Fellow 850 enthusiasts:
I have to share this account while still fresh. We just returned from a round trip from Indiana to New Mexico in our 97 850 GLT. The car has seen this trip and more before. 6 months ago or so, I replaced the in-tank fuel pump with a used one from e-bay due to a crack in the plastic flange of the fuel pump housing that leaked only when topping off the tank. (NOTE: Remember this when you get to the end of my story). On our trip, we stopped in Amarillo TX for lunch on the second day of our journey. The car would not stay running when we went to get back on the highway. I suspected a fuel pressure problem as it was intermittent in nature. We went to Auto zone and check out a fuel pressure gauge. The pressure at the rail was 26 psi (should be around 44). I knew I had a problem but wasn't sure if it was a pump or a pressure regulator. We had to be in New Mexico on Saturday so we couldn't spend time on a car problem. I RELUCTANTLY had the car towed to a local indy euro garage…none of my volvos have ever been to a shop and this was a reminder as to why! We rented a car and went to NM to accomplish our task. I got a call from the garage in Amarillo and they said to change the fuel pump, filter and plugs it would be $880.00!! Right. I asked them if I could work on the car in their lot and he said no. We went next door and asked if we could use their parking lot and they said sure. I went and bought a fuel pump (pump only, not assembly) from Auto Zone (another known mistake) (found later to be the wrong part) and when we went to change the pump we found that the connector hose within the pump assembly was loose causing an internal leak (drain back causing a hard start) and insufficient pump pressure. The pump assembly I had purchased 6 months ago on e-bay had a loose hose clamp on the connector hose within the pump assembly and I failed to notice it on installation!.

The reason I share this story is mainly to remind all to check this hose and the two hose clamps when troubleshooting fuel delivery problems. It was causing hard starting and eventually a failure to run problem and was hard to see if you don't physically tug on the hose to see if it is secure.

As a follow on note…I don't fault the garage for trying to make a buck, but my son and I had the pump out in 20 minutes, troubleshot and back in in 15 minutes. That kind of estimate to change a fuel pump, plugs and filter is ridiculous. Beware if you are in Amarillo…

Mark

95 850 GLT
97 850 GLT
91 240 wagon