Hi Chris,
The OP reported that the injectors could be heard clicking on OBD mode 3. The other unknown with regards to fuel is the FPR. He tested the diaphragm, but that does not guarantee that the valve is holding back enough gas to develop sufficient pressure. The fuel may be all returning to the tank.
Without an investment or access to a pressure gauge we'll never know. A less professional alternative might be to throw this at it after the new in-tank pump doesn't cure the fault.
https://www.ebay.com/itm/232513724090?fits=Model%3A240%7CMake%3AVolvo&epid=7021314850&hash=item3622e5deba:g:fj4AAOSwW4ViDa81
I know it's too cheap, but I bought one and 3 years and 30k later it's doing fine.
Phil's point about the check valve is interesting. I've been under the impression that the pump could develop pressure without it, but perhaps it can't.
The odd thing about this is that the engine coughs once in the morning and then goes back to sleep, but runs fine after lunch. As a morning person, I find that quite disturbing.
Peter
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