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I just went through the same problem on my '86 245. My main pump had always been noisy - I was told my more than one person that this was common for rebuilt pumps. After having an intermittent problem with my car dying when the fuel got below 1/2 tank, I replaced the in-tank pump. Life got better for a little while, until the dying problem came back with a vengeance. It quit on the way home from work, and my only option was to limp it to a small Volvo shop that I use for things that require the car to be put on a lift. After putting a known good used pump on the car, it pumped out a molasses-like goo. It turns out my tank was full of crud, some it so fine it would pass through the filter and into the system. A new pump and $300 later, the car has a good clean fuel tank and a quiet pump. The only problem I have is on cold-starting, I believe the used fuel pump they put on has a weak relief valve. I would recommend checking your tank out. The guy at the shop tells me 240's are hard on fuel tanks, and he literally has to go through 10 cars to find 1 good fuel tank.
Lance
near Memphis, TN
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