4 days ago when fuel level was really low car stalled while sitting in drive thru. After sitting for about 5 min it started and ran fine. I filled up. Now today fuel tank is low again and it did the same thing at red light. I let it sit 10 min and started fine drove about 5 min to has station and filled up. Both times it stalled like it was running out of gas, sputtering then finally dying. Is this a sign of bad in tank fuel pump?

 

could well be.

if this is a 240, its easy to test the pumps. assuming its 1985 or newer, remove fuse 4. take a jumper wire, and connect fuse 6 (either side) to the left side of fuse 4, that should spin the main pump only, you should be able to hear it run under the car. now jumper fuse 6 to the right side of fuse 4, and only the in tank pump should be running... you probably have to open the gas cap and listen with your ear right near the filler pipe to hear it, so using an alligator clip jumper, or a helper is useful.

see In the Tank - 240 Volvo Tank Pump and Sender for *way* too much intel on the transfer (in tank) pump, heh. I wouldn't bother to take one apart and try and fix it, but do note the bit about how too many of the after market fuel sender assemblies are wired backwards, and also many of the aftermarket pumps are basically junk, but some brands are decent (author likes Airtex).

 

thanks pierce. I will try jumping fuses tomorrow. Looking at the previous owners detailed maintenance records he never replaced fuel pumps on this 89 and he drove it 15 years and I have been driving it 3 years.

 

As a general rule, not a good idea to starve engines of fuel--causes problems!

 

the original fuel pumps were very high quality, our 87 lasted probably 20 years and 300K+ miles.

 

pierce. Do I leave fuse 6 in when I jump to fuse 4?

 

yes. fuse 6 is a source of always-on power, its connected directly to the battery.

 

pierce, I can definitely hear the main pump under the car but cannot hear anything from pump in tank. Should it be as loud as main pump? Is it easy to hear? I took gas cap off and had my ear right there. I listened before jumping wires and after and nothing. I'm ordering filter and both pumps from IPD tonight. I looked at main pump and it looks like its 1000 years old. Should I get a NEW pump relay? I have a couple used ones from junk yard.

 

your symptoms are of a bad tank pump. I would only replace that, along with the bit of hose thats inside the tank, and the 'sock' that acts as a fuel pickup inside the tank.

 

comprehensive write up about in tank pumps here


In the Tank - 240 Volvo Tank Pump and Sender