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I have a 1990 740 GL (non-turbo; rex regina engine) with a rather serious, recurring stall-out problem. The car's performance has not improved despite several visits to two different mechanics (one the volvo mechanic) over the past 6+ weeks. At first there was just some intermittent hesitation at stop signs and lights followed by painfully slow sputtering for the 5-15 seconds it took the car to decide to get up past, say, 1500 rpms. For some time now, though, the problem has progressed to the point that, after about 30-60 minutes of driving (hot engine _does_ matter; even ambient heat seems to affect the p oblem), like clockwork, the car suffers severe hesitation, knocking and sputtering, and frequent stall outs. The engine's even cut out at modest speed once or twice, which is odd, because as a rule the problem only occurs at idle. _My_ mechanics have cleaned the fuel injectors, changed the fuel filter, replaced the throttle positioning sensor, and changed the fuel pump (there's only the one in-tank pump on my car, by the way), the last upon the diagnosis and recommendation of the volvo guy. None of that worked, of course. I've gotten two different error codes from the engine's self-diagnostic unit: 1) 2-2-3, the idle valve, which seems to check out okay when I follow up with the control function 3 test on the diag. unit, and 2) 3-2-1, the cold start valve. But hold on, there's one more part to this story...
Having read and re-read the 700/900 FAQ thoroughly, I decided to go pick up a new fuel pump relay as the first step in ruling out common culprits in such cases. I put the part in and the car seemed to drive quite well - at every stop I held my breath a little expecting a stall out, but nothing ever happened. I stopped to fuel up before continuing my test drive around the neighborhood, only to realize, after filling up, that the tank was leaking gas, possibly mixed with oil (I guess it could have been on the ground from another vehicle). In total, I'd say I lost between 1-2 gallons of gas. When the leaking stopped the car wouldn't start and I had to leave the thing at the station. Is it more likely that the mechanics messed something up down there when replacing the fuel pump or that this is part of the original problem and that something is amiss with delivery from the tank? The problem is worse when the car is in D as opposed to P and having the air conditioner on high seems to affect it, too. I was going to look into the throttle body and the ECU next, but this fuel leakage fiasco has me worried. All I know about my car is what I've read about on this board and in the Chilton's manual, but I'm pretty much willing to try anything myself at this point...the mechanics are certainly of no help. Anyways, any input would be immensely appreciated. Thanks.
Erik
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