Greetings:

This is regarding my 1992 940GL, Non-Turbo, Regina, 275K miles. My apologies for this post being a little long, but I think some history might be required.

Recently I was having my second round of acceleration problems this year. First time was always from a dead stop until about 2K RPM. That turned out to be the fuel pump (single in-tank on this car – much easier job and many thanks to Art Benstein’s pictorial).
I also replaced the fuel filter.

Two months later, the car started not only bogging down from a stop, but stalling frequently too. This only went on for two days before I garaged it. First thing I looked at was the fuel pressure regulator. No gas coming out the vacuum line/side, but a pretty strong odor in the line itself. Replaced this with the “OEM” one for Bosch cars after reading here about it being done with no problem (cheaper too).

Then I noticed a pinhole leak in the return line near the fuel filter. Got this patched up with 5/16” steel brake line and compression unions. Feeling pretty happy about that, I went for the keys and the car refused to start.

I thought possibly I had gotten some kind of air lock. No Schrader valve on the rail that I can see nor pressure gauge available, however in the process of attempting to purge the lines, I didn’t re-seat the fuel pressure regulator tightly and got a strong vertical geyser with KPII. That tells me at least fuel is getting to the rail.

Next check, found no spark at the plugs. I wasn’t quite sure where to start looking for the source of this problem, so I decided to go for the radio suppression relay. BTW, I don’t have the same fan relay in this car so I can’t try a swap. Actions taken and finding are as follows. Hope this help someone help me!

1) Cleaned grounds up (forward of RSR on pas. Side fender) (see pic 1)

2) Tried jumpering from Red to Red/Green heavy wires and checked for 12V at blue coil wire with a test light at KPII. I think I have the right spot I’m not as solid electrically as mechanically. (See pic 2) No voltage. No Start.

3) Checked resistance from Green/Red (#87) to unplugged ground and to battery neg. 9800 ohms is both cases (high?)

4) Tried to check disassembled relay itself by applying 12V from bat. + to Red (#30) and connecting Red/Green (#87) to battery neg. Armature did not close. If I physically close the armature, I read 12V on #87.

5) Plugs are not wet after this testing (#1 checked anyway).

6) Also tried 2 different fuel relays. Felt for "click" at KPII and crank, got both.

PIC 1:



PIC 2:



That’s it for now. PLEASE a little help.