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My 1994 940 stalling problem continues

As mentioned a few days ago this car stalls while driving. Very intermittent, it could be 20 miles or 1 mile. The past 2 days it was gracious enough to do it in the driveway several times.

I started by replacing plugs, wires, cap and rotor as it has been a few years. Then I noticed the coil was quite warm and replaced that, Bosch ignition.

Yesterday I replaced the fuel filter. Also had my son pull the fuel line off the rail and into a soda bottle, plenty of gas as soon as I hit the key.

Today I got into the electrical stuff, damn near got out the Sawzall to get the cigar lighter section out. Finally just ripped it out and found a blind screw behind the lighter and a hidden bolt! I must say that the assembly of this vehicle is nightmare to work on. Ive had it since 97 and nothing is ever simple; or I should say my wife has had it since 97. I drive Fords.

Anyway it appears that the fuel pump relay opens when the stall occurs. Shut off the switch, wait 30 seconds and it starts right up. If I try and start immediately it just cranks over. Swapped relays with a like type ( Marked J and on far left side) Swapped 25A fuse. Swiped relay contacts with clean paper, got a bit of black residue; no pitting seen under a magnifying glass. Nothing appears overheated, corroded, etc.
Still stalls.
The hot +12V from the fuse is always there and doesnt vary on my DVM.

Now Im beginning to wonder if the relay signal from the ECU is failing. Is this a common problem? How do you troubleshoot this?

The + battery terminal has 3 small wires attached (I wire brushed everything to shiny copper) where do they go?

Ive been looking for an excuse to do a Chebby V8 conversion but the wife wont let me unless the engine blows! It has 171K on it.

Sorry for all the questions and gripes, my frustration level is at an all time high. And Ive been working on my own cars for over 45 years.

HELP!!!!!








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My 1994 940 stalling problem continues

The ECU usually isn't the issue with the '94.

--
'75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me








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My 1994 940 stalling problem continues

Per the FAQ, you have three possible culprits:
-fuel injection relay solder failure (high likelihood)
-radio suppression relay failure
-rpm sensor failure (lesser likelihood)

All three are simple and cheap. Start with the first.
--
See the 700/900 FAQ under 'Select Link' button on the top right.








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My 1994 940 stalling problem continues

Crank position /RPM sensor or wiring to this sensor can do this. See the 700/900 FAQ.








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My 1994 940 stalling problem continues

My 91 945T only stalled twice, not to start again. After replacing the RPM sensor and in tank pump(and switching the suppressor and fan relays), it turned out to be the fuel pump relay. At first I just reflowed the contacts, when that didn't work I added solder to the joints, that did the trick. This procedure is the easiest and cheapest of the different posibilities, give it a shot.








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My 1994 940 stalling problem continues

Couple of questions.

How do you get the radio out so I can get at the relay board? Ive removed the knobs and control shaft nuts and also the 2 10mm bolts up under by the tray. Nothing moves.

Where is the radio suppression relay?

Is there a procedure to jump all these circuits so I can at least drive this thing without stalling? My wife wont get near it now!







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