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Well, she still will not fire! The latest wisdom is to replace the engine wiring harness, part Number YZK-9128165-4. Anyone knowing of a source, we would be eternally grateful.
VolvoGeorge generously donated way too much consulting time over the phone. He spent a long evening, and most of the rest of the next two days on the phone, including Saturday, helping me trace things down. Thank you George for all of your help, but as you know she still will not fire.
The latest go-round was to replace the starter motor and both battery cables, thinking maybe the starter motor was weak (which it was), and maybe the cables were corroded, (which they were). Put some herkin marine duty cables in, and a recycled starter. Turns out the recylced starter was different than the one in the car, and the front mounting bracket was different. Suspect an 850 starter was in there. Results: spins over much faster, but still no spark.
In case you are new to this saga, we have a sparkless '95 960 Green Wagon: (Green Bitch: GB) that has not run in months. We also have a running '95 960 sedan (Wife's Car:WC), that we have been using as a test-bed of sorts. The local Volvo Sr Tech could not make it run after 40+ hours of labor. The Dealer told him to stop working on the car, but he is a personal friend, and has been consulting with me ever since, in hopes that we can make it run again. It's too nice a car to give up on, although I have already... more than once.
So whatever gremlin is keeping this thing from running it is not an obvious fix. The Sr Tech stated that after disconnecting every component that draws power, he was able to get an intermittent weak signal across the plugs, but it would come and go. He suspects a couple of wires somewhere that are shorting out on one another.
We have swapped every electrical component out of the GB, put it into the WC, and the WC starts and runs fine. (Parts swapped are Motronic, Trans computer, all coils, crank sensor, all relays, power stages, ABS computer, battery). The only components we have not swapped are the wiring harnesses, and I do not want to jeopardize my marriage to find out if that is the problem.
We are getting fuel, but no spark. OBD-I tells us 1-3-1, crank position sensor. We bypassed the harness, and ran 2 wires from the sensor directly into the Motronic, and got the same result. We have 3 crank position sensors, all work fine on the WC, but none generates spark on the GB. We have tested for continuity, every wire in the engine harness, through the common plug in the engine compartment, and all the way back to the Motronic, and find them all OK. The grounds all test fine including the power stages, and the 2 grounds on the head. We even ran a separate groung wire from the motor mount, back to the ground terminal on the firewall.
Is it possible that the alarm is somehow FU, and turning off the spark? I have locked, unlocked the doors from the outside of the car a dozen times, to see if that would clear the alarm. I have swapped out the alarm and power lock relays, and they work fine on the WC, but who knows...
After reading SurferDude's post, I am going to pull one of the sparkplugs out to see if it runs. That would be too weird.
So, if you have made it this far in the post, and have any more ideas, I would greatly appreciate hearing what they are. Or if you know of a source for a recycled engine harness, I'd also appreciate it if you pass along contact infomation.
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