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92 940 Periodically Stumbles & Won't Drive Faster Than a Crawl! 900 1992

Warning! Long post follows!!

Strange problem. My wife called me at work and said her 940GL couldn't leave the grocery store parking lot. It wouldn't build up any speed, but it wouldn't die either. After about 15 minutes, she called back to say it started running properly again and was able to drive home without further incident.

That evening, I checked it out and could find nothing wrong. I installed a set of plugs and wires and drove it several miles. It ran great. Then a couple of weeks later, it did it again. This time, she was just a few blocks from home and she limped it home. It never did start running properly that time. When I got home, I drove it and it was perfect! No problems! Since I didn't doubt her experiences, I decided to take it to our local repair shop. We were able to leave it two days. They could find absolutely nothing wrong. It drove perfectly for them. Good fuel pressure. No codes. They had worked on our Volvo a couple of times in the past, including installing a new fuel filter and pump a couple of years ago. They've always been very good to us, and have always stood behind their work.

Today, I got to experience the problem myself. It started stumbling, missing a bit, and wouldn't drive over 10 mph. Idle was extremely erratic. My wife said she would kill the engine and it would always restart. It did the same for me, but never recovered. A few times on the drive home, I would pull over, kill then restart the engine. If I gunned and revved it very high, it sounded fine. But it would return to the very erratic idle and would not drive properly.

This Volvo has been our family since new. It has about 250,000 miles, and my wife loves it. I'm hoping I can get it to the shop while it is acting up, so they can see firsthand what it's doing. But chances are, it'll run perfectly while they have it!

When this has happened, it's been very cold out. And we're keeping the tank full. Airbox looks good, and clean. Any ideas? Could it be a fuel injector problem?

As always, thank you very much for your time and suggestions!! We always appreciate your help!

Steve








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    92 940 Periodically Stumbles & Won't Drive Faster Than a Crawl! 900 1992

    Steve, Last summer my 940 did that crawling thing too only mine did not go away. Well I've seen this kind of thing before, so I told my mechanic friend who is a welder to cut that exhaust converter out and replace it. He said thats not it. I said trust me just do it. So he cut it out and low and behold something had come loose on the inside of that cheap after market converter and blocked the exit port. He welded in another one and all the power returned and it is still running fine. If it does it again have someone hold down the throttle and you put your hand at the tail pipe and see if any exhaust is coming out. Good Luck








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    ANSWER 92 940 Periodically Stumbles & Won't Drive Faster Than a Crawl! 900 1992

    Dear semv940,

    Hope you're well. A nephew has a '90 760 (with B230FT engine). He reported very similar symptoms. He traced them to the Engine Control Unit (ECU), which is mounted behind a plastic panel, on the door-side of the passenger footwell. More specifically, after he re-flowed the solder joints on the ECU circuit board, the problem went away.

    Re-flowing the solder is tedious. You need only keep the tip of a 15- or 20-watt soldering iron on each connection for only 1-2 seconds. That's all required to cause the solder to liquefy. When that happens, the solder changes color, from a dull gray to a shiny silver.

    Over time, solder joints fail - they develop micro-cracks - because of repeated heating and cooling cycles. These micro-cracks are far too small to be seen with an unaided eye.

    It should not be necessary to add solder. Adding solder to very tightly-packed connections means risking joining things that should not be joined.

    But taking the time to reflow the solder on the ECU circuit board seemed to cure his car's intermittent refusal to run at full power, until it was shut-down and re-started.

    Hope this helps.

    Yours faithfully,

    Spook

    This post has been marked as an answer to the original question.








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      92 940 Periodically Stumbles & Won't Drive Faster Than a Crawl! 900 1992

      To All.... I apologize for the very late reply! I wanted to let some time pass to make sure the problem was corrected. I waited too long and forgot about it!

      The ECU had cracked solder joints. The mechanic also mentioned soldering the fuel injection relay (? not sure what he meant). This shop is familiar with Volvos, and had it fixed in no time. All of your comments were sent to the shop, and I know they were very helpful to him. Thanks!

      He had looked at the car earlier regarding the problem, as noted in my first post, but did not find the problem. He had the car for two days and charged a very minimal fee for the diagnostics. This time, he refused to take any money (as I guess perhaps he felt he should have found it the first go around). I try to fix the things I am comfortable with myself. But I am really lucky to have this shop in my town. Since then, we've sent 3 more customers to him... all have been very satisfied.

      Again... thanks to all of you!

      Steve








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      92 940 Periodically Stumbles & Won't Drive Faster Than a Crawl! 900 1992

      Thank you for the tips, guys. What I'm going to do, is take these suggestions to my repair shop, as they may be too much for me to handle right now.

      Thanks again!

      Steve








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    92 940 Periodically Stumbles & Won't Drive Faster Than a Crawl! 900 1992

    You did not state if this was a Regina car or a Bosch car. Either way, first things to check are the crank position sender (it's at flywheel) and the main fuel pump relay for cracked solder joints. Cracked solder joints can be repaired, there is also the fuel injector relay near the battery. But, I'd go for the crank position sensor first. Check for cracked sheath. It's easy and cheap to replace yourself. If a Regina car, check fuel pressure, but this does not sound like fuel pressure to me. CPS or main fuel relay is where I'd put my money if a betting man! Good luck.







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