I've been bringing this car back to life and it's almost ready for inspection. My issue is that the headlights don't work. When I pull the headlight stem back in the third position (or any position for that matter) it will only flash the hi beams but they won't remain on. Previously I could operate the headlights, but sometimes only in the hi position; when it was switched to low the headlights would sometimes turn off altogether. (brand new bulbs) So I opened up the switching relay in the engine bay (passengers side) and cleaned the connectors and contacts. The main contact was bent so as to only make contact on a corner, which I corrected with pliers. After I did this I reconnected it, but the headlights would now only come on so long as I held the headlight branch and only the hi beams worked of course. I reconnected it without the cover so I could observe it's operation. The main hinge swings down and makes contact, however the switching mechanism doesn't move. (not sure why this causes only the brights to work as I manually switched positions and there was no low beam switching.) I found the main relay inside of the center console, however it wasn't hooked up to anything. I looked for a connector or loose wires and couldn't find anything. I figure a previous owner may have done some sort of a bypass on it, not sure why he would've left it in there though. What exactly is the function of that relay? I can only find information on the switching relay in the engine bay. Is it possible for the headlights to be operated using only the switch on the column and in the engine bay? If so, I suppose that would point to the failure of my switching relay.

 

That square relay is needed to turn the lights off when the key is off. 1986+ 240s can leave the headlamp switch on all the time - and the lights will turn off (even if the switch is on) when the key is turned off.
In the earlier cars 86-90? it was mounted near the left foot rest. Later cars mounted near the central locking relays. Common is a melted connection at the relay as pictured below.

https://www.brickboard.com/RWD/index...724&show_all=2

 

I found the relay, it was behind the center console. I just needed a fresh pair of eyes. That relay is good and so are the connectors. Looking at the switch relay, there's a braided wire that's attached to the center 'rocker' and links to spade connector 56 and it's cut. I'm thinking I need a new switch relay, they're awfully expensive though.

Current symptoms: only the hi beams come on when I pull the column switch while in position 3, and do not remain on when pressure is released. Does that sound like a switch relay issue?

I'm also considering one of these: https://www.wagonmeister.com/highvol...lightharnesses but I'm not sure if that includes relays, or if it makes use of the old ones.

 

No - what you describe is normal behavior when the headlamps are turned off (or there is no power to them). The rectangular relay under the hood switches from high to low beam or flashes when the headlamps are off. That is normal operation. Have you tested for switched power at the square relay with your $5 test light?

Wiring diagram is not from a green book - do you have power at the red and green wire at the square relay? Power when lights on at the yellow wire?
https://volvo240-260.com/Wiring%20di...240%201993.pdf

 

My problem is when I rotate the headlight **** all the way to the right, my headlights do not come on at all, only the hi beams and only as long as the lever is pulled back.

 

YES - I understand that. from the diagram below, I've tried to add current flow. Let's trace power to the step relay/headlamps

The blue /red wire from terminal 15 on the ignition switch sends power to the headlamp switch. (up arrow in middle of page)
Do you have 12v at the blu/red wire on the headlight switch with the key on? (other wires at the switch - grn/red = power all the time from fuse #7, sends power to the White wire with switch in position 1 or 2 to the white wire for the parking lights. Do you have power at the white wire and the bottom 2 fuses for the parking lights when switch and key is turned on?)
If power at the blu/red wire do you have 12v at the blu/white wire on the headlight switch with the switch in position 2? (if so the headlamp switch is good)
That blu/wht wire goes to the solenoid coil on the square headlamp relay inside the car. Do you have 12v at the blu/wht wire (terminal 86) on the square relay with key and switch on?
Note the black wire provides ground for the relay coil. Do you have a good ground connection for the relay on the black wire?
The grn/red wire on the headlamp relay has power all the time from fuse #7. Do you have power at fuse #7? Is there power at the green /red wire at the headlamp relay?
The points in the headlamp relay when closed send power to terminal 87, The yellow wire. Do you have power at the yellow wire with key and headlamp switch on?
Moving onto the step relay under the hood - Do you have power at the yellow wire/terminal 56 on the step relay with the key and switch on?

Do all these wire colors match what you have on the car? (this is not a Volvo diagram so don't know how accurate it is)

Hope this helps.

 

I found the issue. Inside of the lo-hi relay there's a braided wire and it's severed. I reconnected it by friction and the function was restored (will see if it can be soldered later), albeit partially. The little metal arm that presses the switch sticks, and the electromagnet doesn't seem to pull strongly enough. While following your helpful instruction, I found that the headlight switch and interior relay worked just fine. Thanks!