1993 244 - Sudden no start

zimmerdale · Post by **zimmerdale** » 01 Aug 2015, 20:08

I bought a 1993 240 sedan in Spring for my son to drive. It has 250K miles and I decided to do a major tuneup before turning him loose with it. I changed plugs, wires, cap, rotor, water pump, coolant hoses, timing belt, alternator, fuel pre-pump, fuel filter, fuel pump relay, vacuum lines, new ceramic fuses, new rubber bits, flushed all fluids, etc.

The car has been running great for the last month.

This week my son said the Check Engine Light came on when he started it. I told him to wait and let me check it out, be he decided to ignore the light and make a 60 mile trip. About 40 mile in, the car died and wouldn't restart. When I went to retrieve it, I pulled only one code from the diagnostic module: 1-2-3.

The first thing I did was order a new coolant temp sensor and replaced that. The car still wouldn't start. Today I bought a new crank position sensor and replaced it. Still no start. The engine cranks like normal, and occasionally there's a hint of firing, but no starting at all.

I verified spark in by pulling a wire and observing spark and by checking each wire with my timing light. I tested both fuel pumps and both run fine when jumped at the fuse. I tried starting the car while jumping the main pump at the fuse. No starting.

The first big clue was when I sprayed starting fluid into a vacuum port in the throttle body. The car will start for a few seconds each time I spray fluid in. So it seems to be a fuel problem.

The vacuum line to the fuel pressure regulator is dry, and there is pressurized fuel in the fuel rail when I press the Schrader valve. I can't start the car to verify running fuel pressure.

I'm good and stumped at this point. I would appreciate any help proceeding from here.

Thanks!
Jason

93Regina · Post by **93Regina** » 01 Aug 2015, 20:14

zimmerdale wrote:1993 240

Check Radio Suppressor relay

zimmerdale · Post by **zimmerdale** » 01 Aug 2015, 20:18

I was under the assumption that 240s don't have radio suppression relays. I thought only 740s have those.

According to Dave Barton (http://www.davebarton.com/volvorelays.html):

"A 240 does not use a Radio Noise Suppression Relay for the Fuel Injection."

93Regina · Post by **93Regina** » 02 Aug 2015, 09:24

zimmerdale wrote:240s don't have radio suppression relays.

I've got two 240s and a 940, my bad.

Check power at injectors or IAC; is there power?

zimmerdale · Post by **zimmerdale** » 03 Aug 2015, 12:05

14 V at IAC with key turned on.

Only 2-3 V at the injectors when cranking the engine.

I also pulled the fuel rail with injectors intact, re-grounded the wiring harness, and cranked the engine. No spray at all from the injectors.

So, I have spark.
I have fuel to the fuel rail.
I have no spray from any of the injectors.
I seem to have very low voltage at the injectors.

What are the possible problems?

Grounding/wiring issues in the harness by the injectors? That could also explain the 1-2-3 code that was originally present.

zimmerdale · Post by **zimmerdale** » 03 Aug 2015, 14:33

As part of my major tuneup, I had to change the fuel sending unit because the wiring was broken inside it and the pre-pump couldn't run.

I noticed when I filled the tank with gas afterwards that the fuel gauge needle didn't go above about 3/4 on a full tank. So I assumed it would register empty lower than normal, too. Or at least in the correct range.

My son drove the car for a a few hundreds miles and then the car stopped working. When I brought it home, the fuel gauge said half a tank, so I assumed it had fuel.

The actual problem with the no start? It was out of gas.

Diagnostic FAIL!

Let that be a lesson for you kids. I've been working on cars for 20 years, and I still make some of the dumbest mistakes around. Don't assume anything!

Now I have to figure out why the new fuel sending unit has a range on the gauge from 1/2 to 3/4 tank.