1989 Volvo 240 Fuel Pump Relay Location: A Complete Guide to Finding and Fixing It

If you own a 1989 Volvo 240 and your car cranks but won’t start, the fuel pump relay is the most likely culprit. The fuel pump relay on a 1989 Volvo 240 is located behind the glove box on the passenger side, mounted on a bracket near the bulb failure warning system relay. This small square relay, often white or green, controls power to both the in-tank and main fuel pumps. When it fails, you’ll get no fuel to the engine, even though everything else looks fine. Here’s how to find it, test it, and get your Volvo running again.

Why the Fuel Pump Relay Matters

The fuel pump relay is a critical component in your 1989 Volvo 240’s fuel system. It acts as a switch that sends power to the fuel pumps only when the ignition is on or the engine is running. This prevents the pumps from running continuously, which would drain the battery and could cause damage. On the 1989 model, the relay powers both the in-tank pre-pump and the main Bosch inline fuel pump located under the car near the left rear wheel.

When the relay fails, the pumps don’t get power, and no fuel reaches the engine. This is a very common failure point on these cars, especially as they age. Many Volvo 240 owners have experienced intermittent starting problems or complete no-start conditions due to a bad relay.

Step-by-Step: Finding the Fuel Pump Relay on a 1989 Volvo 240

Here is the exact procedure to locate the fuel pump relay in your 1989 Volvo 240. The location is the same for all 1985-1993 240 models, including the DL and GL trims.

1. Open the passenger side front door. You’ll be working on the passenger side of the car, not the driver’s side. This is a common mistake.

2. Open the glove box. The glove box is held in place by seven screws around its outer edge. Remove all seven screws and gently pull the glove box out. You do not need to disconnect any wiring from the glove box itself; just set it aside.

3. Look behind the glove box opening. You will see several relays and wiring harnesses. The fuel pump relay is the square relay mounted on a spring clip bracket. It is located in the lower right area of the relay cluster, behind where the glove box was.

4. Identify the relay. The fuel pump relay is square, not round. The round relay you’ll see in the upper left area is the bulb failure warning system relay. The fuel pump relay is typically white or green, depending on the original or replacement part. It is the only square relay in this location.

5. Remove the relay. The relay is spring-clipped into a holding bracket. Simply press the clip and pull the relay straight out of its connector.

How to Test the Fuel Pump Relay

Before you buy a new relay, you can test the old one to confirm it’s the problem. Here are three methods that work on a 1989 Volvo 240.

Method 1: Listen for the Relay Click

Turn the ignition key to position II (the "on" position, just before crank). Listen carefully near the passenger footwell. A working fuel pump relay should click audibly within 1-2 seconds. If you hear the click, the relay is likely working, but it still could be intermittent. If you hear no click, the relay is almost certainly dead.

Method 2: Check for Pump Noise

With the key in position II, listen for a humming sound from the rear of the car. The main fuel pump under the car should run for about 1-2 seconds and then shut off. If you hear the pump, the relay is working. If you don’t, the relay may be the problem.

Method 3: The Paperclip Bypass Test

This is the most definitive test. You can bypass the fuel pump relay entirely to see if the pumps work. Here’s how:

1. Locate the fuse panel in the passenger footwell, in front of the left front door pillar.
2. You need to jump between fuse #4 and fuse #6. On a 1989 Volvo 240, fuse #4 is for the feed pump (tank pump) and is rated at 8 amps. Fuse #6 is for the main fuel pump and is rated at 16 amps.
3. Use a piece of wire with stripped ends or a straightened paperclip. Carefully insert one end into the terminal of fuse #4 and the other end into the terminal of fuse #6.
4. Turn the ignition key to position II. You should hear both fuel pumps start running. If the car starts and runs with the jumper in place, but dies when you remove it, the fuel pump relay is definitely bad.

Important safety note: Do not drive the car for long with the jumper in place. The fuel pumps will run continuously, even after you turn off the ignition. Remove the jumper as soon as you’ve confirmed the diagnosis.

Common Problems That Mimic a Bad Fuel Pump Relay

Sometimes a no-start condition on a 1989 Volvo 240 is caused by something other than the relay. Here are the most common issues to check.

