Haven't been on here in a while because the 240's just keep running but my Daughter starts driving in the fall so I picked up this one.
Just purchased its truly a grandmas car from new tons of paperwork totally unmolested. purchased from the son who drove it for a few years until it started having issues stalling not restarting. 204000 miles He replaced the fuel pump and filter still no start let it sit for a year then I purchased it last week. If you turn the key you can hear the pump prime, if you prime it a couple times when cold it will start and run fine for 30 seconds to a minute I can even get it to rev up and then it slowly dies out. I've replaced the ignition module(Regina) I have fuel to the rail, I have spark, The Crank sensor has the white stripe, Cap and rotor are newer, Plugs look good. No codes as it may have been cleared prior. I'm at the end of my experience. I've read through and tried a ton of suggestions from the posts Jumped out the fuel relay no change battery is fully charged Whats next? Thank you in advance Volvo Professors.

Yes it does have a RSR on the passenger side inner fender. When I run the OBD I can hear and feel them opening and closing. I checked the fuel pressure and it only at 22psi with the relay remove and a jumper placed with a fuel pressure test gauge. So I started checking the connections to the fuel pump access in the trunk. No clamps on the fill tube or vent, fuel line came off easy return line has a hose clamp.

So what do you think? Fuel pump?

The car is super clean! Beside a lil dust it's like new! Just dying to see how it drives.
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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

A couple more checks before you pull the works from the tank.

1) Make sure you're getting reasonable battery voltage all the way to the pump (check the connector back there). With a jumper in place of the fuel pump relay, you should be seeing close to 11V.

2) Check the pressure regulator. With the pump running and your pressure gauge attached, momentarily squeeze the return line out of the back of the regulator. If it is the pump not making pressure, you won't see any reaction on the gauge, but if the regulator is bypassing, you'll see the gauge spike to 70 psi or so.

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Art Benstein near Baltimore

I was going to wear my camouflage shirt today, but I couldn't find it.

I ran the pump with a jumper in place of the relay and I have 11 volts on the pink wire from the pump also squeezed the return line from the fuel pressure regulator and no change from about 20 psi?

Should I pull the pump out and see what's what? from what I can see in parts lists with pictures just for comparison sake it looks like the ragina pump has a connector for the power lines rather then screw on terminals so I could possibly partially pull the pump and have a look to make sure it's correct I think.

Or should I look else where?

I'm so close I can smell fumes.

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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

Should pull the pump out and see. I think the correct pump was installed by PO maybe not OEM. No Bosch in-tank pump ever gives out 22PSI be it for NA or turbo. Just curious to see what made it half-failed - blocked fuel filter sock or what? Could use some long tubing going to bottom of tank, suck out some fuel for inspection.

The IPD oil filter wrench (or something similar) is big enough to undo the fuel tank bung nut, without resorting to use hammer and wood block/screwdriver.

Amarin.

Here's what I can imagine, if we can assume the correct pump was installed and the 94 looks like the 92 I was into.



This damper or accumulator is a press fit on both the pump output and the feed tube it supplies. If it is leaking here, or from the damper itself, the full pressure developed by the pump would be split between the leak back into the tank, and the output to the filter.

Also, either filter could be clogged.
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Art Benstein near Baltimore

No matter how much you push the envelope, it'll still be stationery.

Tried new fuel pump relay no change so I
Pulled the pump it's a delphi FE0069 which is not listed as specific to the regina system just in tank.

Here are the spec's from Rock Autos site
Outlet Outside Diameter 0.375"
Voltage 12
Fuel Type Gas
Maximum Pressure 58.0 psi
Terminal Type Threaded
Gasket or Seal Included No
Terminal Quantity 2
Terminal Gender Male
Wiring Harness Included No
Strainer Included No
Inlet Type Strainer
Outlet Type HOSE
In Tank or External In Tank
Average Current Draw 2
Average Flow Rating 28 GP

SPECTRA PREMIUM SP1255 Listed as Regina in tank
And it will be here tomorrow

Fuel Pump Inlet Type Strainer
Gasket or Seal Included No
Inlet Fitting Thread Size N/A
Internal or External Internal
Maximum Flow Rating 58.20
Maximum Pressure 123.00
Minimum Free Flow Rate 48.90
Minimum Pressure 80.00
Outlet Fitting Thread Size N/A
Outlet Outside Diameter 0.3125
Outlet Quantity 1
Outlet Type For Hose
Pump Type Turbine
Regulator Included No
Strainer Included No
Universal Or Specific Fit Specific
Voltage 12

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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

Dear boysbrick,

Hope you're well FE0069 is a Delphi pump which - on Rock Auto's site - is listed as the equivalent of Volvo #3507736, the Volvo number for the Regina fuel pump. That Rock Auto listing is wrong!

