried the key. The jumper wire was the only way to "cure" the problem. How do you clean the ignition switch - is there a way to test if that is the problem?








      •   REPLY TO THIS MESSAGE    PRINT   SAVE 

        Re: system relay problem 200 1984

        I was dong the key-turning thing, too. But now the car is also shtting off while driving!

        I don't now how to test the switch. "Cleaning" it is just something I learned about.

        As a last resort, I opened mine last night. Lots of goo inside. Don't now if it is supposed to be there or not. Maybe a lube or waterproofer.

        The cover is held on by several bends of its edge around the perimiter. Using a thin screwdriver, carefully pry each one out, then pry the cover loose.

        Note the otientation of the switch movement. It is slipped down over a thin plastic spindle which is what the tip of the key turns where the key enters a rectangular 'keyhole" on the center of the switch cover.

        This movement rotates inside a Stonehenge-looking array of copper contacts which look like the distributor points of old. When you turn the switch with the key (when it is in place in the car), the plastic cams on the switch movement rotate away from these vertical contacts, thus closing them as designed, distributing power to selected output pins.

        I opened each one manually (after taking out the movement, which I don't recommend) to inspect for pittng or burning as a likely source of failure. All looked fine -- evenly worn and clean.

        Underneath the movement is a spring-loaded ball bearing. It stays on the movement when you remove the piece. It travels along a ring just inside the semi-circle of vertical copper contacts. What you feel with the key as it clicks to each position, is this ballbearing pressig into one of three divots in this ring it travels along. Curiously, one of these is elongated. That is the "start" positionyou know how your turn the key all the way to the right and it sptrings back to the left? That's this ball bearing moving in this elongated slot. I did not see what makes it spring back, however.

        (Mine does not spring back now.)

        Probably best if you just hold the thing still in its place while you spray out the jelly with electrical contacts cleaner.

        I applied a lot less "jelly" to replace what I cleaned out. Just t the ball bearing, using dielectric grease. I don't know how much to lube, not where to apply. It is just that I had everything apart and nothing to loose.

        To reassemble, you need to use something to press the cover completely onto the mechanism. It feels spring loaded, or something. I used a large C-clamp to snug it flush with the lip of the bast of the switch while squeezing each edge of the cover into the notches to clampt tight. Used an adjustable pliers, withthe top jaw in notch.

        The only wear I noticed was a shallow groove along the path the ball bearing travels between each "divot". As I said, the contacts themselves looked straight, not pitted, and tight.

        Switch has 205,000 miles on it.

        I'll just get one off a junker. New ones are $17-$55









        •   REPLY TO THIS MESSAGE    PRINT   SAVE 

          Re: system relay problem 200 1984

          Thanks for great description of dismantling ignition switch. Sounds like replacement is the way to go. Must have similar problem - mine also would quit while driving. Daughter needs car daily for work so only have weekends to play with it. Want to check for bad grounds and have a look at ignition switch. Right now it appears to be running fine with jumper (described in earlier post) installed. Will let you know if this fix causes further problems.








          •   REPLY TO THIS MESSAGE    PRINT   SAVE 

            Re: system relay problem 200 1984

            /// If the fuel pump won't run with the new relay in the problem is the coil control circuit for the relay. Look it up in a circuit diagram for your car. Look at the relay socket and find the relay coil connection, battery side. Test for voltage while cranking, or when the engine stops. If y ou have voltage there the problem is the other side of the coil, ground. Test the other side of the coil connector in the relay socket for ground when the engine is stopped, failed. It will read normally if it did not fail first.

            You already checked the fuse for the relay circuit, right. It can't be bad since the pump works when you short the relay switch points. Put your hand over the fuse block after running and clean any others that are hot.

            If the radio and wipers work, (the car runs) the ignition switch should not be involved unless you can find that there are two parallel sets of switches in the ignition switch. There should be only one wire, one switch at the run position of the ignition switch.

            Find out why you do not have a complete circuit through the relay coil when the car fails. Start as I posted above with the relay socket and ground.








            •   REPLY TO THIS MESSAGE    PRINT   SAVE 

              Re: system relay problem 200 1984

              Have tried checking the relay coil circuit. One side (#86) has 12V even when the key is off. The other side (#85) grounds through the ECU according to the diagram that I have. However I get a reading of 2V with the key off - should have checked it with key on. Will try on the weekend. Appreciate the help and will post results if ever solve the problem. Have already replaced the ECU 10,000km ago with a used one. Was running fine until now. Have gone 3 days and 100km. with jumper wire in place and so far no ill effects - runs like a charm. Curiously this problem first happened after car passed Ontario "Drive Clean" emissions test. Passed with flying colors! and two days later car went dead while driving.







<< < > >>



©Jarrod Stenberg 1997-2022. All material except where indicated.


All participants agree to these terms.

Brickboard.com is not affiliated with nor sponsored by AB Volvo, Volvo Car Corporation, Volvo Cars of North America, Inc. or Ford Motor Company. Brickboard.com is a Volvo owner/enthusiast site, similar to a club, and does not intend to pose as an official Volvo site. The official Volvo site can be found here.