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1996 850T something fuel oriented, i think

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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kimothyanne
Posts: 34
Joined: 23 April 2012
Year and Model: 850T 1996 Sedan
Location: Hercules, CA

1996 850T something fuel oriented, i think

Post by kimothyanne »

Happy New Year to all,

Okay. I am an amateur mechanic and that is putting it in the best light possible.

I have a 1996, 850 Turbo Sedan. Here is what has happened in the last month or so and my hope is that someone can help me decipher what is going on.

I have had a vacuum leak problem for months. It is that line that comes out from right under the exhaust manifold. I've had it repaired twice at two different shops yet the line keeps "blowing" off. At least, that is what I think happens. The last one actually looked like it had melted. This is one of the two vacuum lines that are right around the injector rail. The one I am speaking of is NOT the one which is connected to the rail but the one that is between the extreme left cylinder (looking at the car from in front) and it's neighbor.

Although I've had this problem the car still ran pretty well. Now, here is what I have done to the car which may or may not be the reason it no longer runs in any reliable manner....if at all.

1) I pulled off the injector rail in order to see if I could get some idea where that vacuum line runs. The last replacement line installed by a shop literally fell off in my hand but I have no idea where/what it connects to.

2) I removed the injector rail previously when I replaced the injector gaskets.

3) Right after the last time I pulled off the rail and checked around the injectors, I accidentally left the door open which killed my battery.

4) Had auto service come out to jump the car at which time I was told that it "wasn't my battery....I needed a new alternator". Which I decided to attempt myself.

5) When I took a look at the alternator it looked almost new. So, took battery in for diagnostics. It was trashed. Got a new one, installed and car started right up.... then,

6) I cannot drive the car around the block without it stalling. Then, it wouldn't start so I decided to replace the spark plugs...which had not been replaced since I purchased the car almost two years ago. I thought that since the vacuum leak was kept happening perhaps the plugs were fouled. And, THEY WERE.

7) Replaced the plugs and the once again....it started right up. I could almost go a block before it would die. It started right up after the stall, but eventually I could not get it to start again.

8) Before all of this I had replaced the MAF sensor. I also ran into a SNAG when removing the injector rail the first time. That trouble was that little cap/seal at the end of the rail, the one used to release fuel pressure, fell into the car. I could never find it but I found that the cap that fits on the end of the tire refill stem fit. So I put that on.

9) After the spark plug replacement, it started up several times but would not stay running which made me think "fuel". I removed the injector rail, once again, disconnected the fuel line, and that little make-shift cap I put on the end.

10) Put it all back together and it started up like a charm, and ran smoothly. Before leaving garage I started it up once or twice.

11) Did NOT get a block from my garage before it stalled out and would not restart.

12) Under the Spark Plug cover there was oil pooled. Is that normal?

13) Does this sound like a fuel pump to anyone? I had a PO120 error on my little OBD scanner but I cannot find out what that means. It seems to be a "bogus" code?

So, is it normal to have oil under the spark plug cover. Does this sound like a fuel pump problem or does ANYBODY have an idea as to what could be wrong?


I appreciate any help, comments or admonishments as required.

Thanks y'all,
kimberly

cn90
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Post by cn90 »

Wow,

You are the rare poster that is so meticulous and lists every detail so well, so hats off to you.

Search forum for Ozark Lee's fuel relay repair. But first jump 15 and 87 and leave the jumper wire there for now. If this fixes the problem, then the fuel relay is bad, if so, you have 3 choices...

1. Fix the relay using Radio Shack Capacitors.

2. New relay is about $50 at dealer. I don't know much about aftermarket brand. Another choice is junkyard relay, which costs about $2 or $3 each.

3. Jumper wire btw 15 and 87, but there are pros and cons of this ghetto approach, search forum for detail.
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

cn90
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Post by cn90 »

P0120 (not PO120) is throttle position switch, easy fix using junkyard part.

Note that "0" is number and "O" is the letter. You need to search using the number, not the letter.
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

Ozark Lee
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Post by Ozark Lee »

With regard to the vacuum line problem, that is tied in with the PCV system and it goes to a nipple on the intake snorkel down by the turbo. That line is a complete PITA since the elbow always rots and, in your case, it sounds like the hard plastic line that it plugs into has also broken which is common. This is generally telling you that the PCV system needs to be serviced. My biggest PCV problems have not been with clogs but rather the hard plastic lines getting brittle and breaking. There are some alternate methods of dealing with the hard plastic line that involve just using heater hose and a vacuum line. The are more robust and considerably cheaper.

