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Air Leak on 1994 945 B230FD? 900 1994

The 1994 NA 945 I recently purchased is throwing a 2-3-1, 2-2-1, and a 2-3-2 code intermittently (Bosch injection). Today I drove it about 2 hrs at 70-75 mph and the Check Engine Light (CEL) turned on about half way through. When I parked, the ECU spit out a 2-3-2, 2-3-1, and 1-1-3 code. I reset the ECU and to see if it was an injector leak, sprayed a bit of WD40 in each injector seat to see if I could tell an idle speed change and found none. Now that the car is cold, the CEL turns on immediately after starting and throws a 2-3-1 and 2-2-1 code.

The car sometimes idled poorly cold, stalled, and had low power until warm. I thought it was a mass air flow sensor problem or o2 sensor, but after changing my oil to full synthetic, it now idles fine cold (the old oil looked used but I didn't see anything too terrible). There is a bit of hesitation off idle when cold, so I still think the o2 sensor needs to be replaced.

The other codes, however, indicate an air leak somewhere in the system. After spending some time on the FAQ, I'm unclear where to start looking. I cleaned the throttle body a few days ago and still had the poor cold idle/hesitation problem.

Any suggestions? Hope everyone and their loved ones have a happy and safe Thanksgiving.








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    Air Leak on 1994 945 B230FD? 900 1994

    Dear nick 2012,

    Hope you're well. What color is the intake manifold gasket? I recall posts, that the original factory-installed gasket, made of an orange-red material, tended to fail. Replacement gaskets are a pale green. You can test for the presence of intake manifold leaks by carefully spraying starter fluid around the intake runners, while the engine is running. If the engine's tempo changes - because starting fluid has been sucked into the manifold - the intake manifold gasket has failed. That extra, un-metered air, could cause the rough-running and codes.

    It is also possible that the fuel pressure regulator is failing. Remove the vacuum hose. If the hose is wet with gasoline, the regulator needs to be replaced.

    Hope this helps.

    Yours faithfully,

    Spook








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      Air Leak on 1994 945 B230FD? 900 1994

      Hi Spook -

      Thank you very much for the information. The intake manifold gasket is new, but I have yet to try the starter fluid test.

      I installed a new Bosch OEM o2 sensor this weekend. The cold start issue still persists, but it doesn't seem as bad. What's odd is when the CEL turns on, the car starts fine when its cold or hot. When I clear the code by resetting the ECU, it starts really rough and has low power off idle but is fine above 2000 RPMs.

      I tightened the hose clamp leading from the fuel pressure regulator to the fuel rail which seemed a bit loose and cleaned the engine coolant temp wiring harness under the 3rd intake runner. The car is still warm and I'll update if this solves the issue.









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