Hello, Ive got a 91 240 and on new years day I went to start my car and the engine would not even turn over. When I turned the key to start I got a distinct CLICK noise that sounded like it was coming from the passenger side dash. It sounds like a relay.

I thought that it was a battery problem so I went and got a new one. The old battery was about 5 years old so it needed one anyway.

When I got home and installed the battery the temp had warmed a bit to about 10 degrees F above zero and she started right away. Problem solved for that moment but the next morning when it was well below zero (-6 degrees) I was having the same problem and it refused to turn over until the weather warmed up a bit.
It is only doing this in the morning when it is the coldest.

My Volvo guy that works on all my cars suggested that the starter needed to be rebuilt but I have a hunch that a relay is to blame due to that clicking noise I am hearing.

If anyone has an idea what this might be please share and hopefully i wont need to take the car in to the shop and can repair myself.

Thanks, Matt.