1992 Volvo 240 running issues

injection · Post by **injection** » 07 Oct 2012, 07:45

3 months ago I replaced the in tank fuel pump because I went on a road trip and during the road trip I kept stalling when trying to go up steep hills at high elevations and I kept smelling gas every time it would stall and the in-tank pump was making an odd noise it was like a scraping noise.

Now fast forward 3 months later and I am having the same issue again but this time I can only drive between 1-5 miles before the car starts to act like it's out of fuel. I am not able to immediately restart the vehicle. I have to wait 30 minutes or so before I can even attempt to even put it into gear and drive anther 1-5 miles before it happens again if I am lucky.

I've swapped out the fuel pump relay with the one from my dad's 240 and I still had the same problem. One problem I did notice is that the fuel pump relay gets really hot to the touch. The on-board diagnostics do not show any error codes.

Before I start spending money on parts is there anything else that I can check?

Post by **billofdurham** » 07 Oct 2012, 10:58

Welcome to Matthew's Volvo Site.

When you replaced the in-tank pump did you replace the sock filter? What was the condition of the original sock filter? Usually they start to break up and small particles of the filter can be pulled through the system, into the main filter, where it can cause a blockage. If the main filter is partially blocked the relay will get hot due to physical resistance associated with the pump.

If any of the connectors leading to the relay are loose or corroded the relay can overheat.

Bill.

injection · Post by **injection** » 07 Oct 2012, 11:10

I was sick with a kidney infection when my dad replaced it and when I asked him today about it he did not put a sock on it.

Post by **billofdurham** » 07 Oct 2012, 11:30

The sock filter is a necessity, in fact at one time on the 240 it was a service item.

The in-tank pump could be pulling debris through from the tank. The main filter will stop it but will soon become clogged causing the problems with running and overheating relay.

I would be replacing both filters ASAP.

Bill.

injection · Post by **injection** » 07 Oct 2012, 13:49

Ok. I'll get right on it.