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By way of introduction, my name is E.J., and I'm located in the SE Wisconsin area. I'm a "retired" mechanic (30 years Mercedes-Benz, Jaguar, BMW, and a bit of Volvo). Never cared much for Volvo, although I am well-aware of their mechanical longevity. The way the interior plastic garbage falls apart is just inexcusable to me. However, a very cheap, high-mileage Turbo came my way, and I bought it from an owner about to give up on it. It's got 200k, and appears to be a loved and well-maintained car. The previous owner had the usual intermittent stall-by-the-side-of-the-road problems, and had a local, independant import shop look at the car. They decided that: It needs a new fuel tank, and both fuel pumps. Having worked on Volvos during the 1988-1994 years, I never saw a fuel pump failure(but did replace plenty of relays), and I recall only replacing 1 fuel tank-I remember due to some recall on an early 700 series car. I have driven the car for a few weeks, and have had a few stoppages. Installed new fuel pump relay, but to no avail. It finally decided to just quit completely, so I can do some diagnostics. I followed the troubleshooting tips, and bridged the relay terminals, and determined that the main fuel pump is inop, but the tank pre-pump is working. What I don't recall is how the wiring to the pumps from the relay is set up. When bridging terminal 30 to terminal 87/2, only the pre-pump runs, and it runs even with the ignition off. Having a good basic understanding of Bosch fuel injection, I don't believe that the main and pre-pump would be operated off the same relay terminal. I have no access to wiring diagrams, so a bit of advice would be appriciated. This same repair shop supposedly replaced the gas tank with a new one, but the tank is not new, and shows no signs of having been removed. It does leak fuel, when fully filled, about 1 gallon, and the fuel gauge only seems to read the top 5-7 gallons in the tank. Imagine my surprise, going from my home to Madison, Wi, a distance of about 80 miles, and using a full tank(according to the gauge) to get there! So, I fill the tank, and it only takes $7.00 to fill! I would suspect that the shop tried to get the sending unit out of the tank, and did some damage in the process. Any thoughts??
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