Justin has an outstanding writeup on servicing the PCV here:

https://www.matthewsvolvosite.com/forums ... =1&t=28487

CN90 has the cheaper and better modifications to that procedure in this thread:

https://www.matthewsvolvosite.com/forums ... =1&t=53448

All that said, the PCV problems and the elbow on the intake manifold will not cause the car to stall and it sounds like you are on the right track looking at the fuel pump / fuel pump relay. After the car stalls have you depressed the Schrader valve on the end of the fuel rail to get an idea of how much pressure is there? Ideally you would use a fuel pressure gauge on it but if you press the Schrader valve and gas just dribbles out then it is a fuel pump related problem for sure. If you try that trick have a rag handy and be careful not to get gasoline sprayed in your eyes.

Fuel pressure problems don't trip a Check Engine Light and don't post an error code.

...Lee
'94 850 N/A 5 speed
'96 Platinum Edition Turbo
Previous:
1999 V70XC - Nautic Blue - Totaled while parked.
1999 V70XC - RIP - Wrecked Parts Car.
1998 S70 T5
1996 850 N/A
1989 740 GLT
1986 740 GLT
1972 142 Grand Luxe

kimothyanne
Posts: 34
Joined: 23 April 2012
Year and Model: 850T 1996 Sedan
Location: Hercules, CA

Post by kimothyanne »

Thank you to all who answered my plea for help.

The "Schrader Valve" sounds like the little "thingie" on the end of the injector rail that I put a tire stem cap on when I lost the Schrader valve. When I took off the injector rail today, I also disconnected the fuel line (the one that takes a 17mm & 14mm wrench to undo). A bit of fuel, not more than an ounce or so, came out of the rail when I did that.

I ordered a new "schrader valve" cap, I hope we're both talking about the same thing. The cap is the same size as a those that one puts on the stems coming from ones' tire ($2.85 cheapest Volvo part from the dealer EVER). I will read your treatise on the fuel relay and I am hoping I will discover what it means to "jump between 15 & 87".

Learning new things is what makes the world a brighter place and I really do appreciate your responses. Please, bear with me as I learn about this stuff. And thank you to all who replied so quickly and concisely. I really, truly appreciate your time in answering.

I am sure I will be back to ask other questions in my quest to keep my husband from making me buy a Japanese car. I just like Volvo's and would like to stay a "Proud Volvo Owner".

Sincerely,
kimberly

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abscate
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Post by abscate »

Welcome Kim...

MVS has a long tradition of breaking up marriages by making killer female mechanics cure Male challenged Mechanic syndrome, which is easily recognized by the presence of Japanese cars...

Nurse Amy was one of our classics, who solved her fuel relay problem while telling us she had trouble getting under the hood with her 'bump' !!

That does sound a classic fuel pump relay problem, stand by for some links..
Empty Nester
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1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 XC90-in-Red
Link to Maintenance record thread

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abscate
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Post by abscate »

At the front part of this thread are some pictures of the fuel pump relay and jumping instructions. Post back here if you have questions.

https://www.matthewsvolvosite.com/forums ... =Nurse+amy

Apologies if this is too basic .

The fuel pump relay is an electrically operated switch. What we are going to do is bypass the electrical part by pulling the relay out and putting a paper clip in its place. If you have wire and terminals, that is a better thing to use than a paper clip.

I'm also searching for Roberts (rspi) video on this.

Don't forget you get to charge Hubby 115 USd per hour for this.
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 XC90-in-Red
Link to Maintenance record thread

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rspi
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Post by rspi »

'95 855 T-5R M, Panther - 22/28 mpg, 546,000 miles
'95 955 T-5R Yellow Wagon, Lemonade, 180,000 miles
--------------------
Volvo's of past: '87 740 GLE, '79 262C Bertone, '78 264, 960's, '98 S70 GLT, '95 850 T-5R YellowVolvo Repair Videos

kimothyanne
Posts: 34
Joined: 23 April 2012
Year and Model: 850T 1996 Sedan
Location: Hercules, CA

Post by kimothyanne »

Thanks for the info & links. I am going to start reading and HOPEFULLY, get my car back near my home.
Yikes!

kimothyanne
Posts: 34
Joined: 23 April 2012
Year and Model: 850T 1996 Sedan
Location: Hercules, CA

Post by kimothyanne »

Thank you for the link & video. I do have questions:

Do I try to turn the engine over after I jump it, or just turn the key to "on".
Do I have to disconnect the fuel line and drain the gas?
If it IS the fuel relay, is it a Volvo only part to replace it.

Thanks in advance for your time. I did "like & subscribe" to your channel.

Thank you,
k

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