Hello All ! Looks Like a great forum here
I just autozone scanned our "96" 960 and I received the following:

1) P0410 Secondary air injection sys malfunction
2) P0118 engine coolant temp circuit high input
3) P0304 Cylinder 4 misfire detected

I would like to fix Number 3 first.
Any advice and direction would be much appreciated !
Thanx !

#3. First check the wires and make sure the conections are good at all coilpacks. I just went through this with my 96 960. I would recomend repalcing all the coilpacks. I did one at a time, after I replaced one another went bad. Cylinder 1 is to the front of the motor 6 is at the back.

#1. That could be a bad vacum line or the round thing to the left of the engine that ties into the exhaust. The vacum line goes from just behind the windshield washer fluid tank to the round thing to the left of the engine. I also had that code and replaced mine.

#2. Not sure what that is, I replaced my whole cooling system.


1996, 960, 235,000 miles

My S70 only runs on 5 cylinders too (sorry couldn't resist)

You beat me to it. I was going to say that's still one more than my 4 cylinder, so what's the problem?

Have you pulled the cover off and looked at the plugs, coils and wiring for all the cylinders? That would be my first suggestion.

AS for the secondary air injection (0410), check over on the s90 board last month, a guy asked about it and I posted a diagram of the things to check. That is the secondary air injection system and on my car, a small vac. leak was causing the code. Other than that, go through the faq's and you will pick up some good information.
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97 S90 with 180K miles still going strong

After you go through the usual causing this problem, spark plug, coil, wires, change coils, etc., also disconnect the injectors to see which cylinder is not firing by noticing no change in idle. Last, change the power stage front to back and back to front to see if now you have a different cylinder missing. If that is the case, the power stage is fried. This things are very reliable and there only two things that I know of cause them to fail. Alternator overcharge and heat. The alternator may be tested with a voltmeter hooked to the cigarette lighter, hard to detect a fault if it is intermittent. The heat issue comes fronm the flap in the air intake filter being stock open to the hot air from the exhaust manifold. You can fix it permanently open to fresh air only or buy a new air filter housing. Good luck, I hope is nothing.

You can get a new thermostat for the present box. I posted the part number a couple weeks ago. (Don't have it handy at the moment.)
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'96 965, 16' wheels, rear 18mm bar & Koni + 204HP cams at 123K. Had '85 745 Turbo Diesel for 200K.

Please if you find it post the number. I have my air intake fixed permanently. The part place at the dealer only offers the whole bottom of the air intake housing. thanks