|
 <<<
Here is the 240 headlight step relay. The
original relay, PN 1307991, is still available
as a new part, however as the years go by, they
are getting to be more and more expensive.
As original Volvo 240 headlight step relays
become more expensive or less common, here I am
offering an alternative that you can assemble
yourself to completely
eliminate the Volvo 240 Step Relay if
you want to. This
method uses two readily available relays to
accomplish the same functions.
|
 <<< For those of you that
are new to this, it's found under your hood on
the left inner fender. |
Here's a quick
little rabbit trail for owners of OTHER
Volvos:
| 760 and 960
Headlamp Relays |
As an
example of what can happen to the
availability of 240 step relays,
which I hope doesn't happen, these
images below are of the headlight step
relay found in a 1988-94
Volvo 760 and 960 series.
This relay is PN 1392900 and has been
no
longer available new for many years.
Used
relays are showing up online for
OVER $100!
If YOU can help, I would be happy to
work out a similar solution to eliminate
THIS relay in other Volvos if someone
out there with one of these cars would
be willing to lend me a relay for some
testing. So far no one has
spoken up.
CONTACT
ME
if you can help with
this.
 
|
  |
 |
And
there is also a Canadian
version of this relay
for 760/960 models. This photo
was sent by Jesse W. The extra
Pin #15 is thought to
be for Daytime
Running
Lamps (DRLs).
PN
3523535
|
|
|
BACK
TO THE 240 STEP RELAY
|
|
This is a bottom
view of the relay plug connectors for the 240
step relay.
|
|
Original Volvo 240 Step
Relay Circuits.
Wire colors may vary slightly
depending on year.
|
15
|
BLUE
|
12V Battery
(common with 81a).
|
81a
|
BLUE
|
12V Battery
(common with 15). |
31b
|
BROWN
|
Signal from
high beam lever (negative ground
switched).
|
56
|
YELLOW
|
12V from
dash light switch (or from headlight relay
in 1986 and later 240).
|
56a
|
RED/WHITE, RED
|
Dash high
beam indicator light (RED/WHITE).
High beam headlamp (RED).
|
56a
|
RED
|
High beam
headlamp.
|
56b
|
BLUE/WHITE
|
Bulb
failure sensor. Then from bulb failure
sensor to low beam headlamp.
|
|
  <<< You will need to
locate one of these relays. They are easy to
find. You can search for "LR35 relay"
or “VW latching headlight relay.”
This is basically a copy of an old VW headlamp
dip relay. Cost will be around $20. This is
a special mechanical latching relay that has the
latching requirement identical to what the Volvo
240 step relay does.
You can search, but I have found no available
connector plugs that will fit this
relay. Those pins are standard .250 inch
(6.3 mm), so simple 1/4 inch crimp connectors
will be fine.
|
|
 <<< You will need one
standard relay for this project.
<<< This relay can be an
SPST type as shown in these photos. 40A
capacity is recommended. SPST means Single Pole,
Single Throw. An SPST relay will usually have 5
pins, with the center pin marked 87b (or sometimes
just 87). With this type of relay, pins 87and 87b
are common and both give power at the same
time. You may also use pretty much any other
standard relay, since for this project, the center
pole is not being used. I offer the brown
relay shown here if you need one at this link: https://www.240turbo.com/volvorelays.html#1324749-006brown.
|
Removing
Terminals from Original 240 Step
Relay Plugs
|
|
 <<< Here we have a typical relay socket plug used in Volvos. NO, This is NOT a step relay socket plug , but it'll work for this demonstration.
Notice the metal teminals inside the holes? Not all the holes always have terminals.
|
 <<< You'll need a tool for this part... a long sharp pick will do. A micro screwdriver can also be used. If your tool is not small enough on the tip, a little grinding will fix it as I did on this pick. Even a stiff piece of piano wire can work for this step.
|
 <<< Now pay attention to the little openings at the top of the little rectangular holes. That wide spot is where you need to insert your pick. The idea is to insert the pick in about 3/8 inch (10 mm) or so and push down to flatten the locking tab on the terminal. That locking tab holds the terminal in the socket. In the next photos, the locking tab will be easy to see.
If your socket doesn't have a wider opening that you can see, just pay attention to the below pics to know which side of the terminal to insert the pick into to push on the tab.
|
 <<< In this photo you can see the terminal backing out of the hole after the locking tab was released.
|
 <<< Here's a good view of the locking tab on the crimp terminal. After you depress and release the tab and pull the terminal out of the socket, you may find that your tool bent and flattened the tab a bit too much. If you will be re-inserting this terminal into a connector, the tab may need to be pushed back out so it still engages when re-inserted. It needs to be sticking out like in this photo to work correctly. If you accidentally break the tab off, you'll need to crimp on a new terminal.
And make sure the locking tab is on the correct side of the socket hole when re-inserting. As it gets inserted, you should hear a 'click' which tells you it has locked into place. Always make sure by giving the wire a little tug.
And pay close attention when you plug a sockets back onto a relay to see if any terminals got pushed back out. That can happen sometimes if the tab hasn't fully locked the terminal in place.
|
To help you understand the idea, here's a
simplified diagram showing the functions of
the two replacement relays involved.
|
And
here's a diagram that shows the pins from
the original Volvo step relay plugs and
where they go on the two new relays.
The latching outputs in
the new latching "step" relay are poles 56a
and 56b. They will alternate with each tug
of the high beam lever.
|
Here's a link to a page created by a 245
owner who did this mod for his car in 2017. He
also added relays for his high and low beams, as
well as driving lights.
https://brokedownbrick.wordpress.com/2017/11/21/headlights-and-under-hood-power-distribution/
|
Here's
a printable PFD document that
covers my step relay modification
in detail.
<<< Click on
image for 2-page PDF.
|
