About a month ago I posted about this car and received a lot of good advice on the 245. The one thing I learned is that I needed to go to "basics" on the car, especially the fuel system and the fuel tank. I removed the fuel rail and found out that all of the injectors were clogged beyond recovery, at least with any tools that I have. Four new ones are on the way (delay for back order) and a new pressure regulator (while I've got it off might as well), I've cleaned the rail with Gumout until it ran clear all through it and scrubbed it with a brass brush. Very varnished.

All that varnish was coming from somewhere. The guy I bought it from said it ran for him for about five minutes and then wouldn't run anymore. I think that the entire fuel system was coated in varnish and when he started it, it got sucked through the whole system all the way up to the injectors. Last Saturday I drained the tank and dropped it from the car. The gas in it was the color of black coffee. There is about an inch and a half of "molasses" in the bottom of the tank. The sending unit was completely disintegrated, the in tank filter was hard as a rock, and the in tank pump was missing completely. I've got all those parts and a new main pump and filter from IPD.

The tank is either going to have to be "boiled out" or replaced.

I believe that if I can get the fuel system completely cleaned this car will start and run. My concern are the fuel lines. I have heard that they are NLA from Volvo or aftermarket, that I need to carefully remove the end fittings from the lines and then shrink wrap them to new fuel line.

If anyone can give any advice or information it would be appreciated:

1. Fuel line--from tank and return line--what size (interior and exterior diameter) and what pressure tolerance do I need for each? (I know I could measure this myself when I get them off but I'd feel more confident if someone who has done this can confirm).

2. Any suggestions on cutting out the old fittings and heat shrinking them to the new line?

3. The one radiator shop has priced $300 to $350 for cleaning the tank with acid and resealing it. IPD has a Volvo OEM tank for @400, can get aftermaket from Advanced for @310. Has anyone had any experience with these aftermaket tanks?

Thanks again for everyone's help. It may not seem like it but I'm having fun with this.