1991 Volvo 240 problems
The Volvo 200 Series (or 240 and 260 Series) is a range of mid-size cars produced by Swedish company Volvo Cars from 1974 until 1993, with more than 2.8 million total units sold worldwide. Like the Volvo 140 Series (1966 to 1974), from which it was developed, it was designed by Jan Wilsgaard.
The series overlapped production of the Volvo 700 Series (1982 to 1992). As the 240 Series remained popular, only the 260 Series was displaced by the 700 Series, which Volvo marketed alongside the 240 for another decade. The 700 was replaced by the 900 Series in 1992, a year before the 240 was discontinued. Production of the 240 ended on 14 May 1993, after nearly 20 years, with the basic platform and architecture lasting 27 years, if the production run of the original 140 Series is aggregated.
History
The Volvo 240 and 260 series were introduced in the autumn of 1974, and was initially available as six variations of the 240 Series (242L, 242DL, 244DL, 244GL, 245L and 245DL) and two variations of the 260 Series (264DL and 264GL). The 240 Series was available as a sedan (with two or four doors) or a station wagon, however, the 260 Series was available as a coupé (262C Bertone), two-door sedan, four-door sedan, or station wagon. The 200 looked much like the earlier 140 and 164, they shared the same basic body shell and were largely identical from the cowl rearward. However, the 200 incorporated many of the features and design elements tried in the Volvo VESC ESV in 1972, which was a prototype experiment in car safety. The overall safety of the driver and passengers in the event of a crash was greatly improved with very large front and rear end crumple zones. Another main change was the new engines offered, which were of an overhead cam design based on the earlier B20. The 260 series also received a V6 engine in lieu of the 164's inline-six.
The 200 Series had MacPherson strut-type front suspension, which increased room around the engine bay, while the rear suspension was a modified version of that fitted to the 140 Series. The steering was greatly improved with the introduction of rack-and-pinion steering, with power steering fitted as standard to the 244GL, 264DL and 264GL, and there were some modifications made to the braking system (in particular the master cylinder).
The front end of the car was also completely restyled with a "shovel nose" which closely resembled that of the VESC prototype vehicle – that being the most obvious change which made the 200 Series distinguishable from the earlier 140 and 160 Series. Other than all the changes mentioned above, the 200 Series was almost identical to the 140 and 160 Series from the bulkhead to the very rear end. In 1978, a facelift meant a redesigned rear end for sedans, with wraparound taillights and a trunk opening with a lower lip. The dashboard was derived from the safety fascia introduced for the 1973 model year 100 Series - the main change for the 200 Series was the adoption of slatted "egg crate" style air vents in place of the eyeball style vents used in the 140/160 and the square clock. All models were available with a choice of four-speed manual or a three-speed automatic transmission. Overdrive was also optional on the manual 244GL, while a five-speed manual gearbox was optional on the 264GL and 265GL.
In the autumn of 1975 (for the 1976 model year in America), the 265 DL estate became available alongside the existing range, and this was the first production Volvo estate to be powered by a six-cylinder engine. The choice of gearboxes was also improved, with overdrive now available as an option in all manual models except the base-model 242L and 245L. As before, a three-speed automatic was optional in every model. The B21A engine gained three horsepower; a new steering wheel and gearknob were also introduced.
At the 1976 Paris Motor Show Bertone first showed the stretched 264 TE, a seven-seat limousine on a 3,430 mm (135.0 in) wheelbase, although it had entered production earlier. The raw bodies were sent from Sweden to Grugliasco for lengthening, reinforcing, and finishing. Carl XVI Gustav of Sweden used one, as did much of East Germany's political leadership.
For 1977 the B19A engine with 90 PS (66 kW) replaced the B20A in most markets, although the old pushrod type soldiered on for another two years in some places. This is also the year that the sportier 242 GT arrived.
In 1978 the grille was altered, now with a chrome surround. Rear view mirrors were now black, while the front seats were changed as were the emblems, while interval wipers were introduced. 1978 models were also the first 240s to receive a new paint formula, to help solve the severe rust problems in previous model years.
