I have a 90 240 with 160K miles. Car will not start; cranks (battery is fine) but does not turnover. I was thinking it may be the fuel relay. Where is the relay and how easy is it to replace? Also, any other suggestions to fix my problem. Thanks,
DJN

If all went well, you've found it by now. It is, as Smitty says, up over the passenger's feet, near the firewall on the right side of the car, under the dash. They're white, about 1" by 2" and have a date code stamped on them. If yours has a 1989 or 90 code, or anything over 5-6 years old, I'd replace it and then resolder yours as a spare. They're the #1 cause of no-starts. If this doesn't do it, make sure you have spark (pull off coil wire, and I like to tuck it over by the hood hinge so I can see it spark while turning the key). If no spark, then make sure the timing belt is not broken- either pop off distributor cap or peek down the oil fill hole while turning over engine- if you see things turning, then the belt is OK. If the belt is good, but no spark, plan on replacing the engine speed sensor (crank angle sensor) mounted to the top of the bell housing, right behind the head (tight spot on a 240).

Good luck!
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Rob Bareiss, New London CT ::: 86 244DL, 87 244DL, 88 744GLE, 91 244: 808K total

On 240's, the fuel pump relay is indeed a major contributor to no-starts. It's located on the passenger side at the upper portion of the footwell. Peel back the carpet and you'll see it there - it's white. You can replace it cheaply enough (maybe $15-20 at fcpgroton.com), but the typical problem is that with age the internal solder joints crack. If you're handy with a soldering iron, simply re-solder them and that should cure the relay problem.

Are both fuel pump fuses clean and making firm contact?

On mid-80's models at least thru '88 there is also a 25-amp blade-style fuse under the hood on the driver's side, between the battery and the coil, on the inner fender. Not sure if it was still there in '90 (my '91 does not have it); it may have gone away when the EZK system with the diagnostics came along. This fuse tends to corrode and can also be a source of no-start problems.

The relay is inside on the left hand side of the car.
It is usually clipped to a metal bracket, has six pins and is probably green
in your car.

My experience is that the relay rarely fails.
(Having owned a 145 and about 4 x 240s)
It is more likely to be the actual pump(s)

Regards,
David

If you have a Bently manual, Check it. If you don't-BUY IT. the fuel pump relay for my 79 was a large relay located under the drivers side shroud clipped onto a bar above the fuse box. it has (i think) four sets of wires and is easily diagnosed witha voltmeter. I'm sure that another more experienced mechanic will be able to tell you exactly how to ohm it out without the use of the bently. Here are a few more little ideas for you:

Are you getting spark? Is the timing belt shot?Any fuses blown? Sometimes we forget the simple things...

I do think that you can generally hear the fuel pump fire up when you crank the key, and of course the telltale smell of gas is always a giveaway as well.

Good luck
--
...'79 245 rusting and rolling broke od.. 160+

You should hear the pump whir when you turn on the ignition, then cut out when up to pressure. Try giving the pump a thump with your fist - mine sticks about once every 3 months if the car hasn't been used for a day.
But firstly, I'd try cleaning the fuses.

Good luck