1994 850 Turbo died while driving, won't start

[gulfan]

1994 Volvo 850 Turbo
201,000 Miles
Calgary, AB
Outside temp is 6c, 43f

Car ran fine for previous 20 minutes of highway driving. After heavy acceleration, car stalled and died. Engine would crank over, however would not start. Tachometer would bounce around ever so little off the pin, but would not start. Unplugged the battery, waited a few minutes, tried again and nothing.

Next morning I went back to the car and tried to start it, as if it was flooded and no difference. Pulled the codes and I got the following:

3-2-2 Wrong gear value
3-1-3 Faulty signal from PNP
5-4-3 Misfire on at least one cylinder
4-5-2 Misfire cylinder 2
5-4-2 Misfire on more than one cylinder

I reset the codes and tried starting the car again, nothing. I moved the gear selector from P – L 15 times or so, tried again nothing, checked the fuses, all fine. I also removed the fuel relay and jumped 13 to 87, but nothing. Checked the codes again but nothing popped up.

I replaced the camshaft position sensor last year after having trouble starting. PNP switch has given me troubles over the years, but the third gear problem disappeared after a day. It’s given me the flashing light maybe twice over the last 5 years. Never did replace the PNP switch.

Not really too sure what to look at? Sparkplugs are 4 years old, not sure when the caps, cables and rotor were last replaced. Not sure if it’s getting fuel or spark? Starter was replaced a few months ago. Little motor near the throttle body is on when in POSII. Intercooler plumbing didn't collapse .

After I cleared the codes and tried starting it again, no new codes came back. Not too sure where to start, any ideas?

[gulfan]

I took the throttle body cover off and and pressed the schrader valve, no gas sprayed out only a little bit of air. When turning the car into POS II, the fuel pump relay ticked, however the fuel pump made no sound at all. I folded down the back seat and removed the carpet near the trunk. Under the two covers there was quite a bit of dirt / dust. With someone listening again and touching them, while trying to start the car there was no sound or motion.

Would this be the fuel pump being dead? Is this an easy fix (not too much experience)?

[jblackburn]

Yeah, sounds like it died to me.

The replacement is very easy, should take you less than an hour in all.

You can easily buy a pump insert and put it into the existing assembly. The trunk cover unscrews and the whole thing lifts right out, then you put in the new one, button it back up, and reconnect the hoses.

[confused_al]

HTH
https://www.matthewsvolvosite.com/forums ... 6515#56515

http://volvospeed.com/vs_forum/index.ph ... t-how-too/

I got my Walbro ($60) from http://www.europartsdirect.com/

[gulfan]

Thanks, appreciate the help in sorting this problem out. Once I replaced the fuel pump it started up perfectly.

I made a donation to the site.

I’m wondering what else I should replace. When I put the order into FCPGroton I got new plugs, wires, cap, rotor. Starter is quite new, cam shaft position sensor is new. Fuel pump is brand new. Wondering what else I should replace just so I don’t get “stranded” again.

[mirae1]

Timing belt?????

[whoa]

Yeah, I got stuck up near Yosemite with a dead pump. $1000 later we were back on the road.

I'm building up a stock of parts to stash in the car (there are nice stash cavities under the wagon's rear deck) for stuff like that. A new serpentine belt and thermostat are obvious calls. If I run across serviceable used sensors (cam, crank, temp, o2, maf) I'll pick them up. Fuel pump is added to the list.

And do be sure your timing belt, current serp belt, thermostat, water pump, hoses are in good shape. And replace the in-line fuel filter under the rear passenger door; maybe the pump had to work too hard because of it?