stalling 960 with codes 114 and 235

tomatoes4all · Post by **tomatoes4all** » 25 Dec 2011, 17:33

Hi all,
My 960 dies daily now while driving, just stops suddenly, all dash lights come on, showing a stalled engine. Carefully steer to the side of the road, gear selector back into park and the car starts right away. Sometimes just before stalling car seems to run on 5 cylinders or after restarting the same and car will stall again. But it will always re-start immediately without a problem. Fault codes are 114 and 235. The latter is EGR valve issue and 114 is unknown to me as it is not on the list. Does anyone have an idea on what to try? How hard is it to remove and clean/replace the EGR, if this turns out to be the issue? Thanks for the help, again...
Regards, Erik.

Post by **precopster** » 25 Dec 2011, 19:27

When it stalls can you tell if fuel supply is an issue? Press the schraeder valve at the end of the fuel rail.

Also are the relays near the passenger strut tower still the originals? One of them is a fuel pump relay, I think the other does ignition. They could have burned contacts. I bought some relays from a car auto place and swapped them out a while ago.

The other thing I can think of is the fuel pump. Can you switch it to gas (LPG) as soon as it stalls and then try to start? Or does it stall while on gas (LPG) ?

Sometimes it's a lot easier to diagnose when the darn thing stays broke!!

tomatoes4all · Post by **tomatoes4all** » 26 Dec 2011, 14:08

Hi Precopster,

Fuel pressure is OK, good squirt of fuel out of the schraeder valve. Running on LPG or petrol does not make a difference, it stalls with either fuel. The crazy thing is that it runs great for a few hours, then stalls twice in 10 minutes time and then there are not problems for the rest of the trip.
I will check the relays, they are both original ones at a quick glance. I will remove them tonight and have a look.
Any thoughts on the EGR valve? One of the fault codes pointed at that.
Thank you and best regards, Erik

Post by **jimmy57** » 26 Dec 2011, 14:30

113 and 115 are shorted injector groups. I think a 92 only shows 113 even though there are two groups. I found chafed wiring harness to injectors at point where it passes through intake to get up top or on one auto is was chafed below intake manifold.
Re-check and see if it is 113 instead of 114.
When the harness shorts the ECM shuts down and will come back with an ignition off-on and that sure fits your listed condition.

Post by **precopster** » 26 Dec 2011, 19:34

As jimmy57 pointed out that wiring harness that passes through the inlet manifold is a huge problem on older 960s. Has given me some grief too. Take off some tape wrap and see what condition wires are in. They usually have cracks all the way back with copper exposed.

I rewired/insulated what I could reach with the manifold attached but still weary of mine causing issues.

tomatoes4all · Post by **tomatoes4all** » 28 Feb 2012, 22:09

Update: the culprit was the camshaft position sensor! Replaced it and no more stalling. Had the inlet manifold removed to check wiring loom condition, all OK. Inlet manifold gasket was completely disintegrated, with parts missing, which caused huge vaccum leak over many years. Replaced the gasket and replaced the rubber inlet manifold sleeves as well, as mine were brittle and cracked.Could not get them from FCP, so had to get them from the stealer, ouch!! They were $25 each, but what a difference it makes. Nice flat idle, smooth pick up, and more power as well. An added bonus is the improved milage.
Timing gear and waterpump next, then I should be good for another few years.
Thanks all, for your help, I could not keep this car on the road without your help! Best regards, Erik, New South Wales, Australia.

Post by **billofdurham** » 29 Feb 2012, 11:47

Thank you for the update. Happy motoring.

Bill.