Volvo Repair: Volvo 240 - Stalling, fuel pressure regulator, intake manifold gasket


Question
My '88 240 has a problem with stalling.  The problem seems to be heat-related, as it first appeared during the early 90+ degree days this summer.  When accelerating from a stop, the engine acts as if all fuel flow has stopped for a split-second - tach drops below 600RPM, then picks up again.  If I press the pedal to the floor, it will also pick up.  This will also occur when cruising at 2000RPM or less, and the engine has to be up to operating temp before it happens.  When I drive the car to work at 7AM, it doesn't stall.  If I let it sit for a few minutes and start it up again, it will stall.  The tach never drops to zero, so it seems to be a fuel system problem, rather than ignition.

I've replaced the fuel pump relay, cleaned all of the grounds, checked the main fuel pump fuse in the engine compartment and cleaned the fuse block inside the car.  I've also cleaned the electrical connections on the AMM, the knock sensor, the coil and pretty much any other connections on the left side of the engine.  The car also has a new cap, rotor and coil.  I've pulled the in-tank pump, cleaned the "sock" and used some Techron injector cleaner recently.  The O2 sensor is about 2 years old.

So, at this point I'm stumped...  The only other components I can think to check are AMM, fuel pressure regulator, the actual fuel pump and the fuel filter.  Any help you could give would be greatly appreciated.

Thanks!

Answer
WOW....
          You have been a busy camper...all the right things to test...
           Test your vacuum... also spray carb.cleaner or brake cleaner at intake manifold and engine.connection..if the engine speeds up...leaky intake manifold gasket.
         Fuel press regs do fail...not often.
           Look closely at the spark plugs...sometimes they tell a tale.
            I doubt it is your AMM ..but if you could borrow another it would be nice.
            You still have the option of getting a Volvo dealer's opinion...then fixing it yourself.

             It might be a good idea to do  compression test...just to know.

            Good luck,

           Bilbo