So, I picked up 1990 240 a few months back for my teen-aged son. It's a fine specimen, but I've been having some trouble with the fuel-line. Mind you, I'm used to old cars (drive an 88 E30 and do most of my own repairs) but am new to Volvo style repair and maintenance.

First Issue: Son driving. Car sputtered out and died after right turn onto road. Limped home. Turned on car, gas gauge didn't budge, figured "Ah, 16 year old ran it dry." Put a gallon in, drove it to gas station and filled it up. Ran fine. Problem solved? Well, no.

Second Issue: Next day. Same thing, same turn. Limped home. When I got home from work, I turned it on. Ran fine. Drove it to my workplace and back. No issues. Checked on-board diagnostic and received error code for 'Intermittent RPM Sensor Failure." Checked RPM sensor and could see insulation cracked. Ordered and replaced RPM sensor. Drove it a few days without issue. Problem solved? Well, no.

Third Issue: We go out of town for a few days. When we return, Volvo doesn't immediately start. When it does start, it sputters weakly and dies. Later, it cranks right up and I drive it work and back without issue. Check fuses. Seem okay. Jump fuses 4 and 6 to listen for in-tank and main fuel pump. I hear them both whine and assume that's functionality. Replace 4 and 6 fuses. Drive it without error. Problem solved? Well, no.

Today: Son turns right onto highway, car sputters and dies. Coasts into gas station. That's where I am now.

So, I ordered and intend to change fuel pump relay. It's cheap and might as well. I'm thinking of replacing the in-tank pump. Not sure what else to do.

The car has always had a rough idle. Nothing serious, just a little bumpy at times. I had thought it might be a partially clogged injector or something.

So this is what I think I know:

1. It's a fuel supply problem, not an electrical problem (sputtering and such).

2. It's seemingly randomized, but may be associated with turning to the right (or left).

3. It's not the RPM sensor. Not fuse related. Pumps seem operable.

4. It seems to happen only after the car has been sitting for more than 24 hours or so.


It's frustrating because I've been driving the car and haven't been able to reproduce the issue, but the second my kid gets in it does it again. It's his first car and I'm trying to get it sorted. Any wisdom for me?