My turn now - power loss - Page 3

ivor940 · Feb 11th, 2006, 10:20

Hi Richard, Access the Fuel Injection Relay at Fusebox. ( remove ashtray, pull off surround at cigarette lighter. 2 screws hold cubby hole below radio ). Remove Fuel Inj relay at LHR Fwd end of relays ( white one) . My 94 car had original '93 relay. The 92 940 I got bits from had a '98 relay. I opened both relays and they both had solder problems ( dry joints - small circular cracks visable with a magnifying glass with relay opened up ). I bought a new relay from local Volvo dealer ( not dear, and they kept stock as they sell so well! ) and kept the old ones as spare. Failure of this relay can often be intermittent.

ivor940

classicracing · Feb 11th, 2006, 10:23

Thanks mate, will do as you suggest and post back
Richard

RollingThunder · Feb 11th, 2006, 10:25

I paid about £16 at German Swedish & French for the white relay - they're a stock item

Good luck!

classicracing · Feb 11th, 2006, 11:35

Pulled the pump relay
Dated 06/95, car reg 12/95 so original part
No less than 7 joints showing slight cracks
Resoldered, car runs OK but it does for a while anyway
Guess I'll get a new relay though
Thanks IVOR940

Richard

ivor940 · Feb 11th, 2006, 11:42

Great to hear you seem to have fixed it. Keep soldered relay in car as spare. The reason I changed Main Pump was that the car would not start on first turn of key, but always on second start. I checked the non return valve when I was changing the fuel filter and it was faulty. I also noticed that if I opened the fuel pressure regulator, I was not sprayed with fuel ( no pressure kept at fuel rail ). Volvo only sell valve with pump. Car now starts first time, every time.

ivor940

ivor940 · Feb 22nd, 2006, 17:36

Hi, car has run without snags down to fuel warning light on. No intermittant power loss and car is lively compared to a month ago. I had changed Main Fuel Pump( due faulty check valve), Fuel relay ( white) , Radio suppression relay and Fuel Pressure regulator. Driving included 250 UK M-way miles (with car full).

ivor940
94 940 2.0 SE Turbo Est 5 Spd 166.7k (purchased at 139k)

VOC member

andy 240 · Jun 20th, 2007, 21:42

Re: softening the copper washers as detailed above, unlike other metals you must cool copper quickly to soften it, just allowing it to cool will have little effect. heat the washer with a blowlamp but then drop into cold water hey presto now they are anealed (soft)

sml · Mar 15th, 2008, 05:27

With reference to plugging of the fuel lines ....

a.) The larger fuel line from the tank to the fuel pump. A golf tee is too small. A found an old tip from a caulking gun tube which was tapered from about 4mm to 20mm. This was perfect to stick into the fuel line and then give a couple of turns on the torx screw to keep it secure until you are ready to refit.

b.) The fuel line from the fuel filter to the engine. A golf tee would probably work but there is no need. Only a small amount of petrol drains (about 50cc) from this line so you don't even need to plug it.

Not sure where the golf tee fits into the picture.

sml · Mar 15th, 2008, 14:31

Actually a golf tee wouldn't work in the line to the engine either because there is one of those round connection type flow fittings.

At least on a 940GL 230FB anyway.

Feb 11th, 2006, 10:25	#23
RollingThunder Grumpy Old Git Last Online: Jun 11th, 2024 12:46 Join Date: Dec 2004 Location: South Yorkshire View Photos By: RollingThunder	I paid about £16 at German Swedish & French for the white relay - they're a stock item Good luck! __________________ S40 2.4i '07 Japanese import '96 850R - https://www.volvoforums.org.uk/showthread.php?t=312484 Ex Danish Embassy '96 940 GLE LPT - https://www.volvoforums.org.uk/showthread.php?t=326071