Corroded Fuse Contacts

The fuse panel in the 240 is notorious for corroded contacts. The main fuel pump fuse (#6) is especially vulnerable. Even if the fuse looks good, the contacts may be corroded enough to prevent power from reaching the pumps. Remove all fuses, clean the terminals with a wire brush or emery cloth, and reinstall them. If the contacts are loose, gently squeeze them together for a tighter fit.

The 25 Amp Main Engine Bay Fuse

On 1983-1990 non-turbo 240s, the LH-Jetronic fuel injection system uses a 25 amp blade-type fuse located in the engine compartment. This fuse is on the left wheel housing, near the ignition coil. It is not in a sealed holder, so the contacts are exposed to moisture and corrosion. Check this fuse and clean the contacts thoroughly. A quick fix is to pull the fuse out and reinsert it, which often scrapes away enough corrosion to restore contact.

Faulty Crankshaft Position Sensor

On 1989 and later 240s with LH 2.4 fuel injection, a failing crankshaft position sensor can cause a no-start condition. This sensor is located on top of the bell housing where the engine and transmission meet. If the sensor fails, the ECU will not provide ground to the fuel pump relay, and the pumps won’t run. This is a common cause of heat-soak no-start problems, where the car starts fine when cold but fails to restart after a short stop.

How to Replace the Fuel Pump Relay

Replacing the fuel pump relay on a 1989 Volvo 240 is straightforward. Here are the steps.

1. Purchase the correct relay. You need a replacement fuel pump relay for 1985-1993 Volvo 240 models, except for 1985 turbos. The part number is REPL-3523608. Genuine Volvo relays are available, but aftermarket options from brands like URO Parts and Professional Parts Sweden also work. Expect to pay around $20 for an aftermarket relay or a bit more for a Volvo brand one.
2. Remove the old relay. Follow the steps above to access the relay behind the glove box. Unclip it from the bracket and pull it out of the connector.
3. Install the new relay. Push the new relay into the connector until it clicks into place. Make sure it’s seated firmly.
4. Reinstall the glove box. Align the glove box and reinstall the seven screws.
5. Test the car. Turn the key to position II and listen for the relay click and the fuel pump hum. Start the engine and confirm it runs smoothly.

Pro tip: Keep a spare fuel pump relay in your glove box. This is a common failure point, and having a spare can save you from being stranded.

Why the Fuel Pump Relay Fails

The fuel pump relay on a 1989 Volvo 240 fails for several reasons. The relay is a mechanical device with internal contacts that wear out over time. After 30-plus years, the solder joints inside the relay can crack, causing intermittent or permanent failure. Heat from the engine compartment and the passenger footwell can also degrade the relay’s internal components. Many owners report that the relay works perfectly when cold but fails after the car has been driven and the interior heats up.

The age of the car is the biggest factor. A relay that has lasted 200,000 miles and 30 years is well past its expected lifespan. Replacing it proactively is cheap insurance.

Summary: What to Do First

If your 1989 Volvo 240 cranks but won’t start, start with the fuel pump relay. It’s the most common cause and the easiest to check. Locate it behind the glove box on the passenger side. Test it by listening for the click or using the paperclip bypass method. If the relay is bad, replace it with a new one. If the relay is good, check the fuses, especially the 25 amp fuse in the engine bay and the fuse panel contacts. If those are fine, the crankshaft position sensor is the next suspect.

Recommended Product: KEMSO Fuel Pumps

If you need to replace the fuel pump itself, not just the relay, consider a high-quality aftermarket option. The KEMSO brand offers fuel pump products that are designed as high-performance, OEM replacement parts. They come with a lifetime warranty, so you only buy them once. KEMSO fuel pumps are built to meet or exceed the specifications of the original Volvo equipment, ensuring reliable fuel delivery for years to come.

For more information, visit: https://www.kemsoracing.com/

Final Thoughts

The 1989 Volvo 240 is a reliable car, but electrical components like the fuel pump relay are known weak points as they age. Finding and replacing the relay is a simple job that anyone can do with basic tools. The relay is located behind the passenger side glove box, and testing it takes only a few minutes. If you’re stuck on the side of the road, the paperclip bypass test can get you home, but be sure to remove the jumper when you arrive. For a permanent fix, install a new relay and keep a spare in your glove box.

For all your fuel pump needs, remember to check out KEMSO at https://www.kemsoracing.com/ for high-performance, OEM replacement fuel pumps with a lifetime warranty.