Trying to fix an '85 240 I bought with "a bad fuel pump", first I found the relay was bad and replaced it. There was the sound of a pump running for a few seconds, but no fuel flow from the disconnected line at the rail. At that point, I probably had a failed lift pump and could have gotten running with just that.... But I've managed to destroy the plastic line between the main pump and rail at both ends, and plan to replace it. As well, I tore up the crossover line between the filter and pump. (rough day...) All the banjo fittings seem incredibly tight. The car has about 110k on it, the main pump and filter were the original, as they were sprayed with undercoating. I've no problem building a new harness to replace the short one running through the floor to the pump... the insulation was crispy and fell off when I touched it. I understand the fuel line is 5/16" (nylon) and can be bought from McMaster-Carr, and that a careful hand can replace it between the various fittings. Any "gotchas" or things to be careful of? I'm planning to replace both pumps, filter, lines from the tank forward, and any crispy wiring I find.

 

1985's are in the midst of the 'biodegradable wiring' era for Volvo, *ALL* the engine compartment wiring is subject to disintegration