Ok guys, I have been fighting a intermittent rough running issue on our 91 240 wagon... I have replaced the fuel filter twice and each time it was full of crud.. Well since replacing the filter for the 2nd time I still had the problem that after driving for a few minutes it would start to stutter and bog down like it was starving for fuel.... Well today I finally had time to pull the sending unit out and look at the in tank and strainer well much to my dismay not only is the sending unit and all the connections and return tube slap covered in rust and corrosion but all inside the tank is trash and rust. I guess my question is not wanting to deal with a poor fitting aftermarket tank has anyone had success cleaning their tanks and sealing them with some of the kits that are available? Also like I said all the tubes,screws,connections,etc on the sendin unit are rusty as well... I really don't have the cash to buy a oem one are their any parts store brands that are better than the others. I just really don't have the money to spend on a $200 sending unit. Anyway thanks in advance for any help guys! I really would like to be able to enjoy driving this thing soon!

 

You can also get a genuine used Volvo fuel tank from a salvage yard. They might even replace it for you, at a cost though.

 

Who says aftermarket tanks fit poorly? I got a spectra for my S10 off rockauto that fit fine. This isn't something that needs .0001" tolerance.

 

I tried to get a sending unit from the junkyard around here and I found that all the gas tanks are removed from the cars before they are put out in the yard.

They did keep a pile of gas tanks off to the side but it seems that they punch holes in them. Removing them seems to be a safety precaution (don't want all that gas in the yard).

Check with your local junkyard before you make the trip.

Also, if you go with an aftermarket sending unit, make sure you double check all of the wiring on it. The last one I purchase, the fuel pump wire was connected to the sending unit and vice versa. I had to remove the plastic connector key and reverse it. Also, I believe the poles on the in-tank pump were reversed as well. I corrected both of these issues prior to installation and haven't had any problems since.

Good luck.

 

Aftermarket tanks can be had for $100 shipped...and they fit well IMO. The fuel sender remained unchanged from 79 to 93...should not be too tough to locate a used one. Generally, I see them selling for $35 to $50 plus shipping.

 

Do you know which brand tank it was? All the reviews for the Silla brand tanks which for the 240 sells for like $75-100 shipped seem to be pretty poor... The spectra brand tanks seem to be better for around $150 andGranted none of the reviews I found were specifically for Volvos. I just know after reading on most of the and repair kits Im probably going toend better off with a new tank, I have done some cleaning on the sending unit and I think after replacing just the pump it will be ok and I have read how people have found the wiring to be backwards so I'm prepared for that. Also around here all the gas asks are removed at the junkyards not to mention Volvos are slim pickings in the yards local to me

 

Volvo 240's are disappearing at an alarming rate from salvage yards...but it to be expected as the last year of production was nearly 20 years ago. Most yards siphon the tank, puncture it and remove for scrap as soon as the car arrives. Furthermore, a used tank from an unknown source could be as nasty as what you have. I think most of the aftermarket tanks are probably built in the same factory. The brand name is determined by what factory door the units exit.
There is another option if the tank doesn't leak. I've been known to empty the tank, add a little kerosene or diesel, throw in a handful of nuts and bolts, and shake the tank up.I had to do that a few times until the fluid poured out clean. I then had a radiator shop steam clean the tank and then used this stuff. SPECIAL - Sealer & Prep-POR-15 Inc.

 

Ok guys, I cleaned the factory sending unit really well and installed a new tank from spectre.... After changing the fuel filter under the car as well it's now running as good as new! Just wanted to post an update because so many times I see people ask questions but never post the end results. Now after driving I some I realize how much I like it as a daily driver and need to start saving so I can start modifying it some since I can't leave nothing alone lol

 

I worked on a sedan years ago that had a punctured tank. The guy had bought a 6 gallon plastic boat tank and bugee'd it in the trunk. He used the squeeze ball in line to prime the external pump and had driven it this way for years.
There's always a way

 

Are the wagon fuel tanks and the sedan fuel tanks the same unit? I have an 86 240 DL sedan and am getting an 86 240 DL wagon for a parts car.... can I pull the fuel tank off the wagon and mount it on the Sedan?

 

Yes, all the tanks from 79 forward are interchangeable.

 

Just wanted to let you guys know it has been a few months and after swapping the tank for a new one, its been running great! Swapped out the fuel pump changed the fuel filter and it hasn't give me the first problem

 

Great to hear!

 

Are 740 and 240 tanks the same?

 

pretty sure thats, no. for sure, the fuel sender/tank pump access plate is completely different... and the 700/900 have a rather completely different setup for the 'thrust bars' that link the rear axle to the chassis than the 240.