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Your symptoms are very consistent with the problems I had with that same small blue Volvo (Hella) relay in my '95 940 NA. No amount of re-soldering helped -the solenoid coil was gone. The local yard said they rarely went so I got a used one (green Hella, otherwise apparently identical to the blue one) and have had no problem with it since. Beware that a failed relay can often be associated with a worn fuel pump as the increased current draw can fry the relay. Indeed, the fuel pump failed in this car about a year or so later. I first thought it was the relay again, but using a jumper in the relay socket confirmed it was the pump. You can do this using a jumper in the relay socket between socket pins 3 and 4, where relay pins 87 and 30 would insert. If you go for a replacement pump, pay the extra bucks and go for a Bosch, not the wimpy little aftermarket ones such as the Hella (Walbro) one listed as "OEM" (that will be OEM spec, not OEM supplier). They work okay, but my experience is they don't last as long and the effort to get the sender out of the tank makes the savings not worthwhile. This a chore you don't want to do every 2-3 years, just as you've forgotten the details of how you last did it. If you want to stay with your existing pump for a while longer then perhaps remember to keep the tank mostly well filled rather than always close to empty as that eases the load on the pump. Good luck.
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Dave -940's, prev 740/240/140/120 You'd think I'd have learned by now
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