The 1979 model year brought a full facelift front and rear, the most obvious change being the adoption of flush fitting square headlamps on the DL or rectangular headlamps on the GL, GLE in place of the recessed circular units. The sedans received new wraparound rear lamp clusters and a restyled leading edge to the trunk lid, while the rear of the wagons remained unchanged. The GLE was added while the L was cancelled, and the six-cylinder diesel arrived late in the year. For 1980, the sporty GLT arrived, replacing the GT. For 1981 there was yet another new grille, while the station wagons received new, wraparound taillights. The B21A gained some four horsepower, now 106 PS (78 kW), while the carburetted B23A with 112 PS (82 kW) was introduced in some markets. The Turbo arrived, while six-cylinder models now had a more powerful 2.8-liter engine. 1981 also saw the dashboard altered significantly, which a much larger binnacle in order to bring the radio and clock within the driver's line of sight. The instrument pod itself, which had been unaltered since the 1973 model year 100 Series, was also redesigned.
Incremental improvements were made almost every year of the production run. One of the major improvements was the introduction of the oxygen sensor in North America in late 1976 (1977 models), which Volvo called Lambda Sond and developed in conjunction with Bosch. It added a feedback loop to the Jetronic fuel injection system already in use, which allowed fine-tuning of the air and fuel mixture and therefore produced superior emissions, drivability and fuel economy.
For the 1983 model year, Volvo dropped the DL and GLE labels, selling the cars simply as 240s. In the domestic Swedish market, the 240 could be had with a 2.1 or 2.3-liter engine (more options were available in export), but the bigger engine always came coupled with a five-speed transmission and tinted windows. The 1983s also received wider side trim and all models had the larger taillights introduced on the previous year's GLT model. A B23E-engined GLE variant was also added (not available with two doors). Buyers protested against the lack of grades and they returned for 1984. A new manual gearbox also arrived for 1984, while a four-speed automatic option was available in the GL. The GLT and Turbo versions received a taller grille.
While Volvo had been planning to discontinue the 200-series since the early 1980s, the design kept selling well and Volvo provided steady updates. In late 1991, for the 1992 model year, it received 160 detail improvements including changes to the heater controls, heated rear view mirrors, and revised front seats. For the final, 1993 model year, air conditioning units were upgraded to use R-134a rather than the ozone-depleting R-12 (Freon).
About one-third of all 240s sold were station wagons, which featured very large cargo space of 41 cubic feet (1.2 m3). They could be outfitted with a rear-facing foldable jumpseat in the passenger area, making the wagon a seven-passenger vehicle. The jumpseat came with three-point seat belts, and wagons were designed to have a reinforced floor section, protecting the occupants of the jumpseat in the event of a rear-end collision.
A 1993 Volvo 240DL was driven by IKEA founder Ingvar Kamprad, who stopped driving it when he was told the car was too dangerous due to outdated safety design two decades later.
The last 200 produced was a blue station wagon built to the Italian specification and named the "Polar Italia", currently displayed at the Volvo World Museum. It was manufactured the 14th May 1993.
Social links
Common 1991 Volvo 240 problems
The Volvo 240, produced from 1975 to 1993, is known for its robustness and longevity. However, there are several common issues that owners have reported, particularly with the 1991 model.
- Heater Blower Motor: The heater blower motor, located in the deepest confines of the dash, is known for its powerful heating capabilities. However, it can take 3-4 hours for an experienced mechanic to replace, and even longer for beginners. The motor is of decent quality, but if it fails, it may need to be replaced one or more times during the ownership of the car.
- Air Intake Hose & Air Box Thermostats: The large plastic accordion style intake hose that connects the air mass meter to the intake manifold can wear through over time, allowing unfiltered and unmetered air to enter the engine. This can cause erratic behavior and reduced performance. The air box thermostat, which routes hot air from the exhaust manifold to aid in cold start performance, can also fail, causing super heated air to be drawn into the engine and reducing performance.
- Seat Lumbar Support Systems: The lumbar support systems in the Volvo 240 seats are known for failing between 50-100,000 miles. The bottom seat cushion support grid is also a weak spot, causing drivers to struggle when trying to see over the steering wheel when it fails. An improved version of the seat grid will be introduced this fall.
