Mileage is gradually worsening on a 1991 240 brick (123k mi), down from 25mpg in 2001 to 18-20mpg now. The following services have been performed over the past 9 months:
- new timing belt, NGK spark plugs, distributor cap, rotor, air filter, battery
- new fuel filter (September 2001)
- fuel injector service
- new exhaust header pipe
- cleaned flame trap, oil separator (aka "breather box"), throttle body, idle air control valve
- 2 vacuum hoses replaced (connecting to flame trap)
- tried using 91+ octane gas for several tanks

The car runs OK, but gas mileage has not improved!!! It gets 21mpg max on the highway, with air conditioner off, at 60-70mph. Shouldn't the mileage be getting better, not worse???

A year ago, this 240 would crank and start IMMEDIATELY. Now it takes a few seconds of cranking, with 5-6 turns of the engine, before the car starts. Or if you push on the accelerator pedal while cranking, the car will start immediately. This occurs when the engine is hot or cold.

(1) When the battery was replaced six months ago, a technician said the ALTERNATOR was "weak". Could the VOLTAGE REGULATOR be the culprit? Would that cause the cranking/starting problem? Would it affect gas mileage?

(2) While searching the Brickboard about poor gas mileage issues, I found lots of info about the FUEL PRESSURE REGUATOR. However, this car does not have a bad surge like a failed FPR. At what mileage does the FPR tend to fail? (This is the original unit.) Would a weakening FPR causes these problems? What are the signs?

(3) I am replacing front brakes and rotors (warped) this weekend. Should I replace the rotors first, then wait a week or two as I recheck the mileage? Is there anything simpler (and CHEAPER) that I may have overlooked???

My wife and neighbors are beginning to wonder why I spend so much time "Working on the Volvo", and hardly ever any time working on the Honda . . .

[[ southern fried volvo - '91 240 123k mi ]]