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So I'm at my wits end with this car. The backstory is that it sat for 5-6 years, and I've replaced just about everything related to the fuel system: tank, both pumps, filters, injectors, fpr, return line, amm, iac, ect. The problem seems to happen only when it is cold: tonight, when I started it after sitting about 5 hours in 30-degree weather, it started right up, but I couldn't get over 60mph on the freeway, and would downshift whenever I tried to accelerate. I pulled off the road, turned it off, and turned it back on. This time, it would rev higher, but "coughed" under load (no backfiring). So I pulled off again, turned it off, counted to 10, and started it up. This time it ran perfectly. I know 86s had issues with cold starts. I checked the records I got from the original owner and didn't see anything about recall work being done. The only sensors that haven't been replaced are the oxygen sensor (which I have tested) and the TPS. The issue seems to be non-idle related. Is it possible that the TPS is sending a intermittently-bad signal to the computer?
I do have an '88 240, which is also LH 2.2, and I'm thinking of swapping the ECU.
Any ideas?
Dean
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Turns out it was the Ignition Control Module!
Well, I pulled out the wiring harness and replaced the four bad wires. I checked several others but those infamous four were the only ones with bad insulation. Since I was in there, I also pulled the Ignition Module harness and replaced the wires going to the knock sensor and the two that connect to the engine harness as they had hard insulation that had cracked. Put everything back, nice and clean. In the end it wasn't a bad job, and a good way to get to know the engine.
Once everything was back together the car fired right up, and I thought it was running great, getting 20mpg (up from the previous 15mpg), but there was an occasional hiccup. Then it got cold, and the car was back to its old tricks. So when it was running poorly I took my timing light to it and saw that when it hiccuped, the timing retarded momentarily. The only thing left was the ICM. So I swapped the one from my 88 and after tightening some contacts the problem was solved. It started fine this morning and is running great on this snowy night.
Thanks for everyone's input, and for giving me the courage to pull out the harness. Even though it wasn't the source of the problem, those four wires would have failed eventually, and it was good to get in there and clean the engine.
(now I need to get a new module for my 88)
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posted by
someone claiming to be CB
on
Wed Mar 26 16:34 CST 2014 [ RELATED]
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before you toss that ICM. It does have a vacuum module at the bottom that commects to the vacuum advance on the distributor.
Have you tried it with the ICUvaccum module plugged and the vaccum hose to the distributor plugged?
This vaccum advance was put on to give better MPG, by causing an additional retard/advance during accelleration. The engine will run just fine without this.
read this post that explains the dynamics of the "Transducer"
http://www.brickboard.com/RWD/volvo/804019/220/240/260/280/nox_volvochrysler_ignition_lengthy.html
Though the post is about high NOX and how to cure it, pay attention to the explanation of how that Vaccum Mod---here named a TRANSDUCER ---effects the timing.
Your ICU may be fine, but has a failed "transducer... which you don't need to hook up at all.
Just a thought. Post back if you try this, be interested to know if my theory is correct.
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Thanks. I'll give that a try.
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I think you are working with your thoughts leading to components most likely to cause problems you describe.
You first worked through all the bad gasoline items that probably were there due to sitting so long. Best logically choice to do IMHO.
Let me see if I am reading this right. I will try to think this through. You tell me where I make a wrong turn!
It appears that it starts up and idles fine when its cold.
You can drive it around and it shifts up though the gears and pulls nicely until you get up around sixty mph. It is then the power band flattens out and the engine mixture acts like it is running lean or another term running out of gas. The timing could not be advancing far enough but I would think it would do that every time at lower speeds. Just make sure the nylon hose is giving vacuum to the ICU out there under the hood.
When you are at lower speeds, the lower gears reduces the load on the engine at it will pretty much rev up and pull freely. It's after it hits third or overdrive it is bogging down under more loading.
If the engine is getting a lean mixture and the plugs or wires are marginally good it's an ideal condition to develop a high speed miss. Improperly gapped plugs or just one, will cut power 25%.
If we take away that the ignition system as being in play here, we have to address the chances of lean mixture, at high speed, on cold days!
On warmer days the engine does not need to be so rich and leaner is fine!
I can think of two things that play a part in this game.
First is a cold running thermostat being number one!