On www.fcpgroton.com's site, the FE0069 is listed as the equivalent of Volvo #3507436, which part is the in-tank PRE-pump on a two-pump Bosch System.

Thus, whoever supplied the prior owner with the Delphi FE0069, was in error. The price difference - pre-pumps usually cost less than $40 versus $75 and up for Regina-capable pumps - should have tipped-off the seller, that a more powerful pump was needed for a Regina system.

Hope this helps.

Yours faithfully,

Spook

Thanks a ton!
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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

Wow. Chris Mullet and aleekat had the right idea!
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Art Benstein near Baltimore

Money is the root of all wealth.

And you pointed me in the right direction! Thanks so much Art for all your knowledge you have helped me more then once.

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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

The parts listings at some of the mainstream parts houses simply can’t be trusted. In the case of these fuel pumps you have to be very careful and check out the output pressure, etc. I have seen this problem on the B.B. before but it was a few years ago.
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Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (getting ever closer to road worthiness)

And you pointed me in the right direction! Thanks so much Art for all your knowledge you have helped me more then once.

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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

Dear boysbrick,

Hope you're well. The Regina pump is longer - by about 3/4" - than a Bosch pre-pump.

Volvo no longer supplies the Regina pump (#3507736). But AC/Delco supplies a clone, available from www.fcpgroton, for about $75. The Regina pump shown on the www.fcpgroton.com site has solder connections for the power supply wires.

The 1995 Volvo 940 (non-turbo) - with Bosch fuel management and ignition - was factory-equipped with a single in-tank pump (#9445444). Volvo still supplies this pump. It is available from www.fcpgroton.com for $212.00. I reasonably believe that pump's output is equivalent to that of the Regina system main fuel pump.

Hope this helps.

Yours faithfully,

Spook

This wouldn’t be the first time an auto parts store sold the owner a low pressure Bosch system Pre pump instead of the proper high pressure Regina system single pump.
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Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (getting ever closer to road worthiness)

I have to agree looking at what the history was. Hard starting, replaced the pump and never has started since. The non regina is literally half the pressure.
Non Regina:
Maximum Free Flow Rate (gph) 35
Maximum Pressure Rate (psi) 6
Minimum Free Flow Rate (gph) 20
Minimum Pressure Rate (psi) 4

Regina:
Maximum Free Flow Rate (gph) 55
Maximum Pressure Rate (psi) 90
Minimum Free Flow Rate (gph) 45
Minimum Pressure Rate (psi) 80
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Post Back. That's whats makes this forum work.

Seriously?

The pump used in Regina fuel is a two-stage high pressure pump. The tank pumps VDO and AC built for the Bosch fuel are just centrifugal pumps. They might look vaguely similar in that they're both packaged in flimsy made-to-live-indoors aluminum beer cans, but they aren't installed the same way, electrically terminated the same, nor plumbed the same. I think it would be a measurement mistake to read as much as 22 psig from one of these centrifugal pumps.

If this mix-up is really something that has been done before, show us pics. Wild.
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Art Benstein near Baltimore

In The Tank

I don't have 1st knowledge of it being done. I posted the specs for comparison. Who knows what the PO did? He has determined he has a fuel delivery issue. If he picked this up for a song & dance, pull the pump.
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Post Back. That's whats makes this forum work.

The cost of this dance was $500.00 plus $158.00 for a tow. It's a labor of love, as most of you know. I can't use my labor rate.So hopefully at $800.00 I have a very nice 940 with winter and summer wheels sets, Looks like it was garage kept, minimal rust issues, Brochure's magazine articles 23 years of maintenance receipts, Window sticker. Keeping my fingers crossed on the pump install tomorrow

I'll take some pictures and post when I'm finished


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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

You're right. I shouldn't be surprised what a PO can do to an old car. I've been on Turbobricks. (smile)
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Art Benstein near Baltimore

Behind every great man is a woman rolling her eyes.

Now that's funny. Turbobricks is where I learnt to convert my n/a to turbo. Still going strong after 150k miles. Other than 2 head gasket jobs. But it nice having a passing gear on the interstate.
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Post Back. That's whats makes this forum work.

That would keep the injectors from firing.

Dear aleekat,

Hope you're well. Yes. Bosch and Rex-Regina cars have a radio interference suppression (fuel injection) relay.

Hope this helps.

Yours faithfully,

Spook

And OP would be well advised to check the power being switched by that troublesome feature of the 7/9 cars before investing much time elsewhere in the fuel system. The typical oxidation-caused poor connection at the RSR's terminals, subsequent heat damage and damage to the water seal is one good explanation for failing to deliver fuel.
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Art Benstein near Baltimore

Change is inevitable, except from a vending machine.

