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Old 08-13-2019, 01:18 PM   #1
Beatleskid18
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Question Volvo 240(s) headlight troubleshoot

Hi
I have two 1990 240s. One is a wagon, one is a sedan. The sedans headlights always worked properly. I bought the wagon knowing the high beams wouldn’t turn on. So one night I switched the two step relays to see if I could get the wagon to start working but I ended up with no working highbeams again on the wagon. I can’t remember if the sedan worked after the switch. It was getting late, I switched them back. A little while later I began to troubleshoot the wagon by jumping the different pins (I read about troubleshooting on Dave’s Volvo page) and while doing that I was able to get the brights to turn on. I had both step relays out and did the same procedures on both in the wagon. When I reinstalled the sedan step relay, the high beams would now stay on only! Maybe I burned the sedan relay up? And obviously the wagon is still doing the same thing. So I bit the bullet and bought a step relay off IPD. Installed it on the wagon, no change. So now I’m thinking it’s gotta be the stalk but I’m unsure of how to troubleshoot that.
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Old 08-13-2019, 03:05 PM   #2
dl242gt
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You need to get a test light. That way you can follow the path of non working connections or relays and figure it out.

You may have corroded contacts in the wiring connectors for the step relay. That is very common.
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Old 08-13-2019, 05:28 PM   #3
Beatleskid18
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Ok. I’ll check that. It’s still bizarre why this is happening.
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Old 08-13-2019, 05:45 PM   #4
dl242gt
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It may be as simple as your fuse box has bad fuses. After the step relay the headlight wiring loops back to the fuse box and then goes out to the lights. flaky fuses have been a problem on many a 240.
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