Boardmembers,

Bought a '91 240 Wagon that needed some work. Haven't had a 240 in over 5 years so I sold my Bentley's manual on eBay some years ago... so I need some electrical diagnostic help... Here it goes...

Car was running at time of purchase, but battery was weak, so I replaced it with a fresh Bosch Battery. Car was only driven a couple of time, and sat in the driveway for several months. Battery was dead... recharged battery... cranked but no start... gave up for the day. Next day, no cranking from starter, tried another battery, still no crank. Tried shorting the starter wires, not cranking... starter is toast. Replaced starter, engine cranks well.

Checked the Fuel Pump Relay, opened up the plastic case and see that the relay on the LEFT side is closed and energized, and the relay on the RIGHT is open WITH THE KEY OFF!!! Seems strange. There is also 12V at the small wire on the starter solenoid with key OFF. (This probably is what smoked the solenoid and drained the battery.)

When I unplug the Fuel Pump Relay, and plug it back in again, the LEFT relay stays open until the key is turned ON, then the RIGHT relay closes momentarily to prime the pump. Car starts, both sides of the relay closed, engine runs, but when key is turned off LEFT relay remains closed (energized) with key OFF.

All thoughts, ideas, "been there, done that's" are welcome!