- Fuel Pump Relay: The fuel pump relay is known for causing starting problems in the 1991 Volvo 240. However, replacing it may not necessarily solve the problem, as other issues such as faulty spark plugs or clogged fuel filters may also be contributing factors.
- Starting Problems: Some 1991 Volvo 240 owners have reported experiencing starting problems, particularly after moving the car on the drive and then trying to start it again a few hours later. This can be caused by issues with the carburetor, such as a vacuum pipe for the ignition timing or an auto choke that is oiling up.
In summary, while the Volvo 240 is known for its robustness and longevity, there are several common issues that owners have reported, particularly with the 1991 model. These include issues with the main fuses, heater blower motor, air intake hose and air box thermostats, seat lumbar support systems, fuel pump relay, and starting problems. Regular maintenance and inspections can help to identify and address these issues before they become major problems.
Are old Volvo 240s reliable?
8 Robust And Ultra-Reliable
Being the first manufacturer to fit 999,999 mph odometers to its cars, Volvo was underlining its vehicle's potential for longevity, and thanks to many galvanized parts, excellent build quality, and almost bomb-proof mechanicals, the 240 continues to spin those digits.
What engine is in a 1991 Volvo 240?
1991 Volvo 240 SERIES (2.3L 4 -cyl Engine Code [8] B230F 88 1) Motor Oil, Filters and Lubricants - AMSOIL.
How long did the Volvo 240 last?
20 years
On 5th May 1993, after nearly 20 years of huge success and 2,862,573 cars produced (of which 177,402 were 260s), the 240 took its final bow.
Are Volvo 240 rare?
Globally, the Volvo 240 is far from a rare vehicle. There were over 2.8 million models built using the 240 designation over its entire run, with a further 177,000 nearly-identical 260s produced during the same period.
Are old Volvo 240s reliable?
8 Robust And Ultra-Reliable
Being the first manufacturer to fit 999,999 mph odometers to its cars, Volvo was underlining its vehicle's potential for longevity, and thanks to many galvanized parts, excellent build quality, and almost bomb-proof mechanicals, the 240 continues to spin those digits.
What engine is in a 1991 Volvo 240?
1991 Volvo 240 SERIES (2.3L 4 -cyl Engine Code [8] B230F 88 1) Motor Oil, Filters and Lubricants - AMSOIL.
Is the Volvo 240 a safe car?
More than anything else, it was the car's crash safety properties combined with the fine driving characteristics which attracted attention when the car appeared on the market the world over. for Highway Safety, IIHS, cited the Volvo 240 Estate as the safest car on the American market.
Does the 1991 Volvo 240 have airbags?
New member. A driver's side air bag was standard equipment on U.S. spec 1990+ 240s.
1991 Volvo 240 car problems categorized by type of issue
After analyzing all complaints sent to the NHTSA and researching popular Volvo 240 problems, we found that the most common problems with these 2023 model year vehicles are:
- Air bags problems
- Electrical system problems
- Service brakes problems
- Hydraulic problems
- Vehicle speed control problems
The graph below shows statistics for all 1991 Volvo 240 vehicle components and the number of complaints received.
1991 Volvo 240 complaints
The NHTSA has received 17 complaints about various vehicle components related to the 1991 Volvo 240.
