Two main questions: 1) How hot should the fuel pump relay get? 2) do the cutting-out symptoms look like a weak fuel pump?

During the 2K or so miles that I've driven this car I thought that it cut out 4-5 times. Almost like a contact was breaking. But it was so infrequent I thought it was me - perhaps an awkward upshift or bump in the road.

Today it began to stall more:

1) Starting from a stop it would stumble; then cut out after a shift to 2nd gear; if you let off the pedal, the motor catches and it's OK to drive.

2) Most times under load eg. high RPM shift 3rd to 4th it did the same.

3) Shut it off for 5 minutes and took 3 tries to restart; had rough idle; stumbled for the 1st minute. I was in a parking lot and had to let it warm up before I could drive. Then it was OK.

4. 3-4 times it stalled - either coasting or at a stop.

5. When it 1st stalled, I replaced the fuel pump relay with my spare. I opened the one from the car and the metal contacts inside were just a little too hot to hold onto. The 2nd relay felt slightly less hot when I got home.

6. I drove home ~ 35 miles with no real problem except the occasional stumble.

7. At home now the pump itself is not hot. It's noisy I think but I'm not sure how a "normal" pump should sound. I listened at the tank for the pre-pump but I've never really been able to tell on that. I hear fluid gurgling but I think that's the return.


I suspect: a) the main pump is weak and causing the replay to overheat (I don't know if this is possible); b) the fuel filter is bad.

The previous owner bought new and had serviced at Volvo. I asked if he'd replaced the fuel pump and he said it never came up. I don't know if that means that Volvo tested fuel pressure and found it to be OK; or that it hadn't failed so it was left alone.

I'm going out not to try and check amperage draw on the fuel-pump wire and I may just replace this pump & filter with a spare.

If this was a farm truck, I'd suspect a clogged fuel filter or loose/ broken electrical connection. We've had both. If they die in a predictable fashion going up hill that's usually fuel starvation.
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a few 1985-92 240s & 245s - parts cars & drivers