242 / 244 / 245

1974-1993 / Sedan / Estate / Sweden

All 242 / 244 / 245 problems All workshop issues

Critical Electrical

Fuse box corrosion and composite fuse failure

Symptoms

Intermittent electrical gremlins, wipers stop, lights flicker, fuel pump cuts out, gauges go dead. You'll chase your tail trying to diagnose.

Cause

The composite (blade-style) fuses in the main fuse box corrode or crack internally. They look fine but have failed. The fuse holders also corrode. The main power supply fuse for the LH fuel system (25A white holder, under the bonnet) is a common culprit, it melts the plastic housing from heat and resistance.

Fix

Replace any suspect fuses, even if they look OK.

Keep spares in the car (IPD sells kits).

Upgrade the main fuel system fuse holder to a waterproof type to prevent future meltdown.

Clean fuse box terminals with contact cleaner and dielectric grease.

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Other known issues

Critical Electrical

Fuel pump relay failure (covered above under Engine, but worth repeating)

No start, or engine cuts out while driving.

Common Electrical

Headlight relay and wiring overheating

Headlights dim or fail, melted connector at the relay, burnt smell.

Critical Electrical

Bulb failure sensor issues

Brake lights or turn signals stop working, even though the bulbs are fine. Warning light on the dash.

Minor Engine

Oil leaks from valve cover, front crank seal, and rear main seal

Seepage or drips from the valve cover gasket, front timing cover, or rear of the engine. Oil may pool on top of the gearbox bell housing or drip onto the subframe. You'll smell burning oil if it hits the exhaust.

Critical Engine

Clogged PCV system (flame trap, oil separator box)

Oil leaks from multiple places, rough idle, high oil consumption, smoke from the engine bay. Sometimes the oil filler cap pops off under pressure.

Common Engine

Piston ring wear and oil consumption (LH 2.4 engines, 2010-2018 T5/T6)

Engine burns oil between changes, blue smoke on startup or acceleration. Spark plugs may foul. Not specific to the 240, but worth noting for anyone considering newer Volvos.

View all 24 242 / 244 / 245 problems