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Hi,
This might be an ignition problem caused by heat expansion - that is why it won't do it at home. Could be the crank sensor is marginal, and you might try taking some off of its mounting tab so it seats closer to the tone ring.
No, seriously, I read your other post in response to analogdad, so I'm aware this is your idea in the first place after solving the trouble in your 89 240.
Based on my experience with that system, I thought your solution was ingenious.
The only intermittent no-start I have encountered on a 940 (92) was due to a broken brush wire in the Regina's in-tank fuel pump. But the symptoms extended to abnormal drivability too. Radio suppression relay is the most common answer - it gets hot under the hood and it provides the battery side of the injectors. Is your 91 a Rex-Regina?
Regarding your trimming of the CPS - I assume you trimmed the sensor's tab, not the mounting bracket itself? I did just the opposite once as an experiment, to find .040 shim between the tab and bracket yielded a 50% reduction in output.
The other variable (with heat) is warpage of that thin tone ring. In this old post you can see the "shape" of the ring with respect to runout: Intermittent Starting Problem
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Art Benstein near Baltimore
By all means, marry. If you get a good wife, you'll become happy; if you get a bad one, you'll become a philosopher. - Socrates
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