Second is the ECT and wiring to the ECU. You are aware of wiring issues.
These two items will work the same right or wrong but if the weather changes their stuck doing as they do and cannot compensate.
Personally, I would want a Wahler thermostat in there, at 92 degrees centigrade, that's standard issue!
Since are into peeking at the ECU I would look and tell us if you have the 561 and what color the label is. The pink ones have been problematic. White ones are better.
While under the dash, with the battery negative terminal disconnected, pull the connector probe PIN number two and other lead to ground. You want to have resistance changes but holding between 3-400 Ohms Hot and 2300+ Ohms Cold. Since we suspect harness issues,it a good time to do a wiggle and squeeze test. If that wire is frayed, it may be touching other wires inside the wraps that may give a parallel to the resistance, through other paths, go lean or be an open the circuit and go rich.
The TPS can be checked from down there too! It's a pretty simple set up. I would have to look up the PIN numbers for you. You could check diagrams or follow wire colors if you got real good eyes.
What twists me up, is the lack of a complaint in starting? Need more symptoms for clues.
What does it do most of the time?
Easy, in twist the key from outside the car or it cranks a lot? That is, So hard, you prepare yourself to sit there.
How are the plugs running in color across the four? You should have gray but light to white means lean. White insulators with no speckles and squared off electrodes.
Any soots or oil fouling?
I will try to follow this thread and see what others say!
Phil
P.s. I just saw your post that you change the ECT. Good on ya!
I would still check it out. It does the wiring and will make sure you got the proper one in there. Some posters have been given the wrong ones!
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I am thinking that the problem is somehow electrically related. Yesterday I swapped the -544 ECU in this car with the -554 ECU in my '88. There seems to be no differece, both last night after sitting for about 6 hours, and this morning the car started right up but idled very rough. This morning I again would turn off and restart the car until I got a usable idle. This morning, once I got a smooth idle, the car seemed to run fine, but was a bit sluggish. So again, I pulled off and turned it off and then back on again, and it ran normally.
The key here seems to be the restarts. It's almost as if something is resetting itself each time and with repeated restarts it's reset in the correct way. This is why I thought it might be the ECU. But it turns out the ECU is not the factor.
I have replaced the fuel pump relay and that is new.
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I think You, Art and I agree that its is an electrical problem.
I see that Art found the number 3 pin on the ECU to ground out. This operation he is suggesting bypasses the TPS so it will be in "idle mode" all the time.
Nice trick Art! I like to see the back probe tweezers or clip you use to do that with. I wonder what I would use to do it clean & safely down in there. I got fingers & tools like a bears claws! Is it a paper clip by chance?
If it works as he predicts you have to blame the "rough idle" on the switch or harness. Art's experience with harnesses supersedes anything I have dealt with, switches included.
The sixty mph and above power loss is still in a contingency between "lean" conditions or ignition system issue. The harness could playing a large role in electronic communications. This would confirm your fore mentioned instinct that you have!
I do not know how I popped out the 561 number from the dark caverns of my mind? I went and found some notes and I see where my 86 245 has a 544 also! The 561must be on LH 2.4's or on both systems but not mine.
I need better reference material or a mini LED flashlight for the insides of my head! Holding a fluorescent work light up to one ear, is not working. (:*-(
Phil
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I did check the timing today and it is right on, even with increased rpms.
I think the 561 ECU is the infamous pink label LH 2.4 box. I replaced on a few years back with a 951, but only after spending 4 months testing every component at the ECU harness.
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"Is it possible that the TPS is sending a intermittently-bad signal to the computer?
Very much so. Going by the audible click to adjust it works pretty well with a brand new one. On an old one, if you were to measure the voltage on the orange wire, you might discover what I did -- that the microswitch is not as clean switching as you might expect.
Simple to prove, though, without an oscilloscope: Ground the IAC idle contact right at pin 3 at the ecu, where it is clean and dry. Without critiquing the performance off-idle, see if that fixes the idle every time.
Failing that, you know the IAC gets dirty and intermittent in those LH2.0/2.2 cars. Saw you mentioning that as a suspect earlier.
But really, my instinctive reaction is to suspect you haven't seen the worst of the harness rot yet, making repairs to the exposed insulation.

