Hello to all I have a question for the enthusiats,

I have a Volvo s40 2001 1.9 TDI. It has this weird problem where it would stall anytime i get low on fuel (about 1/5th fuel left). I am nowhere close to the low fuel alert but it’s always then that it happens. My Volvo shutted down on me several times. Thrice on the highway at about 120 kph and quite a few times when driving at around 70 kph on country roads. Getting the car firing up right away with the key seems difficult, but the engine has no problem running when I put it in gear while the car is still moving. However the engine will quite often stall and I have to repeat the procedure to get it back running.
I have cleaned the MAF sensor and the throttle body with MAF airflow sensor cleaner. I checked for air vacuum leak using the cigar fume past the air filter, and after about 5 minutes of examination, I haven’t seen any fume going out of any air inlet junction. So I concluded that there is probably no air vaccum leak.
Also the diesel filter is fine. It has been changed quite recently and was still in good shape. No traces of dirt.
Some times ago, I did burn 30 years old diesel. It was about 45L in total. The engine had no problem with it, but I am totally aware this is not good at all.
Now i am clueless as to what could cause this problem. I don’t think I am running out of fuel when I get these stalling issues. When I go refill the tank afterwards, I can fill about 40L diesel. Which means there is still probably 10L left when the issues start to occurs. There is no stalling when I al full of fuel.

Is there a particular reason why my car would act like this? What would be a potential cause for this behavior? It is worth noticing that there was quite a big leak of oil coming from the throttle body. After I cleaned the throttle body, I didn’t see this oily mess yet. Where should I look further for the culprit in your opinion?


Thanks a lot for any inputs, I really appreciate it!

 

Your fuel pickup is not at the bottom of the tank - so you run out of fuel w 10L left. (instead of 2 or3) It's spring loaded so it should sit at the bottom of the tank - but after 20 years who knows what it looks like. Is there any damage to the bottom of your fuel tank? The sender/pickup is in the center of the front of the tank.

 

So you suggest the fuel pick up may not be reaching the bottom of the tank? Can I access the pick up by removing the back seats or do I have to drop the fuel tank?
I will look underneath the tank. Maybe something hit it. Will let you updated.

thanks again!

 

Looks like you can get to it from an access panel under the rear seat.