Greetings again...Thanks to all who replied to my previous post...After replacing the intake gasket on my '96 960...It cranked right up, ran as smooth as anything I have ever seen...After idling a few minutes it cut off... I thought it was out of gas...After refueling, still would not crank... I have determined that fuel pumps are working...For some reason it is not firing...I changed all the plugs(they old ones were wet). Installed new Volvo 3prongers... Still no fire... any and all suggestions/advice are appreciated...Thanks. Walt

There is a ground wire by the drivers side motor mount that powers the spark plugs, actually it is attached to the power stages. When you were disassembling, did you have to undo the wire harness that crosses just below that mount? If you loosened one of the bolts, there is one with a nut that holds the ground wire. Just an idea.

DanR 94 964 216k miles
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DanR

Yes Dan, I had to remove the power stages from both sides of the intake on the bottom...also removed two of the three bolts holding the wiring harness that passed down by the mount...I do not remember seeing a ground of any kind...but, you may be onto something...I will check tomorrow...Thanks for your reply and anything else you might think of, please forward it....
Thanks again, Walt

It's too bad you took all that stuff off. I watched a Volvo Master Tech replace my gasket and all he did was take off the injectors, unscrew the manifold bolts and take the old gasket off. It took about 45 mins, 1 hour due to all the talking we did. I've got pics and I'm going to have to write this up.
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Warren Bain - '99 V70GLT G-Valve > 70K mi, '96 965 >110Kmi Wifemobile near Manassas Va.. Check the 700/900 FAQ via the 'features' pull down menu.

I had this very thing happen to me.
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DanR

Greetings Dan, I do not care what your wife says about you... you are a saint...This was my problem...It was in a very tight place and I could not see, but I found the ground wires just as you stated...I do not see how anyone can remove the bottom anchor nut from the intake from the topside...Thanks again for following up on my problem and solving it for me...If I could I would happily treat you to some hotwings and beer at the local "HOOTERS".
Regards, Walt

When I did my manifold gasket about 3 years ago I followed the "Green" book method and it took me almost 12 hours!!!!!!! Luckely when I took the sucker apart I remembered that ground wire being held in place by a nut on the end of a bolt long enough to go up through the mount. I got a longer bolt and put the ground wire under the bolt head while the manifold was still out. Then I used the nut on the bottom side to hold whatever it had to hold later in the assembly process. (Don't remember what it was now.) I knew I could never get that nut back on the ground strap after the other stuff was in place.
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'96 965 with 16' wheels at 101K. Had '85 745 Turbo Diesel for 200K.

I figured a way to get that blasted nut loose. One has to kneel ontop of the engine and with the left hand, snake the 13mm box end wrench under there. I have actually gotten good at it. Been wrestling with a chech engine light since August, I have had that contraption off twice since then. Found the wire fault last weekend, I plan on sharing it with the board soon.

Never been to Hooters, my wife and I were just talking about that on Saturday night, seems she doesn't believe that I have never been there.

Glad I could help, small price to pay for the mountain of information and money saved from this board. With a 960 that can add up to some cash.

DanR 94 964 216k miles
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DanR

Well Dan, you need to take the wife to "HOOTERS" for some hotwings and beer...actually the buffalo shrimp are dipped in the same hot sauce as the hotwings and they are very very good...at most of the "HOOTERS" that I have been to the waitresses are quite friendly and some of them are hott...my wife gets a kick out of watching the men eating in there almost breaking there neck to see all the girls walking around...My son has been going since I took him the first time for his second birthday...He was a real babe magnet...They were all over us that time(wife did not go that trip)...I tried to reach the nut on the bottom of the intake from the top, but my arm is too big...could not snake it down there....so I had to go up from underneath....Thanks again...yes, you need to be sure that everyone knows about this deal...can save mucho headaches...
Regards, Walt

'96 964 135K wifemobile(her third Volvo, she totaled the other two, 240's)