Jun 20th, 2007, 21:42	#27
andy 240 New Member Last Online: Jan 15th, 2011 21:29 Join Date: Jun 2007 Location: Wetherby	softening copper washers Re: softening the copper washers as detailed above, unlike other metals you must cool copper quickly to soften it, just allowing it to cool will have little effect. heat the washer with a blowlamp but then drop into cold water hey presto now they are anealed (soft)

Feb 11th, 2006, 10:20	#21
ivor940 Master Member Last Online: Sep 16th, 2013 07:55 Join Date: Dec 2003 Location: Malahide View Photos By: ivor940	Hi Richard, Access the Fuel Injection Relay at Fusebox. ( remove ashtray, pull off surround at cigarette lighter. 2 screws hold cubby hole below radio ). Remove Fuel Inj relay at LHR Fwd end of relays ( white one) . My 94 car had original '93 relay. The 92 940 I got bits from had a '98 relay. I opened both relays and they both had solder problems ( dry joints - small circular cracks visable with a magnifying glass with relay opened up ). I bought a new relay from local Volvo dealer ( not dear, and they kept stock as they sell so well! ) and kept the old ones as spare. Failure of this relay can often be intermittent. ivor940

Feb 11th, 2006, 10:23	#22
classicracing Senior Member Last Online: Jul 26th, 2010 09:55 Join Date: Dec 2003 Location: Taunton, Somerset	Thanks mate, will do as you suggest and post back Richard

Feb 11th, 2006, 11:35	#24
classicracing Senior Member Last Online: Jul 26th, 2010 09:55 Join Date: Dec 2003 Location: Taunton, Somerset	Pulled the pump relay Dated 06/95, car reg 12/95 so original part No less than 7 joints showing slight cracks Resoldered, car runs OK but it does for a while anyway Guess I'll get a new relay though Thanks IVOR940 Richard

Feb 11th, 2006, 11:42	#25
ivor940 Master Member Last Online: Sep 16th, 2013 07:55 Join Date: Dec 2003 Location: Malahide View Photos By: ivor940	Great to hear you seem to have fixed it. Keep soldered relay in car as spare. The reason I changed Main Pump was that the car would not start on first turn of key, but always on second start. I checked the non return valve when I was changing the fuel filter and it was faulty. I also noticed that if I opened the fuel pressure regulator, I was not sprayed with fuel ( no pressure kept at fuel rail ). Volvo only sell valve with pump. Car now starts first time, every time. ivor940

Feb 22nd, 2006, 17:36	#26
ivor940 Master Member Last Online: Sep 16th, 2013 07:55 Join Date: Dec 2003 Location: Malahide View Photos By: ivor940	Hi, car has run without snags down to fuel warning light on. No intermittant power loss and car is lively compared to a month ago. I had changed Main Fuel Pump( due faulty check valve), Fuel relay ( white) , Radio suppression relay and Fuel Pressure regulator. Driving included 250 UK M-way miles (with car full). ivor940 94 940 2.0 SE Turbo Est 5 Spd 166.7k (purchased at 139k) VOC member

Mar 15th, 2008, 05:27	#28
sml Member Last Online: Jun 6th, 2015 13:54 Join Date: Dec 2007 Location: Sydney	With reference to plugging of the fuel lines .... a.) The larger fuel line from the tank to the fuel pump. A golf tee is too small. A found an old tip from a caulking gun tube which was tapered from about 4mm to 20mm. This was perfect to stick into the fuel line and then give a couple of turns on the torx screw to keep it secure until you are ready to refit. b.) The fuel line from the fuel filter to the engine. A golf tee would probably work but there is no need. Only a small amount of petrol drains (about 50cc) from this line so you don't even need to plug it. Not sure where the golf tee fits into the picture.

Mar 15th, 2008, 14:31	#29
sml Member Last Online: Jun 6th, 2015 13:54 Join Date: Dec 2007 Location: Sydney	Actually a golf tee wouldn't work in the line to the engine either because there is one of those round connection type flow fittings. At least on a 940GL 230FB anyway.

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