1982 VOLVO 240

Typical onset: 80,000-150,000 mi

Symptoms: Hard starting when hot, engine cranks but won't fire, Stalling at idle or under load, surging during acceleration, Whining noise from rear of car near fuel tank

Fix: Main fuel pump lives in-tank and commonly fails, often diagnosed incorrectly as relay issues. Fuel accumulator (pressure holder) loses pressure overnight causing extended cranking. Full system refresh takes 3-4 hours for pump, 1-2 for accumulator/regulator. Check valve in pump is common culprit.

Estimated cost: $400-900

Typical onset: 90,000-200,000 mi

Symptoms: Overdrive won't engage or kicks out under load, Grinding/clunking when shifting into overdrive, Overdrive switch dashboard light flashing or staying off

Fix: M46 4-speed with electric OD is bulletproof mechanically but electrical components fail. Solenoid on transmission side takes 2-3 hours (drop exhaust, access from underneath). Relay under dash is 15-minute fix. Many techs replace both plus switch. Gear itself rarely fails but solenoid lets pressure drop.

Estimated cost: $300-700

Typical onset: 60,000-80,000 mi intervals

Symptoms: Sudden no-start, engine cranks freely without compression, Visible cracking or fraying on belt if caught early, Squealing on cold starts if tensioner bearing failing

Fix: Non-interference engine so belt failure won't destroy valves, but you're stranded. Original interval was 50k but modern belts go 60-80k. Tensioner bearing seizes frequently and shreds belts prematurely. Always replace tensioner, idler, and water pump together. 3-4 hours labor for full job including front seals.

Estimated cost: $500-800

Typical onset: 100,000-180,000 mi

Symptoms: Rich running, black smoke, fouled plugs, Poor cold starts, requires extended cranking, Idle hangs high (1500+ RPM) or hunts up and down

Fix: Mechanical fuel injection uses a plunger distributor that sticks from varnish buildup. Cleaning sometimes works (1-2 hours) but rebuilt units are $400-600. This isn't a beginner DIY—pressurized fuel system requires special care. Warm-up regulator and cold-start injector also fail but less common.

Estimated cost: $600-1,200

Typical onset: Every 40,000-60,000 mi

Symptoms: Misfiring under load, hesitation when accelerating, Hard starting in damp weather, dies in rain, Rough idle, loss of power above 3000 RPM

Fix: Bosch ignition components degrade predictably. Cap and rotor crack internally, coil fails when hot. Entire refresh (cap, rotor, wires, plugs, coil) is 1.5 hours. Many techs pre-emptively replace every 50k. Coil failure strands you, cap issues just run poorly. Upgrade to Bosch Blue coil recommended.

Estimated cost: $250-450

Typical onset: 120,000-200,000+ mi

Symptoms: Oil spots under car after sitting overnight, Visible dripping from bell housing area, Clutch slipping if ATF contaminates clutch disc

Fix: These seals weep rather than gush. Rear main requires transmission removal (6-8 hours labor, more if clutch is done simultaneously—which you should). Input seal is easier at 3-4 hours. Neither causes immediate failure but will eventually soak clutch. Budget for clutch replacement at same time on manual cars.

Estimated cost: $800-1,500

Typical onset: 100,000-150,000 mi

Symptoms: Power steering fluid leaking onto subframe, Clunking over bumps or when turning lock-to-lock, Wandering steering, requires constant correction

Fix: ZF rack boots crack and let dirt in, destroying internal seals. Tie rod ends wear and develop play. Rack rebuild kits exist but labor-intensive (4-5 hours). Most shops install reman rack (3 hours). Tie rods are 1-2 hours plus alignment. Address both together.

Estimated cost: $600-1,200