My fuel relay went bad (engine wouldn't start, no gas), and I replaced it. Two weeks later my mechanic said there was water in it- he had no idea where the water came from. The water shorted it out, he said.

Now the relay appears about to fail again. Could the water from the air conditioner get in the fuel relay? I've had the car for months but just started using the air conditioner.

The car also has a short in the electrical system. Sometimes the radio works, sometimes not- sometimes the seat belt buzzer make continual noise, and sometimes no noise at all. Could a short cause the problem in the fuel relay?

Thanks

A small leak at the bottom of your windshield can easily be the culprit for a flooded relay (and it's even happened on my '87 245 once). You'll notice that the original relay (should have) had a brass clip/hook attachment so that you could clip it to a tab on the firewall. The factory position for this relay was with the wires pointing down, -thus preventing it from flooding if water should seep in. If you leave the relay hanging upside down from the wiring harness, a little bit of water coming down the bundle will run right into it.

FYI, if you have the newer style of 240 windshield (starting in '89 or '90), you shouldn't have sealing issues. If you have an older vehicle and the windshield needs to be replaced at some point, tell the autoglass technician that the car is a '93. The windshield bracket on the car didn't change (it's the same '75-'93), -just the sealing method that comes on the windshield itself (improved flush-fit style with no leaky trim ring).

God bless,
Fitz Fitzgerald.
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'87 Blue 245, NA 238K

Thanks so much for your helpful message. I will keep in mind the need for the windshield replacement, and make sure the relay is tied up in the correct position.

Since you all have been so helpful, I could use some advice about this car. I bought it for $75.00 at a Goodwill auction in Jan. 04. It currently has 122,000 miles and no rust, small dents here and there, but nothing that couldn't be easily fixed.

However the car has been extremely unreliable. Every week something else goes wrong. In the beginning it had a vacuum leak, which took a long time to isolate, then we found out it had three broken motor mounts, a rusted out exhaust system and bad ball joints. We replaced the rear brakes. Then a wiper motor went, then the fuel relay twice and now brake problems again, something in the hydrolic system.

I want to give the car to my son who is 16 and just beginning to drive, but I don't want to give him a lemon. Is there such a thing as a car that will never work right, no matter what you do?

Thanks in advance for your advice.

Poor little car...it needs a "good" home, because it looks like it didn't have one before. If they were the original ball joints, think about how long they lasted! If there is a reputable independent Volvo shop where you are, go invest the money on a prebuy, and have them prioritize a list for you. This will at least minimize surprises, and in the interim you and your son can get educated on Volvo DIY auto repair. I'll bet alot of things on the list will be doable by the two of you. Give the car a chance; I've got about 650K on my car, and I wouldn't dream of parting with her.

Chris

It's not a lemon, just an old car that needs a little TLC that it probably didn't get in it's previous life.
Give it to you son along with a good set of basic tools and a Bently manual. The 240 is a very safe car, perfect for a new driver. Parts are relativey cheap, it is simple and easy to work on. You got a great deal on it but expect to spend some money to get it on good running condition. Good luck. Dan
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85 245 M46 194K, 92 245 A70 122K

check the grommet where the wiper motor comes through, good spot for a leak. install the relay so it points up, harder to fill up that way.

the other stuff sounds like corrosion in the fuse box. replace all the fuses with brass or copper, not aluminum 1s and clean all the holders in the box. good luck, chuck.

Yep, I always zip tie it up so that it can't fill up again...

Chris