I did remove and replace the RSR with a new one, No Change. I picked up NOID lights I'll test the injector circuit and check for voltage at the tank connection this morning. Plus the pressure with the regulator line pinched and whatever else I can think of.

As I started checking things out before I posted anything I went for the injection relays once I found it was not in the spot as shown I took it apart and cleaned the contacts up and no change held them closed tapped on it, no change Yes it clicks

I have a new fuel injection relay coming soon currently it's a blue one so I ordered a green one. And I didn't have a spare.

I also swapped out the ignition control module under the coil thinking it may be suspect as once I removed it the base seal and some small holes in it, No change

Thanks for all the great suggestions, Keep them coming we'll get it running!
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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

"I have fuel to the rail, I have spark,..."

Understand how you know you have spark because you said "runs on spray." But not sure how you know you have fuel at the correct pressure to the rail.
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Art Benstein near Baltimore

If you can smile when things go wrong, you have someone in mind to blame.

Thank you for the response I sprayed starting fluid and irt will run I separated the fuel line from the rail just to see if it's flowing when I turn on the key. Stuck a soda can over the end to see I need to make a adapter to check pressure. Or I could try the tire gauge. Yikes! I pulled out the ECM 9146261 Siemens to have a look at it and there is a small brown spot under a red block not sure what type of electronics part that is.

If I can rember how to upload photos I'll post a picture.
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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

What made you suspect the ECU? Based on your uploaded photo provided by Art, follow the circuit tracing from that component to its ECU pinout. There could be further clue as to what it connects to which could affect engine operation.

See within the Regina section with ECU pinout:
https://cardiagn.com/1994-volvo-940-wiring-diagram-troubleshooting-manual-pdf/

I've dismantled Bosch ECUs but never a Regina. Based on that limited experience had never seen such brown spot around SMD.

Amarin.

Just seems like the injectors are not firing that's why I headed down that road. I'm going to buy/build an adapter so I can check pressure at the rail. i'll post what I find. I didn't suspect the fuel pump because the PO said it was changed At first I suspected it but it was coming on and running I figured some pressure would at least let it idle.
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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

I forgot about the radio suppression relay (RSR) in the car - thanks Aleekat/Spook. Linking your symptoms to the ECU findings, that small transistor could well be powering a relay. RSR maybe. Worth a check as recently mentioned by Art.

The transistor grounding the injectors is much bigger in size such as TO-220. Only one transistor is used as all 4 injectors fires simultaneously. Yet this just based on my experience with Bosch ECUs.

Luckily IME the RSR is not a troublesome part. It just sits there quietly doing its job. Once every few years I sanded flat its contacts and reuse.

Amarin.

"Just seems like the injectors are not firing ..."

Seems like a 'noid light should be dirt cheap these days but maybe all you can do is buy a whole set when you only need one.
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Art Benstein near Baltimore

I'm great at multi-tasking--I can waste time, be unproductive, and procrastinate all at once.

I apologize for the unfriendly way one needs to connect a pressure gauge to the fuel rail, but feel this is what you need to do, brown spots notwithstanding.
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Art Benstein near Baltimore

Notes on Replacing a Regina Fuel PUmp and Why

No apologies necessary, I'll pick up the adapters I need tomorrow and give that a shot no pun intended. So if it is low pressure would that be the fuel pump? I asked the PO if he specified what system when he purchased the fuel pump he stated regina because that's my grandmas name.

Thanks again
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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

The device you photographed is a transistor. The worm's eye view doesn't do much to identify its function, and my experience would tend to say the heat it produced is probably normal and not harmful to its proper operation. I suggest you look for a 90-degree Schrader adapter of the sort sold to truckers to adapt a Bourdon gauge to the port on the rail, but confess I haven't tried one myself, having already the correct fittings for the hose.

By the way, for those of you who can't see the image: I used the browser's view source tool to find the URL posted in the thread, and then pasted it into the location window: https://www.brickboard.com/GALLERY/images/13450.jpg

Result is:


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Art Benstein near Baltimore

My wife and I were happy for twenty years; then we met.

I would suspect the old gasoline in the tank. It may make the engine runs poorly but shouldn't cause shutdowns. Look for any vacuum leaks especially checking for deteriorated/loose rubber hoses. Are the throttle body and IAC valve clean?

Amarin.

Probe into the pink pump power wire in the trunk with a volt meter and see if the current is dropping off after the engine starts.
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Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (getting ever closer to road worthiness)

With the jumper in place of the relay I have 11 volts
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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (

Installed the new fuel pump and IT RUNS! I even licensed it and put insurance on it before I finished LOL Drives like a dream. I need to get the Overdrive working. Plan on changing all fluids.

Thanks Everyone for all the info and help

More volvo love!
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1992 242 4 speed GLT 1993 245 5 speed 1994 940 Auto : (