Have you replaced the priming pump on top of the fuel filter???
Its quite a common fault and allows air into the system. It should really be on the service schedule as its quite common.
My brothers car went through 2 of them.
You can purchase them from motor factors/general car spares. You dont have to buy from volvo dealer. From a factors i think the last one cost me about £30 but this was about 4 years ago.
If car spare places have no listing for the volvo, ask for the primping pump for Renault 19 1.9TD its identical.
Don't forget to get new copper crush washers for the fuel lines either side. The new priming pump unit should come with the.
If you do find its the diesel injector pump, i have one as i kept the good one when i scrapped my brothers car when it lunched its gearbox.
I think i got the injector pump swap down to about 2 hours time when i did them.
I've kept it in the vain hope of spotting a 400 series diesel with dead injector pump, and then swapping it over and creating myself a nice little economical commuter.
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