EXTERIOR LIGHTING,AIR BAGS,FUEL/PROPULSION SYSTEM PROBLEM
- Date Of Incident: 2017-11-24
- Crash: 1
- VIN: YV1AA8843M1
- Components: EXTERIOR LIGHTING,AIR BAGS,FUEL/PROPULSION SYSTEM
- Summary: "TAKATA RECALL" UNKNOWN
SEATS PROBLEM
- Date Of Incident: 2001-10-03
- Number Of Injuries: 1
- Crash: 1
- Components: SEATS
- Summary: I JUST SAW ON THE NEWS ABOUT SEATS FALLING BACK DURING ACCIDENT WHEN I WAS HIT BY A TRACTOR-TRAILER IN 2002 TWO VOLVO 240 MY SEAT WENT ALL THE WAY BACK LIKE THE NEWS SHOWED LUCKILY NO ONE WAS IN THE REAR SEAT
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 2006-02-02
- Fire: 1
- VIN: YV1AA8845M1
- Components: ELECTRICAL SYSTEM
- Summary: CAR WAS IN DRIVEWAY WARMING UP PRIOR TO DRIVING FOR SCHOOL. AFTER ABOUT 5 TO 10 MINUTES DASH CAUGHT FIRE AND FLAMES WERE COMING FOR HEATER VENTS. USED A GARDEN HOSE TO EXTINGUISH FIRE AND FIRE DEPARTMENT WAS CALLED. DASH AND INTERIOR WAS DAMAGED BUY SMOKE, WATER AND FIRE. *NM
AIR BAGS PROBLEM
- Date Of Incident: 2004-08-19
- Components: AIR BAGS
- Summary: WHILE DRIVING AIR BAGS DEPLOYED AUTOMATICALLY AT 10 MPH IN BUMPER TO BUMPER TRAFFIC. THERE WAS ALSO A CHEMICAL BURNING SMELL INSIDE THE VEHICLE. THE SRS LIGHT ILLUMINATED INTERMITTENTLY. *AK
SERVICE BRAKES, HYDRAULIC PROBLEM
- Date Of Incident: 1999-08-03
- Crash: 1
- VIN: YV1AA8843M1
- Components: SERVICE BRAKES, HYDRAULIC
- Summary: WHEN PULLING INTO PARKING SPACE, AT 5 MPH, APPLIED BRAKES AND THEY WENT TO THE FLOOR, HIT A CONCRETE WALL, AIRBAG DEPLOYED. VEHICLE WAS TOTALLED. DEALER NOT AWARE OF PROBLEM. REAR BRAKE PADS AND ROTORS HAVE BEEN REPLACE SEVERAL TIMES DURING LIFE OF VEHICLE. *AK
AIR BAGS PROBLEM
- Date Of Incident: 1999-05-12
- Number Of Injuries: 1
- Components: AIR BAGS
- Summary: WHILE DRIVING AT 30 MPH DRIVER'S SIDE AIR BAG DEPLOYED FOR NO REASON; NO BUMPS/CURBS,OR POTHOLES WERE HIT, AIR BAG DEPLOYMENT CAUSED BURNS TO THE CONSUMERS ARMS. DEALER HAS BEEN CONTACTED. *AK
VEHICLE SPEED CONTROL PROBLEM
- Date Of Incident: 1993-11-01
- VIN: YV1AA8854M1
- Components: VEHICLE SPEED CONTROL
- Summary: THROTTLE CABLE FREEZES UP CAUSING CONSUMER TO USE EXCESSIVE PHYSICAL EFFORT TO ENGAGE ACCELERATOR PEDAL.
AIR BAGS PROBLEM
- Date Of Incident: 1997-06-17
- Number Of Injuries: 1
- Crash: 1
- Components: AIR BAGS
- Summary: AIRBAG IS DESIGNED/LOCATED IN SAME LOCATION WITH THE HORN CAUSING SERIOUS HAND INJURY WHEN AIRBAG DEPLOYED, AS DRIVERS HAND WAS ON THE HORN DURING VEHICLE COLLISION.
AIR BAGS PROBLEM
- Date Of Incident: 1997-06-17
- Number Of Injuries: 1
- Crash: 1
- VIN: YV1AA8853M1
- Components: AIR BAGS
- Summary: VIOLENT DEPLOYMENT OF DRIVER'S AIR BAG UPON IMPACT, RESULTED IN A SEVERLY FRACTURED WRIST AND FOREARM ABRASIONS AND BRUISES. *AK
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1996-08-29
- VIN: TV1AA8849M1
- Components: ELECTRICAL SYSTEM
- Summary: ELECTRONIC CONTROL UNIT FAILED, CAUSING ENGINE TO STALL.
