'94 940 Suddenly Stalls at 50 m.p.h.

Pianoman702 · Post by **Pianoman702** » 22 Dec 2011, 23:00

Earlier today, my boss sent me on some errands to deliver Christmas "thank-you" presents to some of our biggest clients. Most were local, requiring me to drive a mile or so, turn off my engine, hop back in the car, rinse, repeat, etc.

I was driving on the highway in some mild traffic so it was about 50 miles per hour going up a hill when suddenly I lose throttle. There are no warning lights illuminated and the radio and headlights are still working fine as I coast to a stop. When I get to a stop, the car stalls out. I try to restart it and it turns over and ignites for a few seconds, coughs, and then cuts out again. I have about 1/2 tank of fuel still (the gauge works and I track my mileage) and it seems like it wants to start. As I try a second time, the check engine light blinks on and I go through an expletive "why me, why now" sort of fit and check the codes.

From the A-2 port, I read 2-2-1 (Fuel trim too lean)
From the A-6 port, I read 2-2-4 (ECT sensor absent or faulty) <--Is this even related to the main problem?

I've only run 2 full tanks of gas through this car and I'll admit that I have pushed the tank to it's limits, trying to see how many miles I can squeeze out of it. Could the sludge at the bottom of the tank have possibly clogged a fuel line or a pump? And what are other places to check/repair regarding this?

Just for reference, I bought this 1994 945 about two weeks ago and it checked out when I had it inspected by my local Volvo dealer. It has 135,000 on the NOSE (and the odometer works!)

Thanks, and Merry Christmas!
-Ryan

P.S. - For those still reading, the tow-truck that came to get me wouldn't start after my wagon got loaded on to the flatbed. He said, "This never happens," but when my 850 needed to be towed last May, THAT truck from a different company broke down too. My only two experience needing a tow truck. Apparently, my Volvos are like that scene from Monty Python and the Holy Grail... "I don't want to go on the cart!"

SimLyons · Post by **SimLyons** » 22 Dec 2011, 23:07

Do you know when the last time your fuel filter was changed? And yes, their could be condensate (water) at the bottom of the tank....rust and general crud as well. How long did it sit before you bought it? That is low mileage for a '93. It doesn't sound too serious, but the fuel pump is a possibility too.

Maybe a diagnosis by a reputable indie shop?

Pianoman702 · Post by **Pianoman702** » 23 Dec 2011, 07:07

I'm not sure when the fuel filter was last changed, but I know in the past 6-7 years that the P.O. owned it, it was only driven 20,000. In 2010, it was emissions exempt because it was driven under 5,000. It's going to an indie today that I'm familiar with (he does the major work on my 850). What's ironic is that as I was sitting on the side of the road yesterday, he calls and says my 850 is ready to be picked up and he passed it for inspection/emissions. So, at least I have a back-up Volvo. haha

P.S. - The title is wrong, it's a 1994. It was late and I wasn't watching what I was typing!

Post by **rspi** » 27 Dec 2011, 18:57

So, what's the verdict? My guess was a fuel pump relay. I actually had a 740 do that to me but it was the battery. When I unlocked the drivers door the others did not unlock.

Pianoman702 · Post by **Pianoman702** » 27 Dec 2011, 19:14

I heard back today from my mechanic (because I didn't feel like diagnosing it over Christmas and it was a free tow there). It turned out to be the fuel pump quitting. I don't know enough about this car but he quoted me about $800 for the fix. I know the mechanic and he does excellent work at a decent price, but that seems a bit high. He said it's because the part is expensive and hard to get to, being that the pump is in the fuel tank.

I need to get a Haynes!

SimLyons · Post by **SimLyons** » 27 Dec 2011, 23:33

IPD: Haynes manual about $27.00. Fuel Pump (new) for your engine is about $170.00. Might want to add a few seals and o'rings for a few bucks more. Just drive it till it's pretty empty and go after it. I recommend not smoking while undertaking this job!

Pianoman702 · Post by **Pianoman702** » 28 Dec 2011, 12:20

Is there another fuel pump? Like an auxiliary one in the gas tank? That's where my mechanic said it was that's why it was hard to get to and labor-intensive. Does that sound right?

Pianoman702 · Post by **Pianoman702** » 28 Dec 2011, 12:20

Is there another fuel pump? Like an auxiliary one in the gas tank? That's where my mechanic said it was that's why it was hard to get to and labor-intensive. Does that sound right?

SimLyons · Post by **SimLyons** » 28 Dec 2011, 16:34

If you have a Bosch system (All turbos do) there is a pre-pump for about $40. Then the main pump is about $160.

If you have a Bendix (non-turbo, but some non-turbos use Bosch too) then it's about $20 more for the main pump and same for pre-pump. Add about $30 for new check valve and o'rings/gaskets. Besides IPD check with Amazon and other sits as well.

Good luck! (That is VERY steep for labor time!)

Pianoman702 · Post by **Pianoman702** » 28 Dec 2011, 22:14

I know it's a bit off-topic, but how can I tell if i have the Bosch system vs. the Rex Regina?