Volvo Repair: Volvo 240 is hesitating after warming up., volvo repair facility, exhaust leaks


Question
OUR 1990 VOLVO 240DL SAGA

Hope you can give us some advice! Because of major transmission problems our Volvo sat (outside) for somewhere between 12 to 15 months.

My husband had it towed to a garage (not a Volvo repair facility) and told them it had been parked for over a year due to transmission and exhaust system problems.

Work Performed:
1.   Extracted water from left front headlight
2.   Removed and replaced exhaust manifold gaskets
3.   Checked for exhaust leaks, removed and replaced resonator, axile pipe, muffler and tailpipe
4.   Mounted and balanced one new tire
5.   Installed new 60mos. Interstate Battery
6.   Installed Halogen Headlight Bulb
7.   Installed new wiper blades
1/7/05              COST= $614.87

They referred him to AAMCO Transmission for the transmission problem.

He dropped off Volvo at AAMCO ON 1/7/05.

AAMCO installed a reconditioned transmission with an exchanged rebuilt torque converter with AAMCO 36mos/36,000 miles limited warranty.
1/18/05        COST= $3,224.37
(Personally, I not necessarily my husband, thought this was very costly since 4 years ago I had a new transmission with 50,000 mi warranty put in my Crown Victoria and the cost was $1800.)

Less than 3 weeks later, the Volvo stalled a couple of times and the last time it stalled, it cut off and would not start up.  It was then towed to the same repair place.

Work performed:
1.   Checked for a no start condition and found the ignition breaking down.
2.   Diagnosed and replaced the distributor cap, rotor and ignition module (2hrs.)
3.   After getting the ignition system to fire, car was test driven and it began to lose power, diagnosed and found the liner in the fuel tank coming apart and the fuel pumps were damaged. Removed the fuel tank, flushed the fuel system, replaced both pumps and the filter and test drove the car. (4 hrs.)
4.   Performed 4 cylinder tune up service (.6 hr.)
5.   Performed fuel induction and engine decarb Service (1.0 hr.)
6.   Installed new fuel tank

  COST=$1677.45   yikes! (My comment!)


Two days later, he was filling up the gas tank and noticed that gasoline was leaking under the Volvo. It was discovered that the mechanic who had replaced the fuel tank neglected to place a clamp at the appropriate location, therefore causing the major and dangerous leak.  (I won't go into the problem of this happening at a gas station!)

About 12 days later, the car began hesitating and backfiring while in local traffic. My husband witnessed smoke coming through the floor automatic gearshift. Again, taking car back to garage.
Work Performed:
1.   Performed scan, found code 3-1-1 and 2-3-1, spped (not sure what this word is) sensor signal and fuel too lean, found ignition coil faulty.
2.   Performed compression test, VEH is within specs, 175 pressure
(1.5 hrs.)
3.   Replaced ignition coil and retested system, cleared codes (.5hr.)

4/04/05      COST= $342.47

NOTE by garage on invoice:
"During quality test drive felt slight hesitation-explained to Mr. Anas this might be because fuel injectors may becoming clogged at the screen. Will need to replace all injectors and possibly ignition wires to repair this concern. Customer has been advised of concern. Futher diagnosis needs to be performed to confirm this problem."

About 2 weeks ago, we took it to another garage...actually our regular mechanic--to make a long story short, the car was parked at my in-law's house all that time and the garage was one they used.  Our mechanic actually flushed the injectors and as he said, "he fiddled around with the car." He did replace the plug wires.  He said he had driven it almost 50 miles and it was running great.  He said to drive it around for the weekend before settling up.  He also told my husband if this doesn't work, frankly, he is baffled and we may have to take it to a Volvo dealer in Norfolk, VA--we live just a few miles away. We are not sure if he put in a sensor--he mentioned that to my husband re taking the car to a Volvo dealer. The strange thing is, the car will work o.k. until the car warms up!  We drove it about 20 minutes the day after we picked it up. We parked it about 1-1/2 hr.  When we started it up again, it began hesitating, like it is running out of fuel. (We have not paid our mechanic yet, but the bill may be a few hundred dollars for mostly labor and I think he has probably not charged us for all the labor since he is so frustrated.)

In all that time the oil had not been changed, so we had that done a few days ago.

I think what is truly frustrating is that we have spent over $5,000 and still don't know what is causing the problem.  How much more can we expect to spend?  The car has 125,000 miles on it, which, I understand, is not bad for a Volvo.  I personally think the original mechanic should have been able to give a better figure on what may had to be done.  Not being a mechanic, I realize there could be hundreds of things under the hood that could possible go wrong.  We didn't expect him to be a psychic, but don't you think after this car sitting for at least a year, they might have had a clue that the car needed more than a simple tune-up?  Do you have any idea what could cause this hesitation and is it time to either (a) cut our losses and get rid of it, or (b) take it to a Volvo dealer, or (c) get your take on this and relay that info to our mechanic?  

Thank you  for your time and consideration.  Jackie Anas, Portsmouth, VA


Answer
hello....sorry to hear about your tale of woe...I strongly suggest that you find a smaller repair shop that repairs Volvo as a speciality...ask other Volvo owners where they have their cars fixed.
    Your needs are well beyond my ability to help...

  Best wishes,

Bilbo