Hey guys my friends volvo is getting what seems to be starter solenoid issues. I found this melted wire and I think it's related to the solenoid, maybe cooked because the solenoid stayed open?

It's comes from the extra wire off the positive terminal and goes to this little white fuse holder on the driver's fender. The connectors were all melted together.
It sounds like it may be turning on the fuelpump aswell.



Thanks for your help.

 

This says engine control? If that's right it might be a bit worse than a starter solenoid.
1989 Volvo 240


Pretty sure this is it before it was melted

I need more info than that lol.

 

that white fuse holder is the main power for the fuel injection system. 25 amp fuse runs the ECU, the fuel pumps, the injectors, everything associated with EFI.

the black box next to it, and showed by the red arrow on your 2nd picture, is the 'positive terminal' where most of the other circuits in the car get their power.

 

Is it connected to anything that would cause a no crank condition specifically? When bypassed I still have no crank. I'm thinking the odds of this being unrelated are slim.

 

the big heavy red wire from the battery terminal goes directly to the starter solenoid power input

the ignition key gets its power off that positive terminal on your fender, and when you turn the key to 'start', sends power down a pink wire that goes through the park/neutral safety switch (if you have an automatic), then on to the starter solenoid control input...

there should be a blue terminal somewhere on the left fender with a pink wire. this is for a 'mechanics starter button', which you plug into said blue connector, and clip to the battery +, so you can work the starter from under the hood. this is wired before the park/neutral safety switch that still has to be working.

 

Alright thank you, I'm going to replace it and jump the solonoid to see where that gets me. Really hard to believe but it did melt together so maybe the efi just kept working until I found it.