AIR BAGS PROBLEM
- Date Of Incident: 2024-11-24
- Crash: 1
- Components: AIR BAGS
- Summary: CONSUMER WAS DRIVING DOWN THE ROAD AND ANOTHER CAR WAS PULLING OUT OF THE DRIVEWAY, TO AVOID HITTING THE OTHER CAR, VEHICLE HIT A POLE AND THE DRIVER'S SIDE AIR BAG DIDN'T DEPLOY . *AK
POWER TRAIN PROBLEM
- Date Of Incident: 1994-01-01
- VIN: YV1AA884XM1
- Components: POWER TRAIN
- Summary: POWER TRAIN TRANSMISSION, PARKING PAWL INTER LOCKING, CAN TAKE KEY OUT IGNITION SWITCH IN DRIVE. *AK
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1995-11-08
- VIN: YV1AA8842M1
- Components: ELECTRICAL SYSTEM
- Summary: MAIN COMPUTER (BRAIN) ON VEHICLE FAILED, VEHICLE WILL SHUT DOWN UNEXPECTEDLY. TT
SERVICE BRAKES, HYDRAULIC PROBLEM
- Date Of Incident: 1995-09-18
- VIN: YV1AA8844M1
- Components: SERVICE BRAKES, HYDRAULIC
- Summary: BRAKE FAILURE, WHEN APPLIED COMPLETE LOSS OF EFFECTIVENESS, PEDAL WENT TO THE FLOOR, REPLACEMENT OF DISC PADS. TT
ELECTRICAL SYSTEM PROBLEM
- Date Of Incident: 1995-10-06
- Components: ELECTRICAL SYSTEM
- Summary: THE REAR LIGHT WIRES ARE BEING BROKEN DUE TO METAL FATIQUE AND CAUSING THE REAR BRAKE LIGHT NOT TO WORK. PLESE DESCRIBE. TT
VEHICLE SPEED CONTROL PROBLEM
- Date Of Incident: 1995-04-07
- VIN: YV1AA8840M1
- Components: VEHICLE SPEED CONTROL
- Summary: ACCELERATOR PEDAL STICKS UPON FIRST STARTING VEHICLE, CAUSING EXCESSIVE PHYISICAL EFFORT TO LOOSEN. *SKD
AIR BAGS PROBLEM
- Date Of Incident: 1995-01-03
- Number Of Injuries: 1
- Crash: 1
- VIN: YV1AA8841M1
- Components: AIR BAGS
- Summary: DURING HEAD ON COLLISION AIR BAG DID NOT DEPLOY. TT
Positive 1991 Volvo 240 car reviews
Additional sources
More sources of information about 1991 Volvo 240 problems:
Top 10 Common Issues with Volvo 240 Models
Mar 11, 2011 ... Top 10 Common Issues with Volvo 240 Models · Main Fuses · Heater Fan · OD Relay, Wiring, Switch & Solenoid · Motor & Transmission Mounts · Flame Trap ...
Common Issues With The Volvo 240 | Volvo Owners Forum
Dec 2, 2009 ... Common Issues With The Volvo 240 · 1. rust â€" its hard to replace parts when the hardware is fused together, holes in the floorboards, etc. · 2.
Q&A: Troubleshooting 1991 Volvo 240 Charging System Problems
Dec 17, 2009 ... There is a plug for accessories on the drivers side fire wall disconnect that aand clean and check for broken wires. The wiring harness for ...
1991 Volvo 240 Problems and Complaints - 7 Issues
Problem with your 1991 Volvo 240? Our list of 7 known complaints reported by owners can help you fix your 1991 Volvo 240.
1991 volvo 240. The fuel gauge is broken and I'd like advice on if it ...
Jun 2, 2015 ... I got the volvo in February as my first car. The Guage was broken then too. I was just wondering if this was a common problem that could be ...
Other years of Volvo 240
Are you having problems with your 1991 Volvo 240?
