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Hi mplspm,
Välkommen to the mighty and powerful brickboard.com! Your first post! Välkommen!
Never mind them folks and their brake dust machinations delaying their response to answer your questions. I'm in a good mood today, charged up with the tea of earl grey ...
A 1989 Volvo 780? That'd be the 2.8 (maybe the 2.9 version in 1991 and later?) liter engine. You have the Bosch LH-Jetronic 2.2, according to the Volvo 700/900/90 series FAQ. Your 780 shares some systems with the Volvo 760 GLE V-6 so equipped. Ignore the 900-series with six cylinder.
The PRV V-6-equipped 700-900 series models are not well represented in the FAQ. The any 900 series with V-6 may not be in North America before the white block inline 6 engine. You've read the entries in the Volvo 700-900-90 series FAQ:
https://www.brickboard.com/FAQ/700-900/EngineV6.htm
https://www.brickboard.com/FAQ/700-900/EngineFuelinjection.htm
https://www.brickboard.com/FAQ/700-900/FuelSystem.htm
See section on LH-Jetronic 2.2, EZK (I believe you may have the EZK 115, not sure):
https://www.brickboard.com/FAQ/700-900/EngineOBDCodes.htm
Search for the term 'flood' on this page (leaking injector?, injectors grounded in ECU - you say you replaced the ECU with new or test used? See Injector Ground Wires and Harness - though may not apply after shut down as injectors are depowered at the +VDC side at shut down, yet ....)
https://www.brickboard.com/FAQ/700-900/EnginePerformanceSymptoms.htm
You have wesbites that more specifically treat the Volvo Bertone series (262C and the 780 Bertone):
http://volvobertone.proboards.com/
Section on later RWD Volvos at Matthews Volvo site, including 780 articles:
http://www.matthewsvolvosite.com/forums/viewforum.php?f=2
Did the dealership treat possible causes for engine fuel flooding after engine shutdown beyond replacing engine control systems components such as sensors, ECUs, and such? SO:
- Fuel rail pressure is too high. An overly rich running condition caused by a faulty fuel pressure regulator (FPR). The Bosch K-Jetronic FPR, unless I'm wrong, on your 1989 Volvo 780 is vacuum controlled, with a vacuum line connected to the air intake throttle body. An FPR usually fails in the opposite direction with fuel spilling through the vacuum line and into the throttle body. With the fuel injection relay jumpered, or the connector jumpered (See FAQ), you can activate the pumps with the engine safely OFF. Check the fuel pressure. The fuel pump delivers some ten-fold fuel volume then that needed for injector delivery into the operating engine, with excess passing through the FPR. If the FPR is faulty, with an excessively high fuel pressure, than that can be cause. A dangerous condition.
- You have one or more fuel injectors leaking, and continuing to leak, until the fuel pressure drops low enough to close the faulty fuel injector(s). It is probable the leaking, faulty injector(s) continue to leak fuel into the engine after shutdown until the high fuel pressure side depletes, whether a faulty FPR or not. A dangerous condition.
You and the mechanic's service, then, would need to check fuel pressure at the fuel rail. (See FAQ links, and read through the FAQ). If fuel pressure at the fuel rail drops after engine switched off, you would need to check each injector operation. Any injector may be at fault, including the cold start injector. Though you need not run the engine as you can use the aforementioned method to jumper the fuel injector relay connector.
I'll bet you get a strong fuel smell after engine shut off? The engine oil, at the end of the engine oil level dipstick smells strongly of gasoline? Or a whiff at the open oil fill cap. Do this after the engine is shut off and cooled down. You may have risk of fire or combustion and certainly back fire when you start the engine.
As your 1989 Volvo 780 is equipped with the Bosch LH-Jetronic 2.2 / EZK ignition, both systems do offer an OBD test function using a test light. The Volvo dealership should still have these Volvo factory 'green' service manuals in print, microfiche, or PDF online from Volvo Cars AB or Volvo Cars of America. (See the Volvo tips links, below in this message.)
Let's see what we can find here for you online.
Volvo Tips provides some or all the the Volvo factory service 'green' manuals online in an Adobe Flash or Shockwave (?) or HTML 5 format. I'm unsure. You may want to verify the media runtimes on your chosen web browser, as well as your web browser, are up too date:
http://www.volvotips.com/index.php/740-760-780/volvo-740-760-780-service-and-repair-manual/
and:
http://www.volvotips.com/index.php/740-760-780/
http://www.volvotips.com/index.php/740-760-780/volvo-740-760-buyers-guide/
You may find some useful info at:
http://www.davebarton.com/
http://www.volvomechanics.com/
I hope that helps you and your mechanic service figure out the fault. Sorry I cannot be more specific.
And wash away the brake dust from the wheels. Your Volvo auto car will run better.
Hope that helps.
Questions?
MacDuffy
(Please ignore esoteric references that follow. Or anything with brake dust. Just wash it away.)
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