Edit: reading more carefully this time, I see you are NOT complaining about the idle, but are having trouble getting to move out of its own way. The idle bypass circuit (and TPS) are not much influence once you've opened the throttle appreciably. How do the plugs look? Sounds much more like vacuum leak around AMM (or the AMM itself) to me now that I re-read your OP. Accordionly.
I think I now understand your question I've quoted above. You are asking if the TPS would keep your car from accelerating somehow by its miscommunicating throttle position to the ECU. Nope. Not in this car.
--
Art Benstein near Baltimore
Crusin' and playin' the radio... With no particular place to go.
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Well, I took Art's suggestion and pulled back more of the plastic cover over the large set of wires that feed through the intake manifold, split off to the infamous harness, and go through the firewall on the passenger side. The engine was hot so I didn't venture too far in, but this is what I found:
So, what is the best way to proceed? I used the ipd harness kit to repair the harness and have some extra wire. Should I just splice that in?
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I used to have an '86 Saab 900 Turbo that suffered from crumbling wire insulation. I spent a fair amount of time cutting out wires from a wrecked later model car, removing the affected lengths of bad wire, then soldering and shrink wrapping in the donor wire. I took my time and made it all look as factory as possible, being sure to use the correct color codes.
It was a gratifying repair effort, and one that really puts the mind at ease.
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So I pulled the harness out - the whole thing, and started cutting the now-hard plastic sheathing off. What I discovered was that the only wires deteriorating are the four running to the connector at the firewall. I replaced the connectors and about 6" of wire last summer, but apparently the problem was deeper. Now, these four wires connect to the alternator, starter, oil pressure sender and temp gauge sender. I am trying to solve a poor running condition. How do these four wires affect the engine's performance and fuel economy. I haven't removed all of the sheathing - to the AMM, TCP, Injectors - so is it possible there is additional rot elsewhere?
Also, should I pull off the ignition harness and inspect it as well? Are those wires prone to failure?
Thanks.
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"Also, should I pull off the ignition harness and inspect it as well? Are those wires prone to failure?"
According to Dave Barton, the ignition harness is also affected, although my experience with 4 83's and 1 84 (in the biodegradeable wire era) does not provide examples of this. Many stories about the wires failing at the distributor -- connections to the Hall effect sensor. I don't associate this with your symptoms as I recall them.
In the fuel harness, my injector wiring was particularly flaky. It seems odd to me only the same wires that you can see externally were affected internally, and no, I could not immediately associate those wires with performance and fuel economy either.
--
Art Benstein near Baltimore
GREAT TRUTHS THAT LITTLE CHILDREN HAVE LEARNED:
8) You can't hide a piece of broccoli in a glass of milk.
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Well, I would definitely dig into the harness that runs along the front of the engine, and expect to find things that need fixing. It gets hot down there, and is often fairly oily. If I found what you did, I would be elbows deep in the whole engine harness, if only to eliminate a future failure.
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So I pulled the harness out - the whole thing, and started cutting the now-hard plastic sheathing off. What I discovered was that the only wires deteriorating are the four running to the connector at the firewall. I replaced the connectors and about 6" of wire last summer, but apparently the problem was deeper. Now these four wires connect to the alternator, starter, oil pressure sender and temp gauge sender. I am trying to solve a poor running condition. How do these four wires affect the engine's performance and fuel economy. I haven't removed all of the sheathing - to the AMM, TCP, Injectors - so is it possible there is additional rot elsewhere?
Also, should I pull off the ignition harness and inspect it as well? Are those wires prone to failure?
Thanks.
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Thanks. Should I expose all the wires in the harness to check for rot, or only ones close to the engine? Also, is there a particular brand of electrical tape that works well in these conditions?
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86 has issues with biodegradable engine wire harnesses, if yours is original it is probably bad.
Dan
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I replaced those wires, too. To be sure, I would try wiggling the harness when the car is idling to see if there is any change.
I also replaced the fuel pump relay, coil, dist cap & rotor, plugs and wires.
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Did you replace the entire harness with an updated one?
Dan
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Volvo, Saab, and Mercedes suffered these with the 1986 model year. Volvo 1987 also.
--
Happy Motoring! 92' and 93' 240's past cars "74 140, '75 140, '86 240, '87 240 wagon, '02 S60.
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Volvo went back to 79 or 80 through 87.
Dan
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