Karson Reynolds 2025-04-11
Above all, it should be noted that a well-maintained 1991 Volvo can run forever, but if maintenance has been shoddy, all bets are off. However, I absolutely love this car! I find myself thinking about it all too often while driving, whether it's because of its surprising uphill pulling power, its ability to fit an astonishing amount of stuff in the back of the wagon, or simply the general comfort of the ride. That's saying a lot, considering that the 240 is not really anyone's idea of a comfortable, powerful car, but from the correct perspective, it is nothing short of a treat. The 240 is full of surprises that make it a joy to drive. Right off the line, the 240 may seem like a bit of a lazy beast, but once the 5-speed hits its stride around 35, it has plenty of big, lazy power. This car may never spin its tires, but it keeps up with traffic perfectly well. The 240 is definitely not a sport coupe, but it feels so good to drive. Heavy, smooth, and surefooted, it's like a very low pickup truck, but somehow better. The rear-wheel drive is great, absolutely amazing in snow, which is where half of the TANK comes from. The other half is pure build quality. The car is solid, overbuilt to hell, and full of big clunky metal parts. It isn't unfair to say the car is full of simple 1970s engineering, but here it is a compliment.In our modern era of puffy plastic lozenges, a spare, hard, pure steel box stands out both for its unusual, utilitarian appearance and brilliant security. This car will take a thrashing, and come out running like a champ. Volvos have saved countless lives - yes, safety technology has come leaps and bounds since 1991, but these are the cars that safety standards were once measured by. You know someone (or at least someone who knows someone) who not only lived through a horrific wreck in a Volvo, but walked away. Repairs are easy for even the most rudimentary shade tree mechanic - with a Bently manual and a metric tool set in hand, almost nothing is off limits. I replaced my own timing belt in an hour and a half in a parking lot - thanks to more smart, simple Swedish engineering, a broken timing belt does not ruin the engine. It's nothing more than a nuisance, a protracted inconvenience. On the downside, these inconveniences increase with age. The legendary engine may run for upwards of a million miles (and beyond, again, with good maintenance), but in that time plastics become brittle, electronics corrode. The fuses are idiotic in placement and execution, the tail light contacts require almost monthly upkeep to avoid a ticket, some relays will burn out and introduce a cascade of electrical gremlins. As a tall person, I take some issue with the size of the cockpit. I fit, I've become used to it, but there isn't a ton of room. The 3rd row seat, while novel, is in the rear crumple zone - a significant rear-ending may not limit the Volvo's ability to limp home, but it may easily kill anyone seated in the way back. But the bottom line is that if you are patient, your expectations are realistic and you have a AAA card on hand, a Volvo will be your friend for a long, long time. We have a Hyundai for quick jaunts to the store. It's fast and easy, but has been in the shop far more than the old beast.
Reymundo Erdman 2025-04-07
Hi there! I hope you're doing well. I just wanted to share my experience with my Volvo wagon. We actually bought it second-hand with 160K miles on it, but it's been such a reliable car for us. It's amazing that even with changing the oil only every 10K miles, it's still going strong at 238K miles! We did have a fuel relay fail on us, but it was an easy and affordable fix. I really wish they still made cars like this - finding a low mileage replacement when ours finally gives out will be a challenge. Take care!
Ernie Kunde 2025-03-15
I drove my trusty Volvo DL wagon for an impressive 25 years! Unfortunately, it was involved in an accident when a young driver made an illegal turn in front of me. Thankfully, I was able to drive my sturdy Volvo home and was unharmed. The other driver's car, a newer plastic Nissan, was completely destroyed. Although it was difficult to part with my beloved car, the insurance offer was actually very good. It's been a few years since the accident, and while I miss my Volvo, I have many fond memories of our time together. In fact, I still wonder what happened to it after it was taken away. Interestingly, I recently discovered that my Volvo was actually a 1988 model, not a 1990 as previously thought.
Amari Ernser 2025-03-01
I hope you're doing well! I only drive my car in the summer because I don't want it to rust. It spends every night in the garage while my wife's cross country stays outside. These cars are great and solid, and with a 5-speed, they get pretty decent highway mileage, around 32-34.
Tom Hermann 2025-02-18
I love Volvos! Your story about the station wagon saving your life is amazing. It's great to hear that you immediately bought another Volvo, this time a sedan. The euro style is so cool and unique, and I agree that the boxy design adds to its charm. Plus, the fact that it's rear-wheel drive means you don't have to worry about axles and boots going bad. And with the engine not being crossed from right to left, there's plenty of space to work on it. It's great that you were able to replace the starter and do a tune-up yourself. Overall, Volvos are known for their solid design, roominess, and reliability. Thanks for sharing your experience with us!