Power Steering + Misfire? (‘96 965)

[ItWasTheSalmonMoose]

Hi everyone, I’m a longtime lurker and have learned much from your experience and expertise. Finally joining the conversation with a peculiar problem I don’t see discussed:

tl;dr - replaced power steering pump, now cylinder 3 misfire and no power steering. ???

I have a ‘96 965 that has a few unsurprising power steering seeping leaks: rack seals and boots; pump shaft main seal. The latter suddenly got bad enough that I had to replace the pump (I know about rebuild kits but don’t think I’m quite there yet...) I also had to yank the alternator to clean off leaked fluid (Lectra-Motive), and also had to give that side of the engine bay a degreasing because the pulleys had flung some of the fluid about.

Flushed the system with new fluid before pulling the pump. Pulled the pump and alternator and cleaned the affected parts of engine bay with degreaser and a hose spray rinse. Replaced the pump with a remanufactured unit. Replaced the return line and added an inline filter (MFP magnetic inline). New O-ring on high pressure side, tightened to FT because I couldn’t find a tightening spec for that connection. Followed VIDA instructions for post-install priming of the system. Everything checked out besides slight seepage out the PS pump cap vent hole when turning the wheel with engine off. Alternator making 14.1V.

First drive out, after about 20 minutes, engine starts idling rough at stop, inconsistently. Next 10-15 mins the roughness becomes more consistent and CEL flashes and then stays on. Over this time, I lost power steering. When stopped, I checked the PS fluid level and it is as it was before driving (though there is slight seepage around the cap now). Checked codes and got a Cylinder 3 Misfire.

I’m stumped. Could the new pump somehow have caused the misfire? Could the misfire cause the loss of power steering? Could the light cleaning have messed things up? Could my new pump be a lemon? I’m going to check the ignition wiring tomorrow and hope that’s a simple connector snafu. But a few years ago I replaced the ignition subharness with one from Dave Barton, so the connectors should be good.

Thanks in advance for Go-Go-Gadget-Volvobrain

[RickHaleParker]

I’m stumped. Could the new pump somehow have caused the misfire? Could the misfire cause the loss of power steering?

You bang something loose when you was changing the pump. That caused the misfire. Check the injector and coil pack wireing harness.

Power steering is a separate problem. Double check your work.

[ItWasTheSalmonMoose]

Update:

The power steering problem seems to have resolved itself. I checked fluid, connections, hoses, rack, etc., and there was nothing to indicate what may have caused it to lose power. I can only theorize that perhaps there was an air bubble remaining somewhere in the system? But there was no foaming/frothing of fluid in the reservoir... Fingers crossed it's nothing else. (I know I have to replace the rack soon due to seeping seals, but I plan to wait until after salt-and-freeze-thaw season for that.)

The misfire also at first seemed to resolve itself, but after driving around for a bit and letting everything warm up, the misfire recurred. I checked connections and wiring harness and all were fine. Pulling coils, I found that the #3 coil well had a bunch of water in it. #4 also had a bit, but not as much. I'm guessing that some moisture from my engine bay rinse post-degreasing made its way in, and that when it got steamy around the coil and plug the spark was affected. (This is surprising given how light a spray I used when rinsing :-/ )

The reason for my original question about the concurrence of symptoms was because I wondered if a [dud] power steering pump that required significantly more power to turn might somehow retard engine rotation.

Thanks again.

[RickHaleParker]

(I know I have to replace the rack soon due to seeping seals, but I plan to wait until after salt-and-freeze-thaw season for that.)

Replace the rack or rebuild it?

Rack and Pinion Seal Kits for the 960 run from $30.00 - $50.00. Do it right and you end up with like new and will not be doing that task again for a long long time to come.

[ItWasTheSalmonMoose]

Interesting. It's a thought, and would be waaay cheaper than replacement. I was under the impression that it was a bit of a bugger of a job, though? I had a look through this overhaul procedure http://www.volvotips.com/service-manual ... anual.html and it seems quite involved, also requiring for final adjustment a few tools I don't have. Though perhaps all I'd need to do would be replace the outer seals and not have to get into a full rebuild? (Found this: http://volvospeed.com/vs_forum/topic/15 ... -leak-fix/ - is that similar to what you're suggesting?) Would you be able to point me to a better set of instructions? And/or would you have any tips for doing this job at home?

Couldn't find rebuild info in VIDA, though that may just be because it's pretty clunky and confusingly organized.

(The 965 is my only car, so I need to not have it up on blocks for ages! And since I'm no pro, things take a lot longer than I usually think they will...)

Thanks!

[RickHaleParker]

Couldn't find rebuild info in VIDA, though that may just be because it's pretty clunky and confusingly organized.

If there where it would be Information\Repair\Overhaul instructions. 2014D does not have it. 2012A might have it or VADIS may have it. 2012A and VADIS had much better overhaul instructions.

(The 965 is my only car, so I need to not have it up on blocks for ages! And since I'm no pro, things take a lot longer than I usually think they will...)

Try to find one somebody else replaced. Good chance you can get it for free or the core price. Take it home and then take your sweet time Overhauling it.