The Vehicle:

o 1985 240 Volvo non-turbo

o LH-Jetronic 2.2

The Background:

o Recently purchased (12/00)

o Complete tune-up; new plugs, rotor, cap, plug wires

o Cleaned throttle body, new air filter

o New intake manifold gasket, new fuel injector seals

o Cleaned and replaced all fuses in fuse block

o Rewired engine compartment wiring harness – careful splicing of bad wiring.

o Cleaned and dielectric greased all connectors/plugs

After the above, car started everytime, ran great, except for occasional complete cut-out of power during cruse and acceleration – but never completely killed engine – always idled, and would resume power after 5-10 seconds.

Diagnosed above cut-out problem as bad (not running) in-tank fuel pump – checked by removing pump and testing on bench (no workie); replaced in-tank fuel pump.

Then, car started immediately, and ran for 5 minutes; turned off ignition, and then car would not restart. Strong gas smell, but no leaks present.

The Ongoing Diagnosis:

o While cranking engine: no spark at pulled and grounded plug; no spark at coil wire

o Battery voltage at #15 terminal on coil; same for terminal #1

o Good ground at #10 at ignition control box

o Battery voltage at #2 at ignition control box

o Pulled connector at distributor; jumped B and C, and no spark at grounded spark plug (the manuals mention a "calibrated ignition tester" – is this really necessary)?

o Checked for battery voltage at A terminal on distributor connector – no voltage – (but I swear I got battery voltage there a couple of days ago…).

o Checked continuity between A terminal on distributor connector and end of wire into ignition control box - OK

o Replaced ignition control box with known good unit – no change…

o Checked coil resistance – OK

o With ignition switch ON, grounded terminals B and C on distributor connector – no spark at grounded spark plug, but injectors fire for 1 second; same test, and good spark from coil wire and injectors fire for 1 second…

o Replaced fuel pump relay with brand-new unit – no change…

o Hooked up Volvo fuel pressure gauge; jumped terminals #30 and #87 at fuel pump relay – get 2.5 Bar pressure…

o Checked for voltage at in-tank fuel pump connector in trunk – good battery voltage…

Further Background:

o Previous Owner had new main fuel pump, fuel regulator, and fuel filter replaced within 1000 miles of present…

I’m at a bit of a quandary on this diagnosis – probably a case of being too close to the case, and I’m not seeing something, or not testing in the right sequence… HELP!!!