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Got this from the FAQ, check Coil Pack Connectors part;
960 Engine Stalls and Won’t Restart: Wiring Harness. These brief notes are in honor of Tom Irwin, who has suffered more grief from the engine wiring harnesses and connectors on his 1995 960 than any one person should bear! All of us 940 owners salute you, Tom, for extraordinary patience and hard diagnostic work, much done late at night. [Query from Tom Irwin:] I stranded in 100 degree heat. Got the car 4 blocks to home (thanks Triple A). Ran the codes and came up with DTC's 113 and 115. This points to Injector groups 1 and 2. Twice before, only 113 came up. I've done everything I reasonably can. Checking all connections and ohm specs. I greased the 55pin connector at the ECM. [Responses: Abe Crombie, Tom Irwin, Rafael Riverol]
Wiring Bundle Chaffing at Manifold: Check the wiring harness on engine where it comes up through intake between the # 4 and 5 intake runners. It may have rubbed through and grounded to engine. About a .750"d loom. I had just enough clearance to sneak in a bentnose plier and move it around. The loom cracked away like egg shells. I could not see the rub point on the wires, but right at the head casting extrusion was a bright, shiny, rub spot. I pulled the loom/harness away from the head. And BOOM! Christine sprang to life. This makes total sense. It has always died upon acceleration. The torsional moment of the engine would tend to bite into anything against it. I lost only group one the first time because only one wire was worn through. With time, two wires, thus both groups lost.
Tie Points: This is where all 6 GRN/RED wires join together. It occurs once up on top of the engine and again down the side of the block, under the intake manifold. Both can rot. Both can cause ghost problems in the EFI and ignition. The secondary tie point is buried inder the intake manifold. Must remove for access. The wires were stripped, twisted, crimped and ultrasonically welded. The welds APPEAR to be solid, but microscopic corrosion occurs between the individual wire strands, you know, where the SHOULD BE solder. No easy fix. I literally cut out the whole joint, re-stripped the wires clean. Braided the wires in between with copper rope, twisted tight into a mass. Then I silver soldered the living hell out of it! Heated it thoroughly and just flowed a couple ounces of high grade solder into the joint. I wrapped it in that stretchy, silicone, self-fusing stuff used on Hi -voltage wires, then tape and loom.
Motor Mount Ground Point: While you are down there do NOT miss the chance to clean and tighten the left motor mount ground point, that nasty little ring terminal that bolts on the lower left motor mount. This is ANOTHER source of impossible electrical problems.
Coil Pack Connectors: [Tip from Rafael Riverol] If you have a 960, I please take off the plastic cover atop the engine that reads "24 valves" and examine the female connectors at each of the six coils. I suspect you will likely find crumbling insulation, brittle barrels and poor connections. I can tell you these can fail you anytime. You will also likely find crumbling wire sleeves that will allow wire chaffing againt the engine head. Parts Source: [John Randstrom] Borton Volvo gave me this part #3523813(List $6.10ea, net $2.76) as the replacement ignition coil female terminals for my '93 960. These have the rubber isolators on them. Experience with Radio Shack and other sources is not good: the female connectors de-tension and fail to maintain contact.
Cam Carrier Ground Leads: De-ox and dress the two ground leads atop the cam carrier edge. Both, if corroded or broken, will kill an EFI system right quick. I cut mine off and soldered in some solid copper lugs.
MORAL: If you own a 960, watch your engine wiring harness, connectors, leads and all other electrical components very carefully. If you suffer from unexplained driveability problems, start with a careful check of every bit of harness and every connector near the engine. If the wiring is failing, you may want to consider a new engine harness.
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